U.S. patent application number 17/401321 was filed with the patent office on 2022-08-18 for thermoplastic polyurethane elastomer fiber and method for manufacturing the same, and fabric thereof.
The applicant listed for this patent is NAN YA PLASTICS CORPORATION. Invention is credited to SEN-HUANG HSU, TE-CHAO LIAO.
Application Number | 20220259771 17/401321 |
Document ID | / |
Family ID | |
Filed Date | 2022-08-18 |
United States Patent
Application |
20220259771 |
Kind Code |
A1 |
LIAO; TE-CHAO ; et
al. |
August 18, 2022 |
THERMOPLASTIC POLYURETHANE ELASTOMER FIBER AND METHOD FOR
MANUFACTURING THE SAME, AND FABRIC THEREOF
Abstract
A thermoplastic polyurethane elastomer fiber and a method for
manufacturing the same, and a fabric thereof are provided. The
method for manufacturing the thermoplastic polyurethane elastomer
fiber includes steps as follows. A thermoplastic polyurethane
elastomer particle having a Shore hardness ranging from 45D to 80D
is provided. The thermoplastic polyurethane elastomer particle is
melted to manufacture the thermoplastic polyurethane elastomer
fiber.
Inventors: |
LIAO; TE-CHAO; (TAIPEI,
TW) ; HSU; SEN-HUANG; (TAIPEI, TW) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
NAN YA PLASTICS CORPORATION |
TAIPEI |
|
TW |
|
|
Appl. No.: |
17/401321 |
Filed: |
August 13, 2021 |
International
Class: |
D01F 6/70 20060101
D01F006/70; D01F 1/04 20060101 D01F001/04; D01D 5/16 20060101
D01D005/16 |
Foreign Application Data
Date |
Code |
Application Number |
Feb 18, 2021 |
TW |
110105465 |
Claims
1. A method for manufacturing a thermoplastic polyurethane
elastomer fiber, comprising: providing a thermoplastic polyurethane
elastomer particle which has a Shore hardness ranging from 45D to
80D; and melting the thermoplastic polyurethane elastomer particle
to manufacture the thermoplastic polyurethane elastomer fiber.
2. The method according to claim 1, wherein the thermoplastic
polyurethane elastomer fiber is manufactured at a production speed
ranging from 1200 m/minute to 6000 m/minute.
3. The method according to claim 1, further comprising: stretching
the thermoplastic polyurethane elastomer fiber at a temperature
ranging from 50.degree. C. to 150.degree. C. in a drawing
process.
4. The method according to claim 3, wherein a draw ratio of the
drawing process ranges from 1 to 4.
5. The method according to claim 3, further comprising: setting the
thermoplastic polyurethane elastomer fiber at a temperature ranging
from 50.degree. C. to 150.degree. C. in a setting process after the
drawing process.
6. The method according to claim 5, wherein the temperature of the
setting process is higher than the temperature of the drawing
process by 5.degree. C. to 20.degree. C.
7. The method according to claim 1, wherein the thermoplastic
polyurethane elastomer particle contains 0.1 wt % to 4 wt % of a
pigment based on a total weight of the thermoplastic polyurethane
elastomer particle being 100 wt %.
8. The method according to claim 7, wherein the thermoplastic
polyurethane elastomer particle includes a normal thermoplastic
polyurethane elastomer particle and a color thermoplastic
polyurethane elastomer particle, and the color thermoplastic
polyurethane elastomer particle contains the pigment.
9. The method according to claim 1, wherein the thermoplastic
polyurethane elastomer particle is extruded by an extruder to form
the thermoplastic polyurethane elastomer fiber after being melted,
and a temperature of the extruder is set to range from 150.degree.
C. to 250.degree. C.
10. The method according to claim 1, wherein a main component of a
material forming the thermoplastic polyurethane elastomer particle
is thermoplastic polyurethane
11. The method according to claim 1, wherein the thermoplastic
polyurethane elastomer particle is formed from thermoplastic
polyurethane that has a weight average molecular weight ranging
from 30000 to 450000.
12. A thermoplastic polyurethane elastomer fiber manufactured by
the method as claimed in claim 1, wherein a Shore hardness of the
thermoplastic polyurethane elastomer fiber ranges from 45D to
80D.
13. The thermoplastic polyurethane elastomer fiber according to
claim 12, wherein fiber strength of the thermoplastic polyurethane
elastomer fiber is higher than 2.0 cN/F.
