Patent Application
20200385522
The present invention relates to a textile material, such as a yarn, a fiber, a filament (monofilament or multifilament), a membrane, a porous membrane, or a woven or nonwoven textile, comprising at least one synthetic fiber made of thermoplastic elastomer polymer.
In the present description of the invention, the following definitions apply:
Among the textiles are, notably, fiber laps (dressings, filters, felt), roving (dressings), yarns (for sewing, knitting or weaving), nonwovens, webs, nets, knitted fabrics (rectilinear, circular, fully-fashioned), fabrics (traditional, Jacquard, multiple, double-sided, multiaxial, 2.5D, 3D), and many others.
In certain fields, it is important to have available textile materials that are, simultaneously, flexible, stretchable, strong, i.e. tear-resistant, and anti-pilling, i.e. abrasion-resistant.
The aim of the present invention is to improve the flexibility, stretchability and strength of these textile materials and their abrasion resistance.
The flexibility is evaluated by means of the following moduli: the tensile modulus according to the standard ISO 527 1A:2012, and the flexural modulus at 23° C. according to the standard ISO 178:2010. A decrease in these modulus values tends toward better flexibility of textile materials.
The stretchability is evaluated by means of the elongational rheology test, as defined hereinbelow in the examples of the present patent application.
The anti-pilling property is measured by the abrasion resistance, which is evaluated by the loss of mass according to the standard ISO 527-1A:2012: the lower the loss of mass of the material, the better the abrasion resistance of textiles made from this material.
The tear strength is, for its part, evaluated according to the standard ISO 34-1:2015.
Among the block copolymers known for the manufacture of textile materials, mention may be made of copolymers containing polyamide blocks and polyether blocks (PEBA). These PEBA belong to the particular class of polyetheresteramides when they result from the copolycondensation of polyamide blocks bearing reactive carboxylic ends with polyether blocks bearing reactive ends, which are polyetherpolyols (polyetherdiols), the bonds between the polyamide blocks and the flexible polyether blocks being ester bonds.
PEBAs are known for their physical properties such as their flexibility, their impact strength and their ease of implementation by injection molding. However, these copolymers are difficult to transform into textile material form by extrusion, notably on account of a low melt viscosity and a low melt strength resulting therefrom.
Various means exist for modulating the melt viscosity of a polymer.
Thus, it may be envisaged to increase the polyamide content, which has a tendency to increase the viscosity. Moreover, extrudable polymer compositions may be obtained by compounding the block copolymer with other polymers, notably polyolefins.
It is also possible to increase the melt viscosity by lengthening the polymer chains, for example by prolonging the polymerization. This approach has been disappointing on account of the degradation of the blocks, which also brings about yellowing of the material, without being able to achieve the desired levels of melt viscosity, of at least 300 Pa·s, measured according to the standard ISO 1621-10:2015.
Finally, it may be envisaged to increase the melt viscosity by simultaneously increasing the size of the various blocks of the polymer, for example of the polyamide blocks and of the polyether blocks in the case of PEBA. For example on passing, for a PEBA PA6-PEG, from 1500-1500 to 2000-2000, it should be possible to increase the melt viscosity for an equivalent degree of polymerization. However, the tests performed along these lines were inconclusive: the reactivity between the PA blocks and the PEG blocks is greatly reduced.
The aim of the invention is thus also to provide an improved process for manufacturing stretchable, flexible and anti-pilling textile materials based on block copolymers, in which the extrusion is facilitated and the maximum achievable extrusion rates are increased.
The Applicant has now found that the use, under certain conditions, of a polycarbodiimide in a process for manufacturing a textile material based on a copolymer containing polyamide blocks and flexible blocks including at least one carboxylic acid chain end makes it possible to significantly improve the drawability of said copolymer in textile material form and/or to increase the extrusion rate of said copolymer, while at the same time improving the stretchability of the textile material thus obtained, the flexibility of the textile material, its abrasion resistance and its tear strength, without sacrificing its recyclability.
In the present description, it is pointed out that when reference is made to ranges, expressions of the type “ranging from . . . to . . . ” or “including/comprising from . . . to . . . ” include the limits of the range. Conversely, expressions of the type “between . . . and . . . ” exclude the limits of the range.
Unless otherwise mentioned, the percentages expressed are mass percentages. Unless otherwise mentioned, the parameters to which reference is made are measured at atmospheric pressure and at room temperature (20-25° C., generally 23° C.).
The invention is now described in detail and in a nonlimiting manner in the description that follows.
One subject of the invention is thus a flexible, stretchable and anti-pilling textile material based on a block copolymer comprising at least one rigid polyamide PA block and at least one flexible block, characterized in that said copolymer includes at least one carboxylic acid chain end blocked with a polycarbodiimide.
In the present description, it is pointed out that the “copolymer-based” textile material means that the textile material comprises at least 51% by weight of copolymer relative to the total weight of the textile material.
