Elastomeric yarn for safety applications

Abstract

The elastomeric yarn for safety applications discloses an elastomeric yarn that reliably breaks at 200% stretch and is therefore appropriate for use with a sacrificial textile. The elastomeric yarn for safety applications discloses the polyurethane segments, the copolymer segments, the necessary plurality of cross-links required to form a structure of a polyurethane based elastomeric yarn that reliably breaks at 200% stretch.

Claims

1. A polyurethane-based elastomeric yarn comprising a copolymer based structure; wherein the copolymer based structure comprises a plurality of individual copolymer structures and a plurality of cross-links; wherein each individual copolymer structure comprises a plurality of polyurethane segments and a plurality of copolymer segments; wherein each polyurethane segment selected from the plurality of polyurethane segments is selected from the group consisting of an aromatic molecule and an aliphatic molecule; wherein the proportion of the plurality of polyurethane segments that comprises an aromatic molecular section is a number P; wherein P is greater than or equal to zero; wherein P is lesser than or equal to one; wherein the proportion of the plurality of polyurethane segments that comprises an aliphatic molecular section is equal to (1−P); wherein the copolymer segment is a molecular structure that interconnects the individual polyurethane segments; wherein each cross-link selected from the plurality of crosslinks joins a first individual copolymer structure selected from the plurality of individual copolymer structures of the polyurethane-based elastomeric yarn to a second individual copolymer structure selected from the plurality of individual copolymer structures of the polyurethane-based elastomeric yarn; wherein the polyurethane-based elastomeric yarn breaks at a span of stretched length lesser than three times the relaxed length of the polyurethane-based elastomeric yarn; wherein each cross-link selected from the plurality of cross-links attaches a first polyurethane segment selected from the plurality of polyurethane segments of the first individual copolymer structure to a second polyurethane segment selected from the plurality of polyurethane segments of the second individual copolymer structure; wherein the aromatic molecule selected for the polyurethane segment is an aromatic diisocyanate; wherein the aliphatic molecule selected for the polyurethane segment is an aliphatic diisocyanate; wherein the aromatic molecule selected for the polyurethane segment is 2,4-tolylene diisocyanate (CAS: 584-84-9); wherein the aliphatic molecule selected for the polyurethane segment is 1,6-hexanediisocyanate (CAS: 822-06-0); wherein the value of P is greater than 0.23; wherein the value of P is lesser than 0.37.

2. The polyurethane-based elastomeric yarn according to claim 1 wherein the copolymer segment is derived from 1,4-butylene adipate (CAS: 24936-97-8).

Description

BRIEF DESCRIPTION OF DRAWINGS

(1) The accompanying drawings, which are included to provide a further understanding of the invention are incorporated in and constitute a part of this specification, illustrate an embodiment of the invention and together with the description serve to explain the principles of the invention. They are meant to be exemplary illustrations provided to enable persons skilled in the art to practice the disclosure and are not intended to limit the scope of the appended claims.

(2) FIG. 1 is a structural view of an embodiment of the disclosure.

(3) FIG. 2 is a detail view of an embodiment of the disclosure.

(4) FIG. 3 is a detail view of an embodiment of the disclosure.

(5) FIG. 4 is a detail view of an embodiment of the disclosure.

(6) FIG. 5 is a detail view of an embodiment of the disclosure.

(7) FIG. 6 is a detail view of an embodiment of the disclosure.

DETAILED DESCRIPTION OF THE EMBODIMENT

(8) The following detailed description is merely exemplary in nature and is not intended to limit the described embodiments of the application and uses of the described embodiments. As used herein, the word “exemplary” or “illustrative” means “serving as an example, instance, or illustration.” Any implementation described herein as “exemplary” or “illustrative” is not necessarily to be construed as preferred or advantageous over other implementations. All of the implementations described below are exemplary implementations provided to enable persons skilled in the art to practice the disclosure and are not intended to limit the scope of the appended claims. Furthermore, there is no intention to be bound by any expressed or implied theory presented in the preceding technical field, background, brief summary or the following detailed description.

(9) Detailed reference will now be made to one or more potential embodiments of the disclosure, which are illustrated in FIGS. 1 through 6.