14. The thermoplastic polyurethane elastomer fiber according to
claim 12, wherein an extensibility of the thermoplastic
polyurethane elastomer fiber is lower than or equal to 80%.
15. The thermoplastic polyurethane elastomer fiber according to
claim 12, wherein a boiling water shrinkage of the thermoplastic
polyurethane elastomer fiber is lower than or equal to 30%.
16. A thermoplastic polyurethane elastomer fabric manufactured from
the thermoplastic polyurethane elastomer fiber as claimed in claim
12.
Description
CROSS-REFERENCE TO RELATED PATENT APPLICATION
[0001] This application claims the benefit of priority to Taiwan
Patent Application No. 110105465, filed on Feb. 18, 2021. The
entire content of the above identified application is incorporated
herein by reference.
[0002] Some references, which may include patents, patent
applications and various publications, may be cited and discussed
in the description of this disclosure. The citation and/or
discussion of such references is provided merely to clarify the
description of the present disclosure and is not an admission that
any such reference is "prior art" to the disclosure described
herein. All references cited and discussed in this specification
are incorporated herein by reference in their entireties and to the
same extent as if each reference was individually incorporated by
reference.
FIELD OF THE DISCLOSURE
[0003] The present disclosure relates to a thermoplastic
polyurethane elastomer fiber and a method for manufacturing the
same, and a fabric thereof, and more particularly to a
thermoplastic polyurethane elastomer fiber having high fiber
strength and a method for manufacturing the same, and a fabric
thereof.
BACKGROUND OF THE DISCLOSURE
[0004] A conventional polyurethane (PU) fiber is manufactured
through a dry spinning process. During the dry spinning process,
monomers needed for synthesizing polyurethane are prepared in a
reactor tank and then synthesized to form polyurethane
Subsequently, a spinning solution is formed by dissolving the
polyurethane in a solvent. The spinning solution passes through an
extruder and a die so as to shape the polyurethane therein, and
then enters an environment full of a heated gas. The solvent in the
spinning solution is vaporized due to a high temperature, so that a
polyurethane filament is formed. The polyurethane filament can be
further stretched, set, washed, and dried to obtain a polyurethane
fiber.
[0005] However, in the dry spinning process, a great amount of the
solvent is required, which causes environmental concerns. In
addition, since a step of dissolving the polyurethane is carried
out after synthesizing, physical properties of the polyurethane
fiber are weakened. Moreover, the polyurethane fiber is unable to
endure a high tension due to having weak physical properties.
Accordingly, a production speed of the polyurethane fiber cannot be
increased or the polyurethane fiber is easily broken. Therefore,
the conventional method for manufacturing the polyurethane fiber
still has room for improvement.
SUMMARY OF THE DISCLOSURE
[0006] In response to the above-referenced technical inadequacies,
the present disclosure provides a thermoplastic polyurethane
elastomer fiber and a method for manufacturing the same, and a
fabric thereof.
[0007] In one aspect, the present disclosure provides a method for
manufacturing a thermoplastic polyurethane elastomer fiber. The
method includes steps as follows. A thermoplastic polyurethane
elastomer particle which has a Shore hardness ranging from 45D to
80D is provided. The thermoplastic polyurethane elastomer particle
is melted to manufacture the thermoplastic polyurethane elastomer
fiber.
[0008] In certain embodiments, the thermoplastic polyurethane
elastomer fiber is manufactured at a production speed ranging from
1200 m/minute to 6000 m/minute.
[0009] In certain embodiments, the thermoplastic polyurethane
elastomer fiber is stretched at a temperature ranging from
50.degree. C. to 150.degree. C. in a drawing process.
[0010] In certain embodiments, a draw ratio of the drawing process
ranges from 1.0 to 4.0.
[0011] In certain embodiments, the method for manufacturing the
thermoplastic polyurethane elastomer fiber further includes: after
the drawing process, setting the thermoplastic polyurethane
elastomer fiber at a temperature ranging from 50.degree. C. to
150.degree. C. in a setting process.
[0012] In certain embodiments, the temperature of the setting
process is higher than the temperature of the drawing process by
5.degree. C. to 20.degree. C.
[0013] In certain embodiments, the thermoplastic polyurethane
elastomer particle contains 0.1 wt % to 4 wt % of a pigment based
on a total weight of the thermoplastic polyurethane elastomer
particle being 100 wt %.