Preferably, the textile material according to the invention comprises at least 60% by weight of said copolymer as defined by the invention. Preferably, it contains at least 70% by weight, preferably at least 80% by weight, or even at least 90%, or better still at least 95% by weight of copolymer as defined by the invention, relative to the total weight of the textile material.
The copolymer containing rigid polyamide PA blocks and flexible blocks thus defined according to the invention falls among the thermoplastic elastomer polymers. The term “thermoplastic elastomer polymer”, abbreviated as “TPE”, denotes a polymer which constitutes a polyphasic material having at least two transitions, namely a first transition at a temperature T1 (in general this is the glass transition temperature) and a second transition at a temperature T2 above T1 (in general this is the melting point). At a temperature below T1, the material is rigid, between T1 and T2 it has elastic behavior, and above T2 it is molten. Such a polymer combines the elastic behavior of materials of rubber type with the transformability of thermoplastics.
A polyamide-based thermoplastic elastomer (TPE-A) for the purposes of the invention, such as a PEBA, is a block copolymer comprising an alternating sequence of rigid or hard blocks (HB) and flexible or soft blocks (SB), according to the following general formula:
—[HB—SB]n-
and in which:
For the purposes of the invention, the expression “low glass transition temperature” for a polymer included in the composition of an SB means a glass transition temperature Tg below 15° C., preferably below 0° C., preferably below −15° C., more preferably below −30° C. By way of example, said soft block may be based on PEG with a number-average molar mass equal to 1500 g/mol and a Tg of the order of −35° C. Said glass transition temperature Tg may also be below −50° C., notably in the case where said soft block is based on PTMG.
Copolyether block amides, also known as copolymers containing polyether blocks and polyamide blocks, abbreviated as “PEBA”, result from the polycondensation of polyamide blocks bearing reactive ends with polyether blocks bearing reactive ends, such as, inter alia:
1) polyamide blocks bearing diamine chain ends with polyoxyalkylene blocks bearing dicarboxylic chain ends;
2) polyamide blocks bearing dicarboxylic chain ends with polyoxyalkylene blocks bearing diamine chain ends, obtained by cyanoethylation and hydrogenation of α,ω-dihydroxylated aliphatic polyoxyalkylene blocks, known as polyetherdiols;
3) polyamide blocks bearing dicarboxylic chain ends with polyetherdiols, the products obtained being, in this particular case, polyetheresteramides.
The polyamide blocks bearing dicarboxylic chain ends originate, for example, from the condensation of polyamide precursors in the presence of a chain-limiting dicarboxylic acid. The polyamide blocks bearing diamine chain ends originate, for example, from the condensation of polyamide precursors in the presence of a chain-limiting diamine.
The number-average molar mass Mn of the polyamide blocks is between 400 and 20 000 g/mol and preferably between 500 and 10 000 g/mol.
The polymers containing polyamide blocks and polyether blocks may also comprise randomly distributed units.
Three types of polyamide blocks may advantageously be used.
According to a first type, the polyamide blocks originate from the condensation of a dicarboxylic acid, in particular those containing from 4 to 20 carbon atoms, preferably those containing from 6 to 18 carbon atoms, and of an aliphatic or aromatic diamine, in particular those containing from 2 to 20 carbon atoms, preferably those containing from 6 to 14 carbon atoms.
As examples of dicarboxylic acids, mention may be made of 1,4-cyclohexanedicarboxylic acid, butanedioic acid, adipic acid, azelaic acid, suberic acid, sebacic acid, dodecanedicarboxylic acid, octadecanedicarboxylic acid, terephthalic acid and isophthalic acid, but also dimerized fatty acids.
As examples of diamines, mention may be made of tetramethylenediamine, hexamethylenediamine, 1,10-decamethylenediamine, dodecamethylenediamine, trimethylhexamethylenediamine, the isomers of bis(4-aminocyclohexyl)methane (BACM), bis(3-methyl-4-aminocyclohexyl)methane (BMACM) and 2-2-bis-(3-methyl-4-aminocyclohexyl)propane (BMACP), and para-aminodicyclohexylmethane (PACM), and isophoronediamine (IPDA), 2,6-bis(aminomethyl)norbornane (BAMN) and piperazine (Pip).
As regards the polyamide rigid block, the standard NF EN ISO 1874-1: 2011 defines a nomenclature for polyamides. In the present description, the term “monomer” should be taken as meaning “repeating unit”. The case where a repeating unit of the polyamide consists of the combination of a diacid with a diamine is particular. It is considered that it is the combination of a diamine and of a diacid, i.e. the “diamine diacid”, also called “XY”, pair, in equimolar amount, which corresponds to the monomer. This is explained by the fact that, individually, the diacid or the diamine is only a structural unit, which is not enough by itself to polymerize.
Examples thereof are the blocks PA412, PA414, PA418, PA610, PA612, PA614, PA618, PA912, PA1010, PA1012, PA1014 and PA1018.