(10) The disclosed polyurethane based elastomeric yarn 100 takes advantage of the observation that the primary determinant of the overall stretch available from a polyurethane-based elastomeric yarn 100 is separate from the primary determinant of the modulus of the polyurethane-based elastomeric yarn 100. Specifically, this application discloses the substitution of a proportion of aromatic structures that form the urethane link 104 with aliphatic hydrocarbon structures such that P % of the polyurethane segment 101 comprises an aromatic molecule for the urethane link 104 and (1−P) % of the polyurethane segment 101 comprises an aliphatic molecule for the urethane link 104.

(11) For example, the applicant estimates that if the urethane link 104 of the polyurethane segment 101 of a polyurethane-based elastomeric yarn 100 is 2,4-tolylene diisocyanate (CAS: 584-84-9) 111 and the copolymer segment 102 of the polyurethane-based elastomeric yarn 100 is 1,4-butylene adipate (CAS: 24936-97-8) 112, then the replacement of roughly 70% (0.23<=P<=0.37) of the 2,4-tolylene diisocyanate (CAS: 584-84-9) 111 by 1,6-hexanediisocyanate (CAS: 822-06-0) 114 (0.63<=P<=0.77) would result in a polyurethane based elastomeric yarn 100 structure that would break before stretching to three times its relaxed length.

(12) The applicant estimates that substituting the 1,6-hexanediisocyanate (CAS: 822-06-0) 114 in the above ratio would be sufficient to create the described product. This change is not anticipated to require modifications to existing equipment.

(13) More generally, the applicant believes that the substitution of any aromatic ring in a polyurethane segment 101, can be substituted with an aliphatic diisocyanate, including 1,6-hexanediisocyanate (CAS: 822-06-0) 114, to create a similar result.

(14) Once the break stretch is set, the number of the plurality of cross-links 103 between the polymer molecules needs to be established between the remaining aromatic molecules forming the urethane link 104 of the polyurethane segment 101. The process of establishing the plurality of cross-links 103 is similar to the processes used for yarns formed exclusively with the aromatic version of the urethane link 104. The curing time will increase using this method.

(15) Alternately, the curing time can be reduced through the addition of functional groups, such as methyl groups, to the 1,6-hexanediisocyanate (CAS: 822-06-0) 114 thereby increasing the number of bonding sites available for to form the plurality of cross-links 103.

(16) The applicant estimates that to create an elastic yarn that approximates the performance of commercially available spandex yarns at the lower break stretch, an increase in the number of crosslinks per average molecular weight of the polymer of over 30% is required.

(17) The following definitions were used in this disclosure:

(18) Aliphatic: As used in this disclosure, aliphatic refers to an organic molecule that does not contain a ring structure.

(19) Aromatic: As used in this disclosure, aromatic refers to an organic molecule that contains a ring structure.

(20) Carbamate: As used in this disclosure, a carbamate is a functional group consisting of an O—(C═O)—N structure. Carbamate is informally referred to as urethane.

(21) Copolymer: As used in this disclosure, a copolymer is a polymer formed from two or more repeating molecules (also referred to as monomers).

(22) Crosslink: As used in this disclosure, a crosslink refers to a molecular bond or a hydrogen bond that attaches a first molecular chain to a second, parallel, molecular chain. Typically, the molecular chain will be a polymer.

(23) Denier: As used in this disclosure, the term denier is a unit of weight that can be used to describe the fineness of nylon, polyester yarn, rayon, elastomeric or silk yarn. Denier is calculated as grams per 9000 meters.

(24) Elastic: As used in this disclosure, an elastic is a material or object that deforms when a force is applied to it and that is able to return to its relaxed shape after the force is removed. A material that exhibits these qualities is also referred to as an elastomeric material. A material that does not exhibit these qualities is referred to as inelastic or an inelastic material.

(25) Elastic Textile: As used in this disclosure, an elastic textile is a textile that contains elastic yarns as some of the yarns that make up the textile. An elastic textile is constructed such that the elastic textile will stretch when a force is applied and will return to its original shape when after the force is removed.

