Fibers made from copolymers of propylene/α-olefins

• US 7,504,347 B2
• Filed: 03/15/2006
• Issued: 03/17/2009
• Est. Priority Date: 03/17/2004
• Status: Active Grant

• Current Assignee: Dow Global Technologies LLC (Dow, Inc.)
• Original Assignee: Dow Global Technologies, Inc. (Dow, Inc.)
• Inventors: Chen, Hongyu, Patel, Rajen M., Lai, Shih-Yaw, Poon, Benjamin C., Cheung, Yunwa W., Chang, Andy C., Chiu, Yuen-Yuen D., Sen, Ashish, Peng, Hong, Doufas, Antonios K.
• Primary Examiner(s): Salvatore; Lynda
• Application Number:
  US11/377,725
• Publication Number:
  US 20060199006A1
• Time in Patent Office: 1,098 Days
• Field of Search: 428/296.7, 442/327, 442361-364
• US Class Current: 442/361
• CPC Class Codes: D01F 6/30 comprising olefins as the major constituent
• CPC Class Codes: Y10T 428/249938 Composite or conjugate fiber [e.g., fiber contains more than one chemically different material in monofilament or multifilament form, etc.]
• CPC Class Codes: Y10T 428/2913 Rod, strand, filament or fiber
• CPC Class Codes: Y10T 442/60 Nonwoven fabric [i.e., nonwoven strand or fiber material]
• CPC Class Codes: Y10T 442/637 Including strand or fiber material which is a monofilament composed of two or more polymeric materials in physically distinct relationship [e.g., sheath-core, side-by-side, islands-in-sea, fibrils-in-matrix, etc.] or composed of physical blend of chemically different polymeric materials or a physical blend of a polymeric material and a filler material

Abstract

A fiber is obtainable from or comprises a propylene/α-olefin interpolymer characterized by an elastic recovery, Re, in percent at 300 percent strain and 1 cycle and a density, d, in grams/cubic centimeter, wherein the elastic recovery and the density satisfy the following relationship: Re>1481-1629 (d). Such interpolymer can also be characterized by other properties. The fibers made therefrom have a relatively high elastic recovery and a relatively low coefficient of friction. The fibers can be cross-linked, if desired. Woven or non-woven fabrics can be made from such fibers.

Claims

1. A fiber obtainable from or comprising a propylene/α

-olefin interpolymer, wherein the propylene/α

-olefin interpolymer is characterized by one or more of the following properties;

(a) a Mw/Mn from about 1.7 to about 3.5, at least one melting point, Tm, in degrees Celsius, and a density, d, in grams/cubic centimeter, wherein the numerical values of Tm and d correspond to the relationship;

T_m>

−

2002.9+4538.5(d)−

2422.2(d)²;

or

(b) a Mw/Mn from about 1.7 to about 3.5, and a heat of fusion, Δ

H in J/g, and a delta quantity, Δ

T, in degrees Celsius defined as the temperature difference between the tallest DSC peak and the tallest CRYSTAF peak, wherein the numerical values of Δ

T and Δ

H have the following relationships;

Δ

T>

−

0.1299(Δ

H)+62.81 for Δ

H greater than zero and up to 130 J/g,

Δ

T≧

48°

C. for Δ

H greater than 130 J/g,

wherein the CRYSTAF peak is determined using at least 5 percent of the cumulative polymer, and if less than 5 percent of the polymer has an identifiable CRYSTAF peak, then the CRYSTAF temperature is 30°

C.;

or

(c) a Mw/Mn from about 1.7 to about 3.5 and an elastic recovery, Re, in percent at 300 percent strain and 1 cycle measured with a compression-molded film of the propylene/α

-olefin interpolymer, and a density, d, in grams/cubic centimeter, wherein the numerical values of Re and d satisfy the following relationship when propylene/α

-olefin interpolymer is substantially free of a cross-linked phase;

Re>

1481−

1629(d);

or

(d) a Mw/Mn from about 1.7 to about 3.5 and a molecular fraction which elutes between 40°

C. and 130°

C. when fractionated using TREF, characterized in that the fraction has a molar comonomer content of at least 5 percent higher than that of a comparable random propylene interpolymer fraction eluting between the same temperatures, wherein said comparable random propylene interpolymer comprises the same comonomer(s) and has a melt index, density, and molar comonomer content (based on the whole polymer) within 10 percent of that of the propylene/α

-olefin interpolymer.