According to a second type, the polyamide blocks result from the condensation of one or more α,ω-aminocarboxylic acids and/or of one or more lactams containing from 6 to 12 carbon atoms in the presence of a dicarboxylic acid containing from 4 to 12 carbon atoms or of a diamine. As examples of lactams, mention may be made of caprolactam, oenantholactam and lauryllactam. As examples of α,ω-aminocarboxylic acids, mention may be made of aminocaproic acid, 7-aminoheptanoic acid, 11-aminoundecanoic acid and 12-aminododecanoic acid.
Advantageously, the polyamide blocks of the second type are made of polyamide-11, polyamide-12 or polyamide-6.
According to a third type, the polyamide blocks result from the condensation of at least one α,ω-aminocarboxylic acid (or a lactam), at least one diamine and at least one dicarboxylic acid.
In this case, the polyamide PA blocks are prepared by polycondensation:
Advantageously, the dicarboxylic acid containing Y carbon atoms is used as chain limiter, which is introduced in excess relative to the stoichiometry of the diamine(s).
According to one variant of this third type, the polyamide blocks result from the condensation of at least two α,ω-aminocarboxylic acids or from at least two lactams containing from 6 to 12 carbon atoms or from one lactam and one aminocarboxylic acid not having the same number of carbon atoms, in the optional presence of a chain limiter.
As examples of aliphatic α,ω-aminocarboxylic acids, mention may be made of aminocaproic acid, 7-aminoheptanoic acid, 11-aminoundecanoic acid and 12-aminododecanoic acid. As examples of lactams, mention may be made of caprolactam, oenantholactam and lauryllactam. As examples of aliphatic diamines, mention may be made of hexamethylenediamine, dodecamethylenediamine and trimethylhexamethylenediamine. An example of a cycloaliphatic diacid that may be mentioned is 1,4-cyclohexyldicarboxylic acid. As examples of aliphatic diacids, mention may be made of butanedioic acid, adipic acid, azelaic acid, suberic acid, sebacic acid, dodecanedicarboxylic acid, dimerized fatty acids (these dimerized fatty acids preferably have a dimer content of at least 98%; they are preferably hydrogenated; they are sold under the brand name Pripol® by the company Unichema, or under the brand name Empol® by the company Henkel) and α,ω-diacid polyoxyalkylenes. As examples of aromatic diacids, mention may be made of terephthalic acid (T) and isophthalic acid (I). As examples of cycloaliphatic diamines, mention may be made of bis(4-aminocyclohexyl)methane (BALM), bis(3-methyl-4-aminocyclohexyl)methane (BMACM), 2-2-bis(3-methyl-4-aminocyclohexyl)propane (BMACP) and para-aminodicyclohexylmethane (PACM) isomers. The other diamines commonly used may be isophoronediamine (IPDA), 2,6-bis(aminomethyl)norbornane (BAMN) and piperazine.
In the case where the PA blocks of the PEBA according to the invention comprise at least two different monomers, called “comonomers”, i.e. at least one monomer and at least one comonomer (monomer other than the first monomer), they comprise a copolymer, such as a copolyamide, abbreviated as CoPA.
As examples of polyamide blocks of the third type, mention may be made of the following:
The mass Mn of the flexible blocks is between 100 and 6000 g/mol and preferably between 200 and 3000 g/mol.
Preferably, the polymer comprises from 1% to 80% by mass of flexible blocks and from 20% to 99% by mass of polyamide blocks, preferably from 4% to 80% by mass of flexible blocks and from 20% to 96% by mass of polyamide blocks.
According to a preferred embodiment, the rigid polyamide block, in the copolymer containing rigid PA blocks and flexible blocks according to the invention, comprises at least one of the following polyamide units: 11, 12, 6, 610, 612, 1010, 1012, and mixtures or copolyamides thereof.
The polyether blocks PE are formed from alkylene oxide units. These units may be, for example, ethylene oxide units, propylene oxide units or tetrahydrofuran (which leads to polytetramethylene glycol sequences). Use is thus made of PEG (polyethylene glycol) blocks, i.e. blocks formed from ethylene oxide units, PPG (propylene glycol) blocks, i.e. blocks formed from propylene oxide units, PO3G (polytrimethylene glycol) blocks, i.e. blocks formed from polytrimethylene glycol ether units (such copolymers with polytrimethylene ether blocks are described in patent U.S. Pat. No. 6,590,065), and PTMG blocks, i.e. blocks formed from tetramethylene glycol units, also known as polytetrahydrofuran. The PEBA copolymers may comprise in their chain several types of polyethers, the copolyethers possibly being in block or statistical form.
Use may also be made of blocks obtained by oxyethylation of bisphenols, such as for instance bisphenol A. The latter products are described in patent EP 613 919.
The polyether blocks may also be formed from ethoxylated primary amines. As examples of ethoxylated primary amines, mention may be made of the products of formula:
in which m and n are between 1 and 20 and x is between 8 and 18. These products are commercially available under the brand name Noramox® from the company CECA and under the brand name Genamin® from the company Clariant.
