Monofilament, fabric and production method

Abstract

A monofilament is particularly suited for use as a component in an industrial textile such as a papermachine clothing (PMC) fabric. The monofilament is formed from a composition including more than 70 weight % to 99 weight % polyamide and from 1 weight % to less than 30 weight % polyphenylene ether.

1 . A monofilament, comprising:
 a monofilament body formed from a composition including more than 70 weight % to 99 weight % polyamide, and from 1 weight % to less than 30 weight % polyphenylene ether.   
     
     
         2 . The monofilament according to  claim 1 , configured for use as a component in an industrial textile such as a papermachine clothing fabric. 
     
     
         3 . The monofilament according to  claim 1 , wherein said composition does not include any compatibilizer. 
     
     
         4 . The monofilament according to  claim 1 , wherein said composition does not include any compound belonging to the group consisting of fumaric acid, maleic acid, itaconic acid, dimethylmaleate, maleimide, tetrahydrophthalimide, maleic anhydride, itaconic anhydride, glutaconic anhydride, citraconic anhydride and tetrahydrophthalic anhydride. 
     
     
         5 . The monofilament according to  claim 1 , wherein the composition does not include any functionalized olefinic elastomer. 
     
     
         6 . The monofilament according to  claim 1 , wherein a polymer part of said composition is a binary mixture of polyamide and polyphenylene ether. 
     
     
         7 . The monofilament according to  claim 1 , wherein said polyamide is selected from the group consisting of PA6, PA6.6, PA6.T, PA6.10, PA6.12, PA6,6.6, PA4.10, PA5.6, PA5.10, PA5.12 and mixtures thereof. 
     
     
         8 . The monofilament according to  claim 1 , wherein said monofilament body has a loop tenacity which is at least 20% greater than the loop tenacity of a comparative monofilament, wherein the comparative monofilament is formed in an identical manner as the monofilament except that the polyphenylene ether is replaced by polyamide. 
     
     
         9 . The monofilament according to  claim 1 , wherein the monofilament has a water absorption which is at least 15% less than a water absorption of a comparative monofilament, wherein the comparative monofilament is formed in an identical manner as the monofilament except that the polyphenylene ether is replaced by polyamide, and wherein the water absorption is determined by immersing the respective monofilament in distilled water at 23° C. for 24 h and weighing the respective monofilament before and after the immersion process. 
     
     
         10 . The monofilament according to  claim 9 , which comprises weighing the respective monofilament before and after the immersion process according to ASTM D570. 
     
     
         11 . The monofilament according to  claim 1 , wherein the monofilament has an abrasion resistance which is at least 50% greater than an abrasion resistance of a comparative monofilament, wherein the comparative monofilament is formed in an identical manner as the monofilament except that the polyphenylene ether is replaced by polyamide. 
     
     
         12 . The monofilament according to  claim 11 , wherein the abrasion resistance of the monofilament is at least 70% greater than the abrasion resistance of the comparative monofilament. 
     
     
         13 . The monofilament according to  claim 1 , wherein the monofilament has a tenacity which is greater than 5.0 gf/den. 
     
     
         14 . The monofilament according to  claim 1 , wherein the monofilament has a thermal stability which is at least 10% greater than a thermal stability of a comparative monofilament, wherein the comparative monofilament is formed in an identical manner as the monofilament except that the polyphenylene ether is replaced by polyamide, and wherein the thermal stability is determined as a percentage of a tenacity retention after exposing the respective monofilament in an oven at 170° C. for 24 h. 
     
     
         15 . A fabric, comprising a plurality of woven or non-woven monofilaments, wherein at least some of said monofilaments are formed from a composition including more than 70 weight % to 99 weight % polyamide and 1 weight % to less than 30 weight % polyphenylene ether. 
     
     
         16 . The fabric according to  claim 15  configured as a papermachine clothing fabric. 
     
     
         17 . The fabric according to  claim 15 , wherein the fabric is completely made up from monofilaments which are formed from a composition including more than 70 weight % to 99 weight % polyamide and 1 weight % to less than 30 weight % polyphenylene ether. 
     
     
         18 . A method for forming a monofilament comprising the steps of:
 preparing a resin composition including more than 70 weight % to 99 weight % polyamide and 1 weight % to less than 30 weight % polyphenylene ether;   extruding the resin composition through a spinneret to form a monofilament; and   drawing the monofilament for one or more times.   
     
     
         19 . A method of forming a papermachine clothing fabric, the method comprising providing monofilaments according to  claim 1  and forming the monofilaments into the a papermachine clothing fabric.