(26) Elastic Webbing: As used in this disclosure, an elastic webbing is a webbing that contains elastic yarns as some of the yarns that make up the webbing. An elastic webbing is constructed such that the elastic webbing will stretch when a force is applied and will return to its original shape when after the force is removed.

(27) Elastic Yarn: As used in this disclosure, an elastic yarn is a yarn formed from elastomeric materials.

(28) Fastener: As used in this disclosure, a fastener is a device that is used to join or affix a first object to a second object.

(29) Hydrogen Bond: As used in this disclosure, a hydrogen bond refers to an electrostatic attraction between: 1) a cation and an anion; 2) a cation and a negative dipole; or, 3) an anion and a positive dipole. The exchange of electrons (as would occur in an ionic bond or covalent bond) does not occur in a hydrogen bond. As a rule, the energy to break an ionic bond is less than the energy required to break a covalent bond or an ionic bond.

(30) Modulus: As used in this disclosure, the modulus of an elastomeric material is a function that describes the percentage change in the span of the elastomeric material as a function of the force applied to elastomeric material. When comparing modulus, a larger modulus is taken to imply that an increase in force is required to get the same percentage change in the elastomeric material.

(31) Monofilament: As used in this disclosure, a monofilament refers to a yarn or a cord that is formed from a single continuous filament.

(32) Monomer: As used in this disclosure, a monomer refers to a molecular structure that bonds to itself in a repeating manner to form a polymer.

(33) Not Significantly Different: As used in this disclosure, the term not significantly different compares a specified property of a first object to the corresponding property of a reference object (reference property). The specified property is considered to be not significantly different from the reference property when the absolute value of the difference between the specified property and the reference property is less than 10.0% of the reference property value. A negligible difference is considered to be not significantly different.

(34) Organic: As used in this disclosure, organic refers to a carbon-based chemical structure. A limited number of carbon-based salts are traditionally considered inorganic chemical structure and are excluded from the study of organic chemistry.

(35) Polymer: As used in this disclosure, a polymer refers to a molecular chain that comprises multiple repeating units known as monomers. The repeating unit may be an atom or a molecular structure.

(36) Polyurethane: As used in this disclosure, a polyurethane is a copolymer wherein the one or more monomer chains are linked together carbamates.

(37) Relaxed Shape: As used in this disclosure, a structure is considered to be in its relaxed state when no shear, strain, or torsional forces are being applied to the structure.

(38) Roughly: As used in this disclosure, roughly refers to a comparison between two objects. Roughly means that the difference between one or more parameters of the two compared are not significantly different.

(39) Sacrificial Structure: As used in this disclosure, a sacrificial structure is a first object or structure that protects a second object or structure from damage. More specifically, the sacrificial structure protects the second object or structure by being damaged instead of the second object or structure.

(40) Tether: As used in this disclosure, a tether is a cord, line, webbing, or strap that is attached to an object to restrict its movement.

(41) Textile: As used in this disclosure, a textile is a material that is woven, knitted, braided or felted. Synonyms in common usage for this definition include fabric and cloth.

(42) Webbing: As used in this disclosure, a webbing is strong, close woven or knitted fabric that is used for straps or belting. As used in this disclosure, webbing is a fully formed material that is only cut to length for use. Webbing is not formed by cutting broader materials into strips. Webbings have tensile strength but are too flexible to provide compressive strength and are not suitable for use in pushing objects.

(43) Yarn: As used in this disclosure, a yarn is a continuous strand of textile fibers and filaments. Yarns are generally used in the production of fabrics. For the purposes of this disclosure, this definition explicitly includes yarns formed from a single filament such as a monofilament yarn.

(44) With respect to the above description, it is to be realized that the optimum dimensional relationship for the various components of the invention described above and in FIGS. 1 through 6 include variations in size, materials, shape, form, function, and manner of operation, assembly and use, are deemed readily apparent and obvious to one skilled in the art, and all equivalent relationships to those illustrated in the drawings and described in the specification are intended to be encompassed by the invention.

(45) It shall be noted that those skilled in the art will readily recognize numerous adaptations and modifications which can be made to the various embodiments of the present invention which will result in an improved invention, yet all of which will fall within the spirit and scope of the present invention as defined in the following claims. Accordingly, the invention is to be limited only by the scope of the following claims and their equivalents.