The flexible polyether blocks may comprise polyoxyalkylene blocks bearing NH2 chain ends, such blocks being able to be obtained by cyanoacetylation of α,ω-dihydroxylated aliphatic polyoxyalkylene blocks referred to as polyetherdiols. More particularly, use may be made of the Jeffamine products (for example Jeffamine® D400, D2000, ED 2003, XTJ 542, which are commercial products from the company Huntsman, also described in patents JP2004346274, JP2004352794 and EP1482011).
The polyether diol blocks are either used in unmodified form and copolycondensed with polyamide blocks bearing carboxylic end groups, or they are aminated to be converted into polyetherdiamines and condensed with polyamide blocks bearing carboxylic end groups. The general method for the two-step preparation of PEBA copolymers containing ester bonds between the PA blocks and the PE blocks is known and is described, for example, in French patent FR2846332. The general method for the preparation of PEBA copolymers of the invention containing amide bonds between the PA blocks and the PE blocks is known and is described, for example, in European patent EP1482011. The polyether blocks may also be mixed with polyamide precursors and a chain-limiting diacid to make polymers containing polyamide blocks and polyether blocks having randomly distributed units (one-step process).
Needless to say, the name PEBA in the present description of the invention relates not only to the Pebax® products sold by Arkema, to the Vestamid® products sold by Evonik® and to the Grilamid® products sold by EMS, but also to the Kellaflex® products sold by DSM or to any other PEBA from other suppliers.
Advantageously, the PEBA copolymers contain PA blocks as PA 6, as PA 11, as PA 12, as PA 612, as PA 66/6, as PA 1010 and/or as PA 614, preferably PA 11 and/or PA 12 blocks; and PE blocks as PTMG, as PPG and/or as PO3G. The PEBAs based on PE blocks predominantly consisting of PEG are to be categorized in the range of hydrophilic PEBAs. The PEBAs based on PE blocks predominantly consisting of PTMG are to be categorized in the range of hydrophobic PEBAs.
Advantageously, said PEBA used in the composition according to the invention is at least partially obtained from biobased raw materials.
The term “raw materials of renewable origin” or “biobased raw materials” means materials which comprise biobased carbon or carbon of renewable origin. Specifically, unlike materials derived from fossil materials, materials composed of renewable starting materials contain 14C. The “content of carbon of renewable origin” or “content of biobased carbon” is determined by application of the standards ASTM D 6866 (ASTM D 6866-06) and ASTM D 7026 (ASTM D 7026-04). By way of example, the PEBAs based on polyamide 11 at least partly originate from biobased raw materials and have a content of biobased carbon of at least 1%, which corresponds to a 12C/14C isotope ratio of at least 1.2×10−14. Preferably, the PEBAs according to the invention comprise at least 50% by mass of biobased carbon relative to the total mass of carbon, which corresponds to a 12C/14C isotope ratio of at least 0.6×10−12. This content is advantageously higher, notably up to 100%, which corresponds to a 12C/14C isotope ratio of 1.2×10−12, in the case, for example, of PEBA containing PA 11 blocks and PE blocks comprising PO3G, PTMG and/or PPG derived from starting materials of renewable origin.
The polyester blocks PES are usually manufactured by polycondensation between a dicarboxylic acid and a diol. Suitable carboxylic acids comprise those mentioned above used for forming the polyamide blocks, with the exception of terephthalic acid and isophthalic acid. Suitable diols comprise linear aliphatic diols such as ethylene glycol, 1,3-propylene glycol, 1,4-butylene glycol, 1,6-hexylene glycol, branched diols such as neopentyl glycol, 3-methylpentane glycol, 1,2-propylene glycol, and cyclic diols such as 1,4-bis(hydroxymethyl)cyclohexane and 1,4-cyclohexanedimethanol.
The term “polyesters” also means poly(caprolactone) and PESs based on fatty acid dimers, in particular the products of the Priplast® range from the company Croda or Uniqema.
It is also possible to envisage a PES block of alternating, statistical or block “copolyester” type, containing a sequence of at least two types of PES mentioned above.
For the purposes of the invention, the term polysiloxane block (abbreviated hereinbelow as PSi) means any organosilicon polymer or oligomer of linear or cyclic, branched or crosslinked structure, obtained by polymerization of functionalized silanes, and consisting essentially of a repetition of main units in which silicon atoms are linked together via oxygen atoms (siloxane bond —Si—O—Si—), optionally substituted hydrocarbon-based radicals being directly linked via a carbon atom to said silicon atoms. The most common hydrocarbon-based radicals are alkyl radicals, notably of C1-C10 and in particular methyl, fluoroalkyl radicals, aryl radicals and in particular phenyl, and alkenyl radicals and in particular vinyl; other types of radicals that may be bonded, either directly or via a hydrocarbon-based radical, to the siloxane chain are notably hydrogen, halogens and in particular chlorine, bromine or fluorine, thiols, alkoxy radicals, polyoxyalkylene (or polyether) radicals and in particular polyoxyethylene and/or polyoxypropylene, hydroxyl or hydroxyalkyl radicals, substituted or unsubstituted amine groups, amide groups, acyloxy or acyloxyalkyl radicals, hydroxyalkylamino or aminoalkyl radicals, quaternary ammonium groups, amphoteric or betaine groups, anionic groups such as carboxylates, thioglycolates, sulfosuccinates, thiosulfates, phosphates and sulfates, and mixtures thereof, this list obviously not being in any way limiting (“organomodified” silicones).