[0014] In certain embodiments, the thermoplastic polyurethane
elastomer particle includes a normal thermoplastic polyurethane
elastomer particle and a color thermoplastic polyurethane elastomer
particle, and the color thermoplastic polyurethane elastomer
particle contains the pigment.
[0015] In certain embodiments, after being melted, the
thermoplastic polyurethane elastomer particle is extruded by an
extruder to form the thermoplastic polyurethane elastomer fiber. A
temperature of the extruder is set to range from 150.degree. C. to
250.degree. C.
[0016] In certain embodiments, a main component of a material to
form the thermoplastic polyurethane elastomer particle is
thermoplastic polyurethane.
[0017] In certain embodiments, the thermoplastic polyurethane
elastomer particle is formed from thermoplastic polyurethane that
has a weight average molecular weight ranging from 30000 to
450000.
[0018] In another aspect, the present disclosure provides a
thermoplastic polyurethane elastomer fiber. The thermoplastic
polyurethane elastomer fiber is manufactured by the aforementioned
method. A Shore hardness of the thermoplastic polyurethane
elastomer fiber ranges from 45D to 80D.
[0019] In certain embodiments, fiber strength of the thermoplastic
polyurethane elastomer fiber is higher than 2.0 cN/F.
[0020] In certain embodiments, an extensibility of the
thermoplastic polyurethane elastomer fiber is lower than or equal
to 80%.
[0021] In certain embodiments, a boiling water shrinkage of the
thermoplastic polyurethane elastomer fiber is lower than or equal
to 30%.
[0022] In yet another aspect, the present disclosure provides a
thermoplastic polyurethane elastomer fabric. The thermoplastic
polyurethane elastomer fabric is manufactured from the
thermoplastic polyurethane elastomer fiber.
[0023] Therefore, by virtue of "the thermoplastic polyurethane
elastomer particle having a Shore hardness ranging from 45D to 80D"
and "melting the thermoplastic polyurethane elastomer particle to
manufacture the thermoplastic polyurethane elastomer fiber", the
thermoplastic polyurethane elastomer fiber and the method for
manufacturing the same, and the thermoplastic polyurethane
elastomer fabric of the present disclosure can overcome the issues
of weak physical properties and the slow production speed.
[0024] These and other aspects of the present disclosure will
become apparent from the following description of the embodiment
taken in conjunction with the following drawings and their
captions, although variations and modifications therein may be
affected without departing from the spirit and scope of the novel
concepts of the disclosure.
BRIEF DESCRIPTION OF THE DRAWINGS
[0025] The described embodiments may be better understood by
reference to the following description and the accompanying
drawings, in which:
[0026] FIG. 1 is a flowchart of a method for manufacturing a
thermoplastic polyurethane elastomer fiber of the present
disclosure;
[0027] FIG. 2 is a schematic side view of a melting spinning
device; and
[0028] FIG. 3 is a schematic side view of a take-up machine of the
melting spinning device of FIG. 2 after the thermoplastic
polyurethane elastomer fiber is wound up.
DETAILED DESCRIPTION OF THE EXEMPLARY EMBODIMENTS
[0029] The present disclosure is more particularly described in the
following examples that are intended as illustrative only since
numerous modifications and variations therein will be apparent to
those skilled in the art. Like numbers in the drawings indicate
like components throughout the views. As used in the description
herein and throughout the claims that follow, unless the context
clearly dictates otherwise, the meaning of "a", "an", and "the"
includes plural reference, and the meaning of "in" includes "in"
and "on". Titles or subtitles can be used herein for the
convenience of a reader, which shall have no influence on the scope
of the present disclosure.
[0030] The terms used herein generally have their ordinary meanings
in the art. In the case of conflict, the present document,
including any definitions given herein, will prevail. The same
thing can be expressed in more than one way. Alternative language
and synonyms can be used for any term(s) discussed herein, and no
special significance is to be placed upon whether a term is
elaborated or discussed herein. A recital of one or more synonyms
does not exclude the use of other synonyms. The use of examples
anywhere in this specification including examples of any terms is
illustrative only, and in no way limits the scope and meaning of
the present disclosure or of any exemplified term. Likewise, the
present disclosure is not limited to various embodiments given
herein. Numbering terms such as "first", "second" or "third" can be
used to describe various components, signals or the like, which are
for distinguishing one component/signal from another one only, and
are not intended to, nor should be construed to impose any
substantive limitations on the components, signals or the like.