2. The fiber of claim 1, wherein the propylene/α

-olefin interpolymer is characterized by an elastic recovery, R_e, in percent at 300 percent strain and 1 cycle measured from a compression-molded film of the propylene/α

-olefin interpolymer and a density, d, in grams/cubic centimeter, wherein the elastic recovery and the density satisfy the following relationship when propylene/α

-olefin interpolymer is substantially free of a cross-linked phase;

R_e>

1481−

1629(d).

3. The fiber of claim 1, wherein the propylene/α

-olefin interpolymer has at least one melting point, T_m, in degrees Celsius and density, d, in grams/cubic centimeter, wherein the numerical values of the variables correspond to the relationship;

T_m>

−

2002.9+4538.5(d)−

2422.2(d)²

and wherein the interpolymer has a M_w/M_n from about 1.7 to about 3.5.

4. The fiber of claim 1, wherein the propylene/α

-olefin interpolymer has a M_w/M_n from about 1.7 to about 3.5, and the interpolymer is characterized by a heat of fusion, Δ

H, in J/g, and a delta quantity, Δ

T, in degree Celsius defined as the difference between the tallest DSC peak minus the tallest CRYSTAF peak, the Δ

T and Δ

H meet the following relationships;

Δ

T>

−

0.1299(Δ

H)+62.81, for Δ

H greater than zero and up to 130 J/g, or

Δ

T≧

48°

C., for Δ

H greater than 130 J/g,

wherein the CRYSTAF peak is determined using at least 5 percent of the cumulative polymer, and if less than 5 percent of the polymer has an identifiable CRYSTAF peak, then the CRYSTAF temperature is 30°

C.

7. The fiber of claim 1, wherein the α

-olefin is styrene, ethylene, 1-butene, 1-hexene, 1-octene, 4-methyl-1-pentene, 1-decene, or a combination thereof.

8. The fiber of claim 1, wherein the fiber is cross-linked.

9. The fiber of claim 1, wherein the propylene/α

-olefin interpolymer is blended with another polymer.

10. The fiber of claim 1, wherein the fiber is a bicomponent fiber.

11. The fiber of claim 8, wherein the cross-linking is effected by photon irradiation, electron beam irradiation, or a cross-linking agent.

12. The fiber of claim 8, the percent of cross-linked polymer is at least 20 percent as measured by the weight percent of gels formed.

13. The fiber of claim 1, wherein the fiber has coefficient of friction of less than about 1.2, wherein the interpolymer is not mixed with any filler.

14. A fabric comprising the fiber of claim 1.

15. The fabric of claim 14, wherein the fabric comprises fibers made by solution spinning.

16. The fabric of claim 14, wherein the fabric is elastic.

17. The fabric of claim 14, wherein the fabric is woven.

18. The fabric of claim 14, wherein the fabric has an MD percent recovery of at least 50 percent at 100 percent strain.

19. A yarn comprising the fiber of claim 1.

20. The yarn of claim 19, wherein the yarn is covered.

21. The yarn of claim 20, where the yarn is covered by cotton yarns or nylon yarns.

5. A fiber obtainable from or comprising a propylene/α

-olefin interpolymer, wherein the propylene/α

-olefin interpolymer is characterized by one or more of the following properties;

(a) having at least one molecular fraction which elutes between 40°

C. and 130°

C. when fractionated using TREF, characterized in that the fraction has a block index of at least 0.5 and up to about 1 and a molecular weight distribution, Mw/Mn, greater than about 1.3;

or (b) an average block index greater than zero and up to about 1.0 and a molecular weight distribution, Mw/Mn, greater than about 1.3.

6. A fiber obtainable from or comprising at least one interpolymer of propylene and C₂ or C₄-C₂₀ α

-olefin, wherein the interpolymer has a density from about 0.860 g/cc to about 0.895 g/cc and a compression set at 70°

C. of less than about 70%.