Preferably, said polysiloxane blocks comprise polydimethylsiloxane (abbreviated hereinbelow as PDMS blocks), polymethylphenylsiloxane and/or polyvinylsiloxane.
For the purposes of the invention, the term polyolefin block (abbreviated hereinbelow as PO block) means any polymer comprising an α-olefin as monomer, i.e. homopolymers of an olefin or copolymers of at least one α-olefin and of at least one other copolymerizable monomer, the α-olefin advantageously containing from 2 to 30 carbon atoms.
As examples of α-olefins, mention may be made of ethylene, propylene, 1-butene, 1-pentene, 3-methyl-1-butene, 1-hexene, 4-methyl-1-pentene, 3-methyl-1-pentene, 1-octene, 1-decene, 1-dodecene, 1-tetradecene, 1-hexadecene, 1-octadecene, 1-eicosene, 1-docosene, 1-tetracosene, 1-hexacosene, 1-octacosene and 1-triacontene. These α-olefins may be used alone or as a mixture of two or of more than two.
Examples that may be mentioned include:
According to an advantageous embodiment of the invention, said at least one polyolefin block comprises polyisobutylene and/or polybutadiene.
According to a particularly advantageous embodiment, the block copolymer according to the invention includes at least one flexible polyolefin block (PO block) and at least one hard hydrophilic block (abbreviated hereinbelow as hHB) comprising both polyamide and polyether, such as a polyetheramide block, a polyetheresteramide block and/or a polyetheramideimide block, etc. Said PO block preferably comprises a polyolefin including acid, alcohol or amine end groups. Preferably, the PO block is obtained by thermal degradation of high molecular weight polyolefins to form polyolefins of lower mass and functionalized (reference method: Japanese Kokai Publication Hei-03-62804). As regards the hHB block, it may also comprise at least one polymer chosen from: cationic polymers of quaternary amine type and/or phosphorus derivatives; and/or anionic polymers, of modified diacid type, including a sulfonate group and which are capable of reacting with a polyol. The addition of organic salt may then be envisaged in the preparation of the hHB block or during the reaction between the PO block and the hHB block. U.S. Pat. No. 6,552,131 describes the synthesis and the various possible structures for the copolymer containing PO blocks and hHB blocks, it being possible, needless to say, for the latter to be envisaged in the process according to the invention.
For the purposes of the invention, the term polycarbonate block (abbreviated hereinbelow as PC block) more particularly means any aliphatic polycarbonate. Aliphatic polycarbonates are described, for example, in DE2546534 and JP1009225. Such polycarbonate homopolymers or copolymers are also described in US 471203. Patent applications WO 92/22600 and WO 95/12629 describe copolymers comprising polycarbonate blocks and also the processes for synthesizing same. The blocks (and the synthesis thereof) described in these documents may be entirely envisaged for the synthesis of a PC block copolymer according to the invention. Preferably, the polycarbonate blocks of the copolymer according to the invention have the formula:
in which a is an integer from 2 to 300; R1 and R2, which may be identical or different, represent a straight or branched, aliphatic or alicyclic chain containing from 2 to 18 carbon atoms, or represent a polyoxyalkylene group, or represent a polyester group.
The polycarbonates in which R1 and R2 are chosen from hexylene, decylene, dodecylene, 1,4-cyclohexylene, 2,2-dimethyl-1,3-propylene, 2,5-dimethyl-2,5-hexylene or polyoxyethylene groups are preferred.
If the block copolymers described above generally comprise at least one rigid polyamide block and at least one flexible block, it is obvious that the present invention in fact covers all the copolymers comprising two, three, four (or even more) different blocks chosen from those described in the present description, provided that at least one of these blocks is a polyamide block.
Advantageously, the copolymer according to the invention comprises a block segmented copolymer comprising three different types of blocks (referred to as “triblock” in the present description of the invention), which result from the condensation of several of the blocks described above. Said triblock is preferably chosen from copolyetheresteramides and copolyetheramideurethanes in which:
According to a preferred embodiment, the flexible block in the textile material based on a copolymer containing rigid PA blocks and flexible blocks according to the invention comprises (and preferably is) a polyether PE block, preferably chosen from PTMG, PPG, PO3G and/or PEG.
According to another advantageous embodiment, the flexible block in the copolymer containing rigid PA blocks and flexible blocks of the textile material according to the invention comprises (and preferably is) a polyester PES block, chosen from polyester diols, poly(caprolactone) and polyesters based on fatty acid dimers.
Advantageously, in the copolymer according to the invention, the weight ratio of the PA blocks to the flexible blocks is within the range from 0.3 to 10, preferably from 0.3 to 6, preferably from 0.3 to 3, preferably from 0.3 to 2.
