Highly Oriented and Crystalline Thermoplastic Filaments and Method of Making Same

Abstract

A melt-spun highly oriented and crystalline thermoplastic filament or fiber having a tenacity of at least about 10 g/d, an elongation less than about 15%, and a modulus of at least about 130 g/d. A method of making highly oriented and crystalline thermoplastic filaments has been developed that comprises extruding a thermoplastic polymer to form at least one molten filament. The at least one molten filament is introduced into a horizontal liquid isothermal bath. The bath is maintained at a temperature between the glass transition temperature and the melting temperature of the thermoplastic polymer. The bath increases the tension along the molten filament to form at least one partially oriented and low crystalline filament. The partially oriented filament is drawn to form the highly oriented and crystalline filament.

What is claimed is: 
     
         1 . A melt-spun oriented crystalline filament and/or fiber formed of polyethylene terephthalate (PET) and having a crystallinity of about 45% to about 60%, an elongation of less than about 10%, and a tenacity of at least about 11 g/d. 
     
     
         2 . The melt-spun oriented crystalline filament and/or fiber of  claim 1 , wherein the filament and/or fiber has a modulus of at least about 130 g/d. 
     
     
         3 . A melt-spun oriented crystalline filament and/or fiber formed of polyethylene naphthalate (PEN) and having a crystallinity of about 45% to about 52%, an elongation of less than about 10%, and a tenacity of at least about 10 g/d. 
     
     
         4 . The melt-spun oriented crystalline filament and/or fiber of  claim 3 , wherein the filament and/or fiber has a modulus of at least about 200 g/d. 
     
     
         5 . A textile material comprising a plurality of melt-spun oriented crystalline filaments and/or fibers formed of polyethylene terephthalate (PET) and having a crystallinity of about 45% to about 60%, an elongation of less than about 10%, and a tenacity of at least about 11 g/d. 
     
     
         6 . The textile material of  claim 5 , wherein the melt-spun oriented crystalline filaments and/or fibers have a modulus of at least about 130 g/d. 
     
     
         7 . The textile material of  claim 5 , wherein the textile material is a woven fabric. 
     
     
         8 . The textile material of  claim 5 , wherein the textile material is a nonwoven material. 
     
     
         9 . The textile material of  claim 5 , wherein the textile material is a knit fabric. 
     
     
         10 . The textile material of  claim 5 , wherein the textile material is a yarn. 
     
     
         11 . The textile material of  claim 5 , wherein the textile material is a braid. 
     
     
         12 . The textile material of  claim 5 , wherein the textile material is a 3D woven structure. 
     
     
         13 . A textile material comprising a plurality of melt-spun oriented crystalline filaments and/or fibers formed of polyethylene naphthalate (PEN) and having a crystallinity of about 45% to about 52%, an elongation of less than about 10%, and a tenacity of at least about 10 g/d. 
     
     
         14 . The textile material of  claim 13 , wherein the melt-spun oriented crystalline filaments and/or fibers have a modulus of at least about 200 g/d. 
     
     
         15 . The textile material of  claim 13 , wherein the textile material is a woven fabric. 
     
     
         16 . The textile material of  claim 13 , wherein the textile material is a nonwoven material. 
     
     
         17 . The textile material of  claim 13 , wherein the textile material is a knit fabric. 
     
     
         18 . The textile material of  claim 13 , wherein the textile material is a yarn. 
     
     
         19 . The textile material of  claim 13 , wherein the textile material is a braid. 
     
     
         20 . The textile material of  claim 13 , wherein the textile material is a 3D woven structure. 
     
     
         21 . A melt-spun oriented crystalline filament and/or fiber formed a blend comprising about 50% by weight to about 99.9% by weight of polyethylene naphthalate (PEN) and about 0.01% by weight to about 50% by weight of polyethylene terephthalate (PET), the filament or fiber having an elongation of less than about 15%, a tenacity of at least about 10 g/d, and a modulus of at least about 130 g/d. 
     
     
         22 . The melt-spun oriented crystalline filament and/or fiber of  claim 21 , comprising a blend of about 99% by weight PEN and about 1% by weight PET. 
     
     
         23 . A textile material comprising a plurality of melt-spun oriented crystalline filaments and/or fibers formed of a blend comprising about 50% by weight to about 99.9% by weight of polyethylene naphthalate (PEN) and about 0.01% by weight to about 50% by weight of polyethylene terephthalate (PET), the filament or fiber having an elongation of less than about 15%, a tenacity of at least about 10 g/d, and a modulus of at least about 130 g/d. 
     
     
         24 . The textile material of  claim 23 , wherein the textile material is a woven fabric. 
     
     
         25 . The textile material of  claim 23 , wherein the textile material is a nonwoven material. 
     
     
         26 . The textile material of  claim 23 , wherein the textile material is a knit fabric. 
     
     
         27 . The textile material of  claim 23 , wherein the textile material is a yarn. 
     
     
         28 . The textile material of  claim 23 , wherein the textile material is a braid. 
     
     
         29 . The textile material of  claim 23 , wherein the textile material is a 3D woven structure. 
     
     
         30 . A melt-spun oriented crystalline filament and/or fiber formed of polypropylene and having a tenacity of at least about 10 g/d, an elongation of less than about 15%, and a modulus of at least about 130 g/d.