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Hybrid Composite Yarn

a composite yarn and hybrid technology, applied in the field of hybrid composite yarns, can solve the problems that high-tenacity and high-modulus polyolefin multifilament yarns have seen little application in the field of fiber-reinforced composites

Inactive Publication Date: 2014-11-13
INNEGRITY C +1
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  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

AI Technical Summary

Benefits of technology

The invention is a hybrid composite yarn that combines two types of yarns: a polyolefin yarn and a yarn from the group consisting of glass, carbon, poly(p-phenylene terephthalamide) and basalt yarns. The resulting composite yarn has specific physical properties, including greater than about 100% of the expected tenacity based on the volume fraction of the second yarn, an initial modulus greater than about 100% of the expected modulus based on the volume fraction of the second yarn, and elongation at break less than about 320% of the elongation at break of the second yarn. The first polyolefin yarn can be made from polypropylene or a blend of polypropylene and another polymer. The second yarn can be made from E-glass, carbon, or basalt, and has properties similar to those described for the individual yarns. The composite yarn also includes microfibrils and voids aligned parallel to the longitudinal axis of the first polyolefin yarn.

Problems solved by technology

However, these high-tenacity and high-modulus polyolefin multifilament yarns have seen little application in the field of fiber-reinforced composites, due largely to the difficulty in combining these yarns with other high-modulus reinforcing fibers.

Method used

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Examples

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example

[0066]Yarn samples were formed on system similar to that illustrated in FIG. 1. In particular, the system included a ¾ inch, 24:1 single screw extruder with three temperature zones, a head with a melt pump and spinneret, a liquid quench tank (40 inch length), with two rollers in the tank, a vacuum water removal system, a spin finish applicator, three heated godet rolls, a forced air oven (120 inch length) and a Leesona® winder.

[0067]Materials utilized in forming the yarns included Atofina® 3462, a polypropylene homopolymer with a melt flow index of 3.7 and Atofina® 3281, a polypropylene homopolymer with a melt flow index of 1.3 (both available from ATOFINA Petrochemicals, Inc. of Houston, Tex.), a 10