[0031] In order to overcome issues of a large usage of solvent in a
conventional dry spinning process, and weak physical properties and
a slow production speed of the thermoplastic polyurethane elastomer
fiber, the present disclosure provides a method for manufacturing
the thermoplastic polyurethane elastomer fiber. The solvent is
absent from the method of the present disclosure. The thermoplastic
polyurethane elastomer fiber of the present disclosure can be
manufactured at a higher production speed and have stronger
physical properties.
[0032] In the present disclosure, the thermoplastic polyurethane
elastomer does not need to be dissolved in a solvent, that is, the
step of dissolving the thermoplastic polyurethane elastomer in the
solvent can be omitted. After being polymerized, the thermoplastic
polyurethane elastomer is directly melted and then shaped.
Accordingly, the physical properties of the thermoplastic
polyurethane elastomer can be retained, rather than being weakened
by the solvent.
[0033] After being melted, the thermoplastic polyurethane elastomer
can be shaped by an extruder and a die. After being cooled, the
thermoplastic polyurethane elastomer fiber that has good physical
properties can be obtained. Therefore, a production speed of the
thermoplastic polyurethane elastomer fiber can be enhanced, and the
thermoplastic polyurethane elastomer fiber is difficult to be
broken.
[0034] Referring to FIG. 1 and FIG. 2, FIG. 1 shows a flowchart of
the method for manufacturing the thermoplastic polyurethane
elastomer fiber of the present disclosure, and FIG. 2 shows a
schematic side view of a melting spinning device.
[0035] The method for manufacturing the thermoplastic polyurethane
elastomer fiber of the present disclosure includes steps as
follows. A thermoplastic polyurethane (TPU) elastomer particle is
provided (step S1). Subsequently, the thermoplastic polyurethane
elastomer particle is put into a feeding tank 1 and then
transported to a heating zone 2 by a screw rod. The thermoplastic
polyurethane elastomer particle is heated by a heating plate in the
heating zone 2 to form a melted thermoplastic polyurethane
elastomer. After passing through a filter device, the melted
thermoplastic polyurethane elastomer is transported via a conveyer
pipe 3 to a spinning beam 4 for manufacturing the thermoplastic
polyurethane elastomer fiber (step 2).
[0036] In the present disclosure, the thermoplastic polyurethane
elastomer is shaped by a melting step, rather than a dissolving
step, so that the solvent is absent from the method, and the
dissolving step can be omitted. Therefore, a solubility of the
thermoplastic polyurethane elastomer is no longer to be considered,
such that the thermoplastic polyurethane elastomer having a higher
molecular weight or a harder hardness can be used as a
material.
[0037] In step S1, a Shore hardness of the thermoplastic
polyurethane elastomer particle ranges from 45D to 80D. The
thermoplastic polyurethane elastomer particle with a high hardness
has a high structural intensity to endure a temperature change or a
physical deformation in subsequent processes.
[0038] In some embodiments, a melting point of the thermoplastic
polyurethane elastomer particle ranges from 150.degree. C. to
250.degree. C. Preferably, the melting point of the thermoplastic
polyurethane elastomer particle ranges from 170.degree. C. to
250.degree. C. More preferably, the melting point of the
thermoplastic polyurethane elastomer particle ranges from
170.degree. C. to 220.degree. C.
[0039] In some embodiments, a weight average molecular weight of
the thermoplastic polyurethane elastomer particle ranges from 30000
g/mol to 450000 g/mol. Preferably, the weight average molecular
weight of the thermoplastic polyurethane elastomer particle ranges
from 35000 g/mol to 400000 g/mol. More preferably, the weight
average molecular weight of the thermoplastic polyurethane
elastomer particle ranges from 40000 g/mol to 400000 g/mol.
[0040] In some embodiments, an intrinsic viscosity (IV) of the
thermoplastic polyurethane elastomer particle ranges from 0.5 to
3.0. Preferably, the intrinsic viscosity of the thermoplastic
polyurethane elastomer particle ranges from 0.5 to 2.5. More
preferably, the intrinsic viscosity of the thermoplastic
polyurethane elastomer particle ranges from 1.0 to 2.0.
