High tenacity fiber and mineral reinforced blended yarns

Abstract

Cut-resistant and abrasion-resistant yarns including blends of technical fibers and mineral, inorganic, or ceramic fibers of substantially the same length as the technical fibers, and methods for manufacturing yarns, are disclosed.

What is claimed is: 
     
         1 . A composite yarn, comprising:
 a blended core yarn, consisting essentially of;
 about 80 to 95% high performance polyethylene stretch broken technical fibers, and 
 5 to 20% inorganic, mineral, ceramic, or filament fibers having a length substantially similar to a length of the high performance polyethylene stretch broken technical fibers; and 
   
       at least one wrapping yarn comprising at least one of a high tenacity polyamide or a high tenacity polyester, wherein the at least one wrapping yarn is wrapped around the core to form the composite yarn having an EN5 cut-resistance level and having dimensions that enable the composite yarn to be knitted with an 18 gauge needle. 
     
     
         2 . The composite yarn of  claim 1 , wherein the technical fibers and the inorganic, mineral, ceramic, or filament fibers comprise a mean length of approximately 90-150 millimeters. 
     
     
         3 . The composite yarn of  claim 1 , wherein the inorganic, mineral, ceramic, or filament fibers comprise at least one of glass fibers, silica fibers, carbon fibers, or basalt fibers. 
     
     
         4 . The composite yarn of  claim 1 , wherein the inorganic, mineral, ceramic, or filament fibers comprise between 2% and 40% of the composite yarn. 
     
     
         5 . The composite yarn of  claim 1 , wherein the denier of the composite yarn is between 70 and 221 denier. 
     
     
         6 . The composite yarn of  claim 1 , wherein the denier of the composite yarn is between 160 and 221 denier. 
     
     
         7 . The composite yarn of  claim 1 , that is used to make a knitted article that is at least one of a glove, glove liner, sleeve, or curtain. 
     
     
         8 . The composite yarn of  claim 7 , wherein the knitted article further comprises a coating, the coating comprising a polymeric, elastomeric, or latex composition. 
     
     
         9 . The composite yarn of  claim 8 , wherein the polymeric, elastomeric, or latex composition further comprises at least one of natural polyisoprene, synthetic polyisoprene, carboxylated acrylonitrile butadiene, non-carboxylated acrylonitrile butadiene, nitrile-butadiene, polychloroprene, polyvinyls, butyl latex, styrene-butadiene (SBR), styrene-butadiene latex, styrene-isoprene-styrene (SIS), styrene-ethylene/butylene-styrene (SEBS), styrene-acrylonitrile (SAN), po/yethylene-propylene-diene, water-based polyurethane, an anionically stabilized polymer composition, solvent-based polyurethane, or combinations or blends thereof. 
     
     
         10 . A composite yarn, comprising: a blended core yarn, consisting essentially of:
 80 to 95% stretch broken technical fibers; and   5 to 20% inorganic, mineral, ceramic, or filament fibers having a length substantially similar to a length of the stretch broken technical fibers; and   at least one wrapping yarn comprising at least one of a high tenacity polyamide or high tenacity polyester, wherein the at least one wrapping yarn is wrapped around the blended core yarn to form the composite yarn having a denier of 260 or less and a EN5 cut-resistance level.   
     
     
         11 . The composite yarn of  claim 10 , wherein the technical fibers comprise at least one of high performance polyethylene, para-aramid fibers, meta-aramid fibers, or copolyamide fibers. 
     
     
         12 . The composite yarn of  claim 10 , wherein the inorganic, mineral, ceramic, or filament fibers comprise at least one of glass fibers, silica fibers, carbon fibers, or basalt fibers. 
     
     
         13 . The composite yarn of  claim 10 , wherein the inorganic, mineral, ceramic, or filament fibers comprise between 2% and 40% of the composite yarn. 
     
     
         14 . The composite yarn of  claim 10 , wherein the technical fibers and the inorganic, mineral, ceramic, or filament fibers comprise a mean length of approximately 90-150 millimeters. 
     
     
         15 . A knitted article that is at least one of a glove, glove liner, sleeve, or curtain made from the composite yarn of  claim 10 . 
     
     
         16 . The composite yarn of  claim 15 , wherein the knitted article further comprises a coating, the coating comprising a polymeric, elastomeric, or latex composition. 
     
     
         17 . The composite yarn of  claim 16 , wherein the polymeric, elastomeric, or latex composition further comprises at least one of natural polyisoprene, synthetic polyisoprene, carboxylated acrylonitrile butadiene, non-carboxylated acrylonitrile butadiene, nitrile-butadiene, polychloroprene, polyvinyls, butyl latex, styrene-butadiene (SBR), styrene-butadiene latex, styrene-isoprene-styrene (SIS), styrene-ethylene/butylene-styrene (SEBS), styrene-acrylonitrile (SAN), po/yethylene-propylene-diene, water-based polyurethane, an anionically stabilized polymer composition, solvent-based polyurethane, or combinations or blends thereof. 
     
     
         18 . A composite yarn, comprising:
 a blended core yarn consisting essentially of 80 to 95% high performance polyethylene stretch broken technical fibers, and 5 to 20% inorganic, mineral, ceramic, or filament fibers having a length substantially similar to a length of the high performance polyethylene stretch broken technical fibers; and   at least one wrapping yarn comprising at least one of a high tenacity polyamide or a high tenacity polyester, wherein the at least one wrapping yarn is wrapped around the core to form the composite yarn having an EN5 cut-resistance level, and wherein the denier of the composite yarn is between 70 and 221 denier.   
     
     
         19 . A method for making a cut resistant blended yarn that consists essentially of:
 about 80 to 95% stretch broken technical fibers, and   5 to 20% inorganic, mineral, ceramic, or filament fibers having a length substantially similar to a length of the high performance polyethylene stretch broken technical fibers,   
       the method comprising: 
       gel, wet, or dry-spinning the technical fiber with the inorganic, mineral, ceramic, or filament fibers, wherein the technical fibers and inorganic, mineral, ceramic, or filament fibers have a length and diameter that is substantially similar to a length and diameter of the technical fibers, to form a cut-resistant blended yarn. 
     
     
         20 . The method of  claim 19 , wherein the stretch broken technical fibers comprise high performance polyethylene.