Preferably, said copolymer based on the textile material according to the invention comprises from 30% to 70% by weight of flexible polytetramethylene glycol (PTMG) blocks, preferably from 50% to 70% by weight of PTMG blocks, relative to the total weight of copolymer.
Preferably, said polyamide PA block of the copolymer used in the textile material of the invention comprises at least one of the following polyamide units: 6, 66, 610, 612, PA1010, PA1012, PA11, PA12, PA6/12, PA6/6.6, and mixtures or copolyamides thereof.
Advantageously, the copolymer comprises a copolymer containing rigid polyamide blocks and flexible polyether blocks (PEBA), preferably chosen from the following PEBAs: PA6-PEG, PA1010-PEG, PA1012-PEG, PA11-PEG, PA12-PEG, PA6/12-PEG, PA66-PEG, PA6/66-PEG, and mixtures thereof, or from the following PEBAs: PA6-PTMG, PA1010-PTMG, PA1012-PTMG, PA11-PTMG, PA12-PTMG, PA6/12-PTMG, PA66-PTMG, PA6/66-PTMG, and mixtures thereof.
Polycarbodiimides that are suitable for the present invention are represented by the following general formula:
R—[—N═C═N—R′]n—
in which R is monovalent, R′ is divalent, n is from 2 to 50, preferably from 2 to 45, preferably from 2 to 20 and preferably from 5 to 20.
R may be, for example, a C1-C20 alkyl or C3-C10 cycloalkyl or C1-C20 alkenyl group, and may be cyclic or branched, or may contain a C8-C16 aromatic nucleus, and may be substituted with functional groups.
R′ may be a divalent group corresponding to all the foregoing, for example a C1-C20 alkylene, a C3-C10 cycloalkylene, etc. Examples of functional groups comprise, without being limited thereto, cyanato and isocyanato, halo, amido, carboxamido, amino, imido, imino, silyl, etc. These lists are intended solely for illustrative purposes and not for the purpose of limiting the scope of the present invention.
As examples of polycarbodiimides that may be used according to the present invention, mention may be made of repeated units of N,N′-dicyclohexylcarbodiimide, N,N′-diisopropylcarbodiimide, N,N′-diphenylcarbodiimide, N,N′-bis(2,6-diisopropylphenyl)carbodiimide, 4,4′-dicyclohexylmethanecarbodiimide, tetramethylxylylenecarbodiimide (aromatic carbodiimide), N,N-dimethylphenylcarbodiimide, N,N′-bis(2,6-diisopropylphenyl)carbodiimide, 2,2′,6,6′-tetraisopropyldiphenylcarbodiimide (aromatic carbodiimide), aromatic homopolymer of 1,3,5-triisopropyl-2,4-diisocyanatobenzene, aromatic heteropolymer of 1,3,5-triisopropyl-2,4-diisocyanatobenzene and 2,6-diisopropylphenyl isocyanate, or combinations thereof.
Specific examples of R′ comprise, without being limited thereto, divalent radicals derived from 2,6-diisopropylbenzene, naphthalene, 3,5-diethyltoluene, 4,4′-methylenebis(2,6-diethylenephenyl), 4,4′-methylenebis(2-ethyl-6-methylphenyl), 4,4′-methylenebis(2,6-diisopropylphenyl), 4,4′-methylenebis(2-ethyl-5-methylcyclohexyl), 2,4,6-triisopropylphenyl, n-hexane, cyclohexane, dicyclohexylmethane and methylcyclohexane, and analogs.
U.S. Pat. Nos. 5,130,360, 5,859,166, 368,493, 7,456,137, US 2007/0278452, US 2009/0176938, and in particular U.S. Pat. No. 5,360,888 describe more examples of polycarbodiimides.
Suitable polycarbodiimides may be obtained from commercially available sources such as the Stabaxol P series from Rhein Chemie, the Stabilizer series from Raschig, and others from Ziko or Teijin, for example.
Advantageously, the polycarbodiimide is chosen from a Stabilizer product, in particular Stabilizer® 9000 corresponding to poly(1,3,5-triisopropylphenylene-2,4-carbodiimide), a Stabaxol® product, notably a Stabaxol® P product, in particular Stabaxol® P100 or Stabaxol® P400, or a mixture thereof.
Preferably, the polycarbodiimide has a weight-average molecular mass of greater than 10 000 g/mol.
Advantageously, the weight-average molecular mass of the polycarbodiimide is within the range from 10 000 to 40 000 g/mol, preferably from 15 000 to 30 000 g/mol. Preferably, the weight-average molecular mass of the polycarbodiimide used in the present invention is measured by gel permeation chromatography (GPC) in tetrahydrofuran (THF).
The weight content of the polycarbodiimide advantageously represents from 0.5% to 10% by weight, preferably from 0.5% to 7% by weight, preferably from 0.5% to 3% by weight, preferably from 0.5% to 2.5%, preferably from 0.5% to 2% by weight, relative to the total weight of the copolymer according to the invention.