[0041] In some embodiments, a main component of a material forming
the thermoplastic polyurethane elastomer particle is thermoplastic
polyurethane elastomer. The term "main component" refers to an
amount of the thermoplastic polyurethane elastomer in the
thermoplastic polyurethane elastomer particle being higher than or
equal to 75 wt %.
[0042] Preferably, the material forming the thermoplastic
polyurethane elastomer particle only contains the thermoplastic
polyurethane elastomer without other polymers, such as nylon or
polyester, etc. Accordingly, the thermoplastic polyurethane
elastomer fiber and the thermoplastic polyurethane elastomer fabric
manufactured from the thermoplastic polyurethane elastomer particle
also only contain the thermoplastic polyurethane elastomer.
Therefore, when the thermoplastic polyurethane elastomer fabric is
worn out, the thermoplastic polyurethane elastomer fabric that has
a single component can be directly recycled and reproduced
[0043] Specifically, the material forming the thermoplastic
polyurethane elastomer particle can be a polyether based TPU or a
polyester based TPU that at least has a 4.sup.th grade resistance
of aging (retaining more than a fiber intensity of 60% at a
temperature of 70.degree. C. and a relative humidity of 95% for 14
days). Since yellowing easily occurs in the polyester based TPU, an
ultraviolet absorbent can be optionally added into the polyester
based TPU to postpone the occurrence of yellowing. The manner of
adding the ultraviolet absorbent is illustrated later.
[0044] The thermoplastic polyurethane elastomer particle has good
physical properties such that the thermoplastic polyurethane
elastomer fiber can be manufactured at a high production speed and
a yield of the thermoplastic polyurethane elastomer fiber can be
increased. In step S2, the thermoplastic polyurethane elastomer
fiber is manufactured at a production speed ranging from 1200
m/minute to 6000 m/minute. Preferably, the thermoplastic
polyurethane elastomer fiber is manufactured at a production speed
ranging from 1500 m/minute to 3000 m/minute. More preferably, the
thermoplastic polyurethane elastomer fiber is manufactured at a
production speed ranging from 2000 m/minute to 3000 m/minute. In
general, for fear of breaking, the thermoplastic polyurethane
elastomer fiber in the conventional dry spinning process is
manufactured at a production speed ranging from 600 m/minute to
1000 m/minute. Therefore, the method for manufacturing the
thermoplastic polyurethane elastomer fiber of the present
disclosure improves the problem of a slow production speed in
conventional technology.
[0045] In some embodiments, a take-up tension of the melting
spinning device ranges from 0.05 cN/F to 0.50 cN/F to prevent the
thermoplastic polyurethane elastomer fiber from breaking.
Preferably, the take-up tension of the melting spinning device
ranges from 0.08 cN/F to 0.35 cN/F. More preferably, the take-up
tension of the melting spinning device ranges from 0.10 cN/F to
0.35 cN/F.
[0046] In some embodiments, a temperature of the melting spinning
device is set from 150.degree. C. to 300.degree. C. Preferably, the
temperature of the melting spinning device is set from 180.degree.
C. to 300.degree. C. More preferably, the temperature of the
melting spinning device is set from 180.degree. C. to 250.degree.
C.
[0047] In some embodiments, a temperature of a gear pump in the
melting spinning device is set from 200.degree. C. to 300.degree.
C. to prevent the material from clogging and damaging the melting
spinning device. Preferably, a temperature of the gear pump in the
melting spinning device is set from 200.degree. C. to 280.degree.
C. More preferably, a temperature of the gear pump of the melting
spinning device is set from 200.degree. C. to 250.degree. C.
[0048] After the thermoplastic polyurethane elastomer fiber is
formed, 3 wt % to 20 wt % of a lubricant is sprayed onto the
thermoplastic polyurethane elastomer fiber by using an oil nozzle,
so that a friction between the thermoplastic polyurethane elastomer
fibers can be reduced. Then, the thermoplastic polyurethane
elastomer fibers are gathered into bundles. Practically, a
concentration of the lubricant sprayed onto the thermoplastic
polyurethane elastomer fiber ranges from 0.3 wt % 3.0 wt %.
[0049] For example, the 20 wt % of the lubricant contains 20 g of
the lubricant and 80 g of water. The lubricant can be an
emulsifying oil containing silicon or an emulsifying oil containing
polyol-ester. Preferably, the lubricant is the emulsifying oil
containing silicon.
