Hybrid fabrics for extreme wear industrial and apparel applications

Abstract

Twisted, non-blended hybrid yarns are provided that are suitable for the fabrication of abrasion resistant garments and other textile articles. One or more polyolefin fibers are ply twisted together with one or more non-polyolefin fibers in a manner that utilizes the properties of each fiber type. A plurality of the twisted, non-blended hybrid yarns is then woven or knitted into fabrics, such as twill woven denim, or formed into ropes, such as braided ropes.

What is claimed is: 
     
         1 . A twisted, non-blended yarn comprising a twisted combination of one or more polyolefin fibers and one or more non-polyolefin fibers, wherein the twisted yarn has a yarn surface area, wherein said polyolefin fibers form greater than 20% of said yarn surface area, and wherein said polyolefin fibers and said non-polyolefin fibers are twisted together. 
     
     
         2 . The twisted, non-blended yarn of  claim 1  wherein said polyolefin fibers are continuous ultra-high molecular weight polyethylene fibers and wherein said non-polyolefin fibers comprise one or more synthetic fibers, one or more natural fibers or both one or more synthetic fibers and one or more natural fibers. 
     
     
         3 . The twisted, non-blended yarn of  claim 1  wherein said polyolefin fibers are continuous ultra-high molecular weight polyethylene fibers and wherein said non-polyolefin fibers comprise one or more elastic fibers, one or more natural fibers or both one or more elastic fibers and one or more natural fibers. 
     
     
         4 . The twisted, non-blended yarn of  claim 1  wherein said polyolefin fibers are continuous ultra-high molecular weight polyethylene fibers and wherein said non-polyolefin fibers comprise one or more elastic fibers, one or more natural fibers and one or more non-elastic synthetic fibers. 
     
     
         5 . The twisted, non-blended yarn of  claim 1  wherein said non-polyolefin fibers comprise both one or more cotton fibers and one or more elastic and/or non-elastic synthetic fibers. 
     
     
         6 . The twisted, non-blended yarn of  claim 1  wherein said non-polyolefin fibers comprise both cotton fibers and elastic fibers. 
     
     
         7 . The twisted, non-blended yarn of  claim 1  wherein said non-polyolefin fibers comprise one or more elastic synthetic fibers, one or more non-elastic synthetic fibers, or both one or more elastic synthetic fibers and one or more non-elastic synthetic fibers. 
     
     
         8 . The twisted, non-blended yarn of  claim 1  wherein said polyolefin fibers form from about 25% of the surface area of the yarn up to about 65% of the surface area of the yarn. 
     
     
         9 . The twisted, non-blended yarn of  claim 1  wherein said polyolefin fibers form from greater than 66% of the surface area of the yarn up to 75% of the surface area of the yarn. 
     
     
         10 . The twisted, non-blended yarn of  claim 1  wherein said yarn comprises a first non-polyolefin fiber and a second non-polyolefin fiber, wherein said first non-polyolefin fiber and said second non-polyolefin fiber are chemically different, and wherein the volume ratio of the first non-polyolefin fiber type relative to the second non-polyolefin fiber type is from about 1:3 to about 3:1. 
     
     
         11 . The twisted, non-blended yarn of  claim 10  wherein said first non-polyolefin fiber comprises one or more elastic fibers and said second non-polyolefin fiber comprises one or more natural fibers. 
     
     
         12 . The twisted, non-blended yarn of  claim 10  wherein said first non-polyolefin fiber comprises one or more natural fibers and said second non-polyolefin fiber comprises one or more different natural fibers. 
     
     
         13 . The twisted, non-blended yarn of  claim 10  wherein said first non-polyolefin fiber comprises one or more nylon fibers and said second non-polyolefin fiber comprises one or more polyester fibers. 
     
     
         14 . The twisted, non-blended yarn of  claim 1  wherein said twisted yarn comprises a greater percentage by weight of said polyolefin fibers relative to said non-polyolefin fibers. 
     
     
         15 . The twisted, non-blended yarn of  claim 1  wherein the yarn has a polyolefin fiber content of from about 40% by volume to about 70% by volume of the yarn. 
     
     
         16 . The twisted, non-blended yarn of  claim 1  wherein said twisted yarn comprises a greater percentage by volume of said polyolefin fibers relative to said non-polyolefin fibers. 
     
     
         17 . A woven, non-woven or knitted fibrous article formed from a plurality of twisted, non-blended yarns of  claim 1 . 
     
     
         18 . A twisted, non-blended yarn comprising a twisted combination of one or more polyolefin fibers and one or more non-polyolefin fibers, said non-polyolefin fibers having a tenacity of 20 g/denier or less and said non-polyolefin fibers having a density of greater than 1.0 grams/cm 3 , and wherein said fibers are twisted together. 
     
     
         19 . The twisted, non-blended yarn of  claim 18  wherein said twisted yarn has from about 0.5 to about 15 twists per inch of length of the twisted yarn, wherein said polyolefin fibers are continuous ultra-high molecular weight polyethylene fibers having a tenacity of greater than 20 g/denier, wherein said non-polyolefin fibers have a tenacity of at least about 10 g/denier and wherein said non-polyolefin fibers have a density of greater than 1.5 grams/cm 3 . 
     
     
         20 . A process for producing a twisted, non-blended yarn, comprising:
 a) providing one or more polyolefin fibers;   b) providing one or more non-polyolefin fibers, wherein said non-polyolefin fibers comprise one or more synthetic fibers, one or more natural fibers, or both one or more synthetic fibers and one or more natural fibers;   c) laying said polyolefin fibers and said non-polyolefin fibers side-by-side in parallel to thereby form a non-blended, untwisted fiber bundle wherein the untwisted fiber bundle has a surface area, and wherein said polyolefin fibers form greater than 20% of said fiber bundle surface area; and   d) twisting said non-blended fiber bundle to form a twisted yarn, wherein said polyolefin fibers and said non-polyolefin fibers are twisted together at a 1:1 ratio relative to each other, wherein the twisted yarn has a yarn surface area and wherein said polyolefin fibers form greater than 20% of said twisted yarn surface area.