Highly cut-resistant yarn and protective articles made therefrom

Abstract

A cut-resistant composite yarn, comprising a high strength organic fiber having a tenacity greater than 15 grams per denier and a hard-particle-filled thermoplastic fiber useful in making fabrics from which protective articles, such as gloves are made.

1 . A cut-resistant composite yarn, comprising a high strength organic fiber having a tenacity greater than 15 grams per denier and a hard-particle-filled thermoplastic fiber.  
   
   
       2 . The yarn of  claim 1 , wherein the thermoplastic fiber is a liquid crystalline polymer selected from the group consisting of aromatic polyester, aliphatic-aromatic polyester, aromatic poly(estercarbonate), aliphatic-aromatic poly(esteramide), aromatic poly(esterimide), aromatic poly(esteramide), aromatic polyamide, aliphatic-aromatic polyamide and poly(azomethine).  
   
   
       3 . The yarn of  claim 1 , wherein the thermoplastic fiber is a semi-crystalline polymer selected from the group consisting of poly(alkylene terephthalate), poly(alkylene naphthalate), poly(arylene sulfide), aliphatic polyamide, aliphatic-aromatic polyamide and polyesters made from monomer units derived from cyclohexanedimethanol and terephthalic acid.  
   
   
       4 . The yarn of  claim 3 , wherein the thermoplastic fiber is poly(ethylene terephthalate).  
   
   
       5 . The yarn of  claim 3 , comprising 32 to 65 weight percent poly(ethylene terephthalate) based on the weight of the yarn.  
   
   
       6 . The yarn of  claim 1  wherein the high strength organic fiber is selected from the group consisting of para-aramids, polybenzazoles, polybenzoxazoles, polybenzothiazoles, polybenzimidazoles, polyacrylates and copolymers thereof.  
   
   
       7 . The yarn of  claim 5 , wherein the high strength organic fiber is para-aramid.  
   
   
       8 . The yarn of  claim 6 , wherein the para-aramid is poly(paraphenylene terephthalamide).  
   
   
       9 . The yarn of  claim 1 , wherein the hard particles are selected from the group consisting of tungsten, copper, brass, bronze, aluminum, steel, iron, monel, cobalt, titanium, magnesium, silver, molybdenum, tin, zinc, aluminum oxide, tungsten carbide, metal nitrides, metal sulfates, metal phosphates, metal borides, silicon carbide, baddelyte, chloritoid, clinozoiste, chondrodite, euclasite, petalite, sapphire, spodumene, staurolite and clay.  
   
   
       10 . The yarn of  claim 8 , wherein the hard particles comprise aluminum oxide.  
   
   
       11 . The yarn of  claim 1 , wherein the average particle size distribution of the hard particles is between 1 and 6 micrometers.  
   
   
       12 . The yarn of  claim 8 , wherein the hard particles are present in the amount of 0.1 to 10 weight percent based on the total weight of the hard-particle-filled thermoplastic fiber.  
   
   
       13 . The yarn of  claim 11 , wherein the thermoplastic fiber has a sheath-core configuration and the hard particles are substantially contained within the core.  
   
   
       14 . A cut resistant fabric, comprising the cut-resistant yarn of  claim 1 .  
   
   
       15 . A cut resistant fabric, comprising a cut-resistant composite yarn, wherein the yarn comprises poly(paraphenylene terephthalamide) and poly(ethylene terephthalate) filled with about 0.1 to 10 weight percent of hard particles, based on the total weight of hard particles plus poly(ethylene terephthalate).  
   
   
       16 . The cut resistant fabric of  claim 13 , wherein the fabric is woven.  
   
   
       17 . The cut resistant fabric of  claim 13 , wherein the fabric is knit.  
   
   
       18 . The fabric of  claim 13 , wherein the fabric has a cut protection performance value of at least 500 grams at a basis weight of at least 6 ounces per square yard when tested in accordance with ASTM F1790-97.  
   
   
       19 . The fabric of  claim 13 , wherein the fabric has a cut protection performance value of at least 1000 grams at a basis weight of at least 12 ounces per square yard when tested in accordance with ASTM F1790-97.  
   
   
       20 . The fabric of  claim 13 , wherein the fabric has a cut protection performance value of at least 1500 grams at a basis weight of at least 19 ounces per square yard when tested in accordance with ASTM F1790-97.  
   
   
       21 . The fabric of  claim 13 , wherein the cut protection performance when tested in accordance with ASTM F1790-97 is greater than the cut protection performance of a fabric of equal basis weight and construction consisting of any single yarn of which the composite yarn of  claim 1  comprises.  
   
   
       22 . A protective article, comprising the fabric of  claim 13 , wherein the protective article is selected from the group consisting of aprons, chaps, sleeves and gloves.  
   
   
       23 . The article of  claim 21 , wherein the fabric is woven.  
   
   
       24 . The article of  claim 21 , wherein the fabric is knit.  
   
   
       25 . A glove in accordance with  claim 21 , wherein the torture chamber life of the glove exceeds the torture chamber life of a glove of equal basis weight consisting of only one fiber of the yarn.  
   
   
       26 . The glove of  claim 23 , having a torture chamber life of at least 90 minutes when the basis weight of the fabric is at least 19 oz/yd 2 .  
   
   
       27 . A glove made form the fabric of  claim 14 , having a torture chamber life of at least 90 minutes when the basis weight of the fabric is at least 19 oz/yd 2 .