[0050] Referring to FIG. 1 and FIG. 2, the method for manufacturing
the thermoplastic polyurethane elastomer fiber of the present
disclosure further includes a step of: stretching the thermoplastic
polyurethane elastomer fiber in a drawing process to adjust a
diameter and a fiber density of the thermoplastic polyurethane
elastomer fiber.
[0051] In some embodiments, the drawing process is implemented at a
temperature ranging from 50.degree. C. to 150.degree. C. (step S3).
Preferably, the drawing process is implemented at a temperature
ranging from 75.degree. C. to 125.degree. C.
[0052] In the drawing process, a temperature of a first roller 51
is adjusted to soften the thermoplastic polyurethane elastomer
fiber. After the thermoplastic polyurethane elastomer fiber is
softened, a draw ratio of the thermoplastic polyurethane elastomer
fiber can be adjusted according to a rotational speed ratio of the
first roller 51 to a second roller 52. During the drawing process,
the thermoplastic polyurethane elastomer fiber is continuously
drawn when the thermoplastic polyurethane elastomer fiber passes
between the first roller 51 and the second roller 52. The drawing
process is implemented until the thermoplastic polyurethane
elastomer fiber completely passes through the second roller 52.
[0053] In some embodiments, the draw ratio of the thermoplastic
polyurethane elastomer fiber is greater than 1.0, and up to 4.0. In
other words, a rotational speed of the second roller 52 is more
than 1.0, and up to 4.0 times higher than a rotational speed of the
first roller 51. Practically, the draw ratio of the thermoplastic
polyurethane elastomer fiber can be adjusted according to product
requirements.
[0054] For example, when the rotational speed ratio of the first
roller 51 to the second roller 52 is 4.0, a fiber density of the
thermoplastic polyurethane elastomer fiber after the drawing
process is 0.25 times the fiber density of the thermoplastic
polyurethane elastomer fiber before the drawing process, and a
length of the thermoplastic polyurethane elastomer fiber after the
drawing process is 4 times a length of the thermoplastic
polyurethane elastomer fiber before the drawing process.
[0055] The method for manufacturing the thermoplastic polyurethane
elastomer fiber of the present disclosure further includes a step
of: setting the thermoplastic polyurethane elastomer fiber at a
temperature ranging from 50.degree. C. to 150.degree. C. in a
setting process after the drawing process. A temperature of the
setting process is higher than the temperature of the drawing
process by 5.degree. C. to 20.degree. C. (step S4). Preferably, the
setting process is implemented at a temperature ranging from
55.degree. C. to 150.degree. C.
[0056] In the setting process, rotational speeds of a third roller
53 and a fourth roller 54 are the same with the rotational speed of
the second roller 52. A difference is that temperatures of the
third roller 53 and the fourth roller 54 are controlled to be
higher than the temperature of the second roller 52 (by about
5.degree. C. to 20.degree. C.).
[0057] In the setting process, the thermoplastic polyurethane
elastomer fiber is softened again due to the high temperature when
the thermoplastic polyurethane elastomer fiber passes between the
third roller 53 and the fourth roller 54, and a strain stored
during the drawing process can be released.
[0058] After the drawing process and the setting process, the
thermoplastic polyurethane elastomer fiber is wound up by a take-up
machine 6. The method for manufacturing the thermoplastic
polyurethane elastomer fiber is completed.
[0059] Referring to FIG. 3, FIG. 3 is a schematic side view of the
take-up machine of FIG. 2 after the thermoplastic polyurethane
elastomer fiber is wound up. In some embodiments, a winding-on
angle .theta. of the take-up machine 6 ranges from 4.degree. to
8.degree. . However, the present disclosure is not limited
thereto.
[0060] In the present disclosure, fiber strength of the
thermoplastic polyurethane elastomer fiber is higher than 2 g/d.
Preferably, the fiber strength of the thermoplastic polyurethane
elastomer fiber is higher than 2 g/d, and up to 10 g/d. More
preferably, the fiber strength of the thermoplastic polyurethane
elastomer fiber is higher than 2 g/d, and up to 5 g/d. An
extensibility of the thermoplastic polyurethane elastomer fiber is
lower than or equal to 80%. Preferably, the extensibility of the
thermoplastic polyurethane elastomer fiber is lower than or equal
to 60%. More preferably, the extensibility of the thermoplastic
polyurethane elastomer fiber is lower than or equal to 50%. A
boiling water shrinkage of the thermoplastic polyurethane elastomer
fiber is lower than or equal to 30%. Preferably, the boiling water
shrinkage of the thermoplastic polyurethane elastomer fiber is
lower than or equal to 20%.
[0061] In addition, other processes can be implemented on the
thermoplastic polyurethane elastomer fiber so as to obtain a
partially oriented yarn (POY), a fully drawn yarn (FDY), or a draw
textured yarn (DTY). However, the present disclosure is not limited
thereto.
[0062] Moreover, bulk of the thermoplastic polyurethane elastomer
fiber can be enhanced by a false twister, and elasticity of the
thermoplastic polyurethane elastomer fiber can be enhanced by a
draw twister, so that the thermoplastic polyurethane elastomer
fiber can have more extensive applications.
[0063] A thermoplastic polyurethane elastomer fabric can be
manufactured from the thermoplastic polyurethane elastomer fiber of
the present disclosure by certain weaving technologies. The
thermoplastic polyurethane elastomer fabric also has advantages of
good physical properties and recyclability.
[0064] It is worth mentioning that the thermoplastic polyurethane
elastomer fiber can be simultaneously dyed and manufactured in the
method for manufacturing the thermoplastic polyurethane elastomer
fiber of the present disclosure. Therefore, an additional dyeing
process of a fiber or a fabric can be omitted.
[0065] In a general dyeing process, the fiber or the fabric is
immersed in a dyeing solution at a high temperature for 30 minutes
to 60 minutes. After rinsing and drying the fiber or the fabric,
the dyeing process is completed. As for the fiber or the fabric
formed from a crystalline polymer, such as polyester, the fiber or
the fabric can be dyed by the aforementioned process. However, as
for the fiber or the fabric formed from a non-crystalline polymer,
such as polyurethane, the fiber or the fabric cannot be effectively
dyed by the aforementioned process. Therefore, a dyeing process
aimed at polyurethane fibers is still required in the conventional
technology.
[0066] In some embodiments, the thermoplastic polyurethane
elastomer particle includes a normal thermoplastic polyurethane
elastomer particle and a color thermoplastic polyurethane elastomer
particle. The normal thermoplastic polyurethane elastomer particle
is a particle formed from a material which has a main component of
the thermoplastic polyurethane elastomer without any pigment. The
color thermoplastic polyurethane elastomer particle is a particle
formed from a material which has a main component of the
thermoplastic polyurethane elastomer and contains the pigment.
[0067] Accordingly, when the normal thermoplastic polyurethane
elastomer particle and the color thermoplastic polyurethane
elastomer particle are mixed and melted, a color of the pigment
displays on the melted thermoplastic polyurethane elastomer. After
the aforementioned steps S2 to S4, the thermoplastic polyurethane
elastomer fiber with the color can be obtained without any dyeing
process.
[0068] Specifically, based on a total weight of the thermoplastic
polyurethane elastomer particle (the normal thermoplastic
polyurethane elastomer particle and the color thermoplastic
polyurethane elastomer particle) being 100 wt %, the thermoplastic
polyurethane elastomer particle contains 0.1 wt % to 4.0 wt % of
the pigment. Preferably, the thermoplastic polyurethane elastomer
particle contains 0.2 wt % to 3.0 wt % of the pigment. More
preferably, the thermoplastic polyurethane elastomer particle
contains 0.3 wt % to 1.5 wt % of the pigment.
[0069] Based on a total weight of the thermoplastic polyurethane
elastomer particle (the normal thermoplastic polyurethane elastomer
particle and the color thermoplastic polyurethane elastomer
particle) being 100 wt %, an amount of the color thermoplastic
polyurethane elastomer particle ranges from 1 wt % to 15 wt %. The
amount of the color thermoplastic polyurethane elastomer particle
can be adjusted according to various types of the pigment used.
Preferably, the amount of the color thermoplastic polyurethane
elastomer particle ranges from 1 wt % to 12 wt %. More preferably,
the amount of the color thermoplastic polyurethane elastomer
particle ranges from 1 wt % to 10 wt %.