According to an advantageous embodiment of the invention, said carboxylic acid of the copolymer, in the textile material according to the invention, forms a urea bond by reaction with a carbodiimide of the polycarbodiimide.
One of the advantages of the block copolymer bearing a blocked acid chain end based on the textile material according to the invention is that it remains in noncrosslinked linear form, the dispersity Mw/Mn of the copolymer being less than 3. This is surprising insofar as, in the prior art, carbodiimides are rather used for increasing the viscosity of polyamides (see, for example, patent FR 3027907), notably by crosslinking them, and for improving their resistance to hydrolysis as described in U.S. Pat. No. 5,360,888.
A subject of the present invention is also the use of a polycarbodiimide in a process for manufacturing a textile material based on a copolymer containing polyamide blocks and flexible blocks including at least one carboxylic acid chain end, for improving the extrudability and/or the drawability of the copolymer in textile material form and/or for improving the extrusion rate of said copolymer, in which at least one carboxylic acid chain end of the copolymer is blocked with a carbodiimide function of the polycarbodiimide.
A subject of the present invention is also the use of a polycarbodiimide in a textile material based on a copolymer containing polyamide blocks and flexible blocks including at least one carboxylic acid chain end, for improving the stretchability of the textile material, the flexibility of the textile material, its abrasion resistance and its tear strength, in which at least one carboxylic acid chain end of the copolymer is blocked with a carbodiimide function of the polycarbodiimide.
Preferably, for the use according to the invention, the polycarbodiimide has a weight-average molecular mass of greater than 10 000 g/mol, preferably within the range from 10 000 to 40 000 g/mol, preferably from 15 000 to 30 000 g/mol.
Advantageously, at least one carboxylic acid chain end of the copolymer is blocked with a urea function formed by reaction with the polycarbodiimide.
A subject of the present invention is also a copolymer-based textile material composition according to the invention, characterized in that it comprises:
Advantageously, the textile material according to the invention comprises a functional polyolefin including a grafting with a monomer chosen from the group comprising unsaturated carboxylic acids, unsaturated carboxylic anhydrides, vinyl monomers, acrylic monomers, and mixtures thereof.
Preferably, the functional polyolefin is chosen from the group comprising ethylene-acrylic ester copolymers, ethylene-acrylic ester-maleic anhydride copolymers, and ethylene-acrylic ester-glycidyl methacrylate copolymers.
Advantageously, the textile material according to the invention has a thickness of less than or equal to 100 μm, preferably less than or equal to 50 μm, preferably less than or equal to 30 μm, preferably less than or equal to 25 μm, preferably in the range from 5 to 25 μm. A subject of the present invention is also a process for manufacturing the textile material according to the invention, notably a spinning process, comprising the steps of:
a) providing the copolymer including at least one carboxylic acid chain end blocked with a polycarbodiimide, optionally as a mixture with other components of the textile material as described above,
b) extruding the copolymer or said mixture from step a),
c) drawing the copolymer or said mixture to form a textile material.
According to a particular embodiment, the process of the invention comprises, prior to step a), the mixing of the block copolymer comprising at least one rigid polyamide PA block and at least one flexible block and polycarbodiimide, so that at least one carboxylic acid chain end of the block copolymer reacts with a carbodiimide function of the polycarbodiimide. Preferably, the mixing is performed using a single-screw or twin-screw extruder or by adding polycarbodiimide during the synthesis of the block copolymer. Advantageously, step c) is performed by extrusion blow molding, blown film extrusion, pultrusion, overjacketing extrusion, extrusion calendering, flat-die extrusion, extrusion coating, lamination and/or coextrusion.
According to a particular embodiment of the process according to the invention, the monofilament manufacture comprises the following steps:
a) providing the copolymer including at least one carboxylic acid chain end blocked with a polycarbodiimide, optionally as a mixture with other components as defined above,
b) extruding the copolymer or said mixture from step a),
b′) cooling,
c) drawing or stretching,
d) annealing, and
e) winding.
Advantageously, step c) draws said copolymer or said mixture in a draw ratio of from 1 to 30, preferably from 1 to 20, or better still from 1 to 15. Advantageously, the extrusion rate of step b) is within the range from 1000 to 10 000 m/min, preferably from 2000 to 8000 m/min. Advantageously, step b) is performed at a temperature in the range from 80 to 350° C., preferably from 100° C. to 300° C., preferably from 150 to 250° C.
The use of a copolymer blocked with a polycarbodiimide according to the invention allows a larger window of processability notably in terms of temperature, and less extrusion instability is observed than with the corresponding non-blocked copolymer, and also higher maximum achievable extrusion rates.
Advantageously, said at least one textile material is in the form of a porous membrane, a woven textile or a nonwoven textile.
Advantageously, said at least one textile material comprises synthetic fibers, notably PET, PA, PP, PBT, PLA, TPU, TPE, synthetic fibers obtained from biobased starting materials, natural fibers, artificial fibers manufactured from natural raw materials, mineral fibers and/or metallic fibers.
Advantageously, said at least one textile material constitutes a felt, a fiber, a filter, a gauze, a cloth, a dressing, a layer, a fabric, a knitted fabric, a clothing article, an item of clothing, a bedding article, a furnishing article, a curtain, a passenger compartment covering, a functional technical textile, a geotextile and/or an agrotextile.
A subject of the present invention is also the use of a textile material according to the invention in the following sectors: medical, hygiene, luggage, manufacturing, clothing, domestic or household equipment, furnishing, carpet, motor vehicle, industry, notably industrial filtration, agriculture and/or construction.
The examples that follow illustrate the invention without limiting it. The standards used in the examples also correspond to those used more generally for characterizing the invention in the description or the claims.
In the examples that follow:
PEBA 1 is a copolymer containing PA 12 blocks and PTMG blocks with respective number-average molecular masses (Mn) of 600-2000.
PEBA 2 is a copolymer according to the invention, containing PA 12 blocks and PTMG blocks with respective number-average molecular masses (Mn) of 850-2000.
PEBA 3 is a copolymer according to the invention, containing PA 12 blocks and PTMG blocks with respective number-average molecular masses (Mn) of 2000-1000.
PEBA 4 is a copolymer containing PA 11 blocks and PTMG blocks with respective number-average molecular masses (Mn) of 600-1000.
PCDI: Polycarbodiimide used in the examples: Poly(1,3,5-triisopropylphenylene-2,4-carbodiimide)
Table 1 below gives the results of the melt viscosity measurement eta* (in Pa.$) at 220° C., as a function of the angular frequency (rad/s) according to the standard ISO 6721-10:2015.
It is observed that the Copo materials according to the invention have a greater melt viscosity than the comparative PEBAs.
The Copo materials according to the invention are thus more readily extrudable into textiles than the comparative PEBA materials.
Principle: A rod is extruded through a die of a capillary rheometer; it is gripped, in molten form, by two pairs of wheels driven by a variable-speed motor. A first pair of wheels and the motor are mounted at the free, deflectable end of a support directly connected to a sensor, representing the restoring force.
The second pair of wheels (coupled to the first pair) makes it possible to guide and to limit the winding of the rod around the upper wheels. Small pads soaked with surfactant liquid (mixture of water, ethanol and surfactant) are also applied to the wheels in order to cool them and thus to limit the sticking effect.
The melt strength curves of
with V: speed at which the rod is drawn: wheel speed
The copolymers Copo 3 and Copo 4 used in the textile materials according to the invention have improved drawability relative to that of the respective controls PEBA 3 and PEBA 4.
The textile materials according to the invention based on block copolymers including at least one carboxylic acid chain end blocked with a polycarbodiimide have improved stretchability relative to that of the textile materials based on the same respective non-blocked copolymers.
The results of these tests are given in table 2 below.
The copolymers Copo 1 and Copo 4 used in the textile materials according to the invention have tensile modulus and flexural modulus values lower than those of the respective controls PEBA 1 to 4.
The textile materials according to the invention based on block copolymers including at least one carboxylic acid chain end blocked with a polycarbodiimide have improved flexibility relative to that of the textile materials based on the same respective non-blocked copolymers.
The results of these tests are given in table 3 below.
The loss of mass is smaller in the case of the copolymers according to the invention, and the copolymer-based textile materials according to the invention thus have better abrasion resistance than the respective control PEBA-based textile materials.
Similarly, the textile materials based on the copolymers according to the invention have a better tear strength than the respective control PEBA-based textile materials.
The weight-average and number-average molecular masses Mw and Mn measured increase, respectively, on passing from a PEBA to the corresponding Copo according to the invention, which indicates that the reaction took place between the carbodiimide function of the polycarbodiimide and the acid function of the PEBA to form the Copo bearing a blocked acid chain end used according to the invention.
The dispersity is determined as being equal to the ratio between the weight-average molecular mass and the number-average molecular mass Mw/Mn. The measurement accuracy is given to within 5%.
The number-average molecular (or molar) mass is set by the content of chain limiter. It may be calculated according to the equation:
Mn=(nmonomer/nlimiter)*Mrepeating unit+Mlimiter
The dispersity Mw/Mn is moreover conserved in each Copo according to the invention relative to the corresponding initial PEBA, and the measured value is less than 3, in all the copolymers, which proves that the copolymers according to the invention remained in noncrosslinked linear form. The textile materials based on these copolymers thus remain perfectly recyclable.
In summary, the polycarbodiimide thus used in the textile material according to the present invention makes it possible to improve the extrudability, stretchability, flexibility, abrasion resistance and tear strength properties of the textile material, while at the same time conserving its recyclability.
These advantageous properties were not able to be observed with monomeric carbodiimides, since their volatility did not enable them to react or to effectively block said carboxylic acid of the block copolymer used in the textile material of the present invention.
| Number | Date | Country | Kind |
|---|---|---|---|
| 1760886 | Nov 2017 | FR | national |
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/FR2018/052882 | 11/16/2018 | WO | 00 |