[0070] In some embodiments, the pigment can be a white pigment,
such as titanium dioxide particles, calcium carbonate particles, or
barium sulfate particles. Based on a total weight of the
thermoplastic polyurethane elastomer particle being 100 wt %, an
amount of the white pigment ranges from 0.1 wt % to 4.0 wt %.
[0071] In others embodiments, the pigment can be a black pigment,
such as graphite powder, nano carbon black, carbon nanotube, or
graphene. Based on a total weight of the thermoplastic polyurethane
elastomer particle being 100 wt %, an amount of the black pigment
ranges from 0.1 wt % to 4.0 wt %.
[0072] In some embodiments, the normal thermoplastic polyurethane
elastomer particle is formed from a material having a main
component of thermoplastic polyurethane elastomer. The color
thermoplastic polyurethane elastomer particle is formed from a
material having thermoplastic polyurethane elastomer and the
pigment. In addition, the materials of the normal thermoplastic
polyurethane elastomer particle and the color thermoplastic
polyurethane elastomer particle do not include other polymers, such
as nylon or polyester, etc. Accordingly, the thermoplastic
polyurethane elastomer fiber and the fabric thereof which are
manufactured from the thermoplastic polyurethane elastomer particle
of the present disclosure can be directly recycled and
reproduced.
[0073] In some embodiments, the thermoplastic polyurethane
elastomer particle can further include a functional thermoplastic
polyurethane elastomer particle. The functional thermoplastic
polyurethane elastomer particle is a particle formed from a
material having thermoplastic polyurethane elastomer and a
functional agent.
[0074] For example, the functional agent can be an ultraviolet
absorbent. An addition of the ultraviolet absorbent can postpone
the occurrence of the yellowing in the thermoplastic polyurethane
elastomer, especially for the polyester based TPU.
[0075] Specifically, based on a total weight of the functional
thermoplastic polyurethane elastomer particle being 100 wt %, an
amount of the functional agent ranges from 0.1 wt % to 4.0 wt %.
Preferably, the amount of the functional agent ranges from 0.2 wt %
to 3.0 wt %. More preferably, the amount of the functional agent
ranges from 0.3 wt % to 1.5 wt %.
[0076] Based on a total weight of the thermoplastic polyurethane
elastomer particle being 100 wt %, an amount of the functional
thermoplastic polyurethane elastomer particle ranges from 1 wt % to
15 wt %. Preferably, the amount of the functional thermoplastic
polyurethane elastomer particle ranges from 1 wt % to 12 wt %. More
preferably, the amount of the functional thermoplastic polyurethane
elastomer particle ranges from 1 wt % to 10 wt %.
[0077] Therefore, the thermoplastic polyurethane elastomer fiber
can be simultaneously manufactured and multi-functionalized in the
method for manufacturing the thermoplastic polyurethane elastomer
fiber of the present disclosure so as to reduce time cost.
Beneficial Effects of the Embodiment
[0078] In conclusion, by virtue of "the thermoplastic polyurethane
elastomer particle having a Shore hardness ranging from 45D to 80D"
and "melting the thermoplastic polyurethane elastomer particle to
manufacture the thermoplastic polyurethane elastomer fiber", the
thermoplastic polyurethane elastomer fiber and the method for
manufacturing the same, and the thermoplastic polyurethane
elastomer fabric of the present disclosure can overcome the issues
of weak physical properties and the slow production speed.
[0079] Further, by virtue of "the thermoplastic polyurethane
elastomer particle including a normal thermoplastic polyurethane
elastomer particle and a color thermoplastic polyurethane elastomer
particle, and the color thermoplastic polyurethane elastomer
particle contains the pigment", and the thermoplastic polyurethane
elastomer fiber and the method for manufacturing the same, the
thermoplastic polyurethane elastomer fabric of the present
disclosure can solve a dyeing difficulty of thermoplastic
polyurethane elastomer fiber.
[0080] The foregoing description of the exemplary embodiments of
the disclosure has been presented only for the purposes of
illustration and description and is not intended to be exhaustive
or to limit the disclosure to the precise forms disclosed. Many
modifications and variations are possible in light of the above
teaching.
[0081] The embodiments were chosen and described in order to
explain the principles of the disclosure and their practical
application so as to enable others skilled in the art to utilize
the disclosure and various embodiments and with various
modifications as are suited to the particular use contemplated.
Alternative embodiments will become apparent to those skilled in
the art to which the present disclosure pertains without departing
from its spirit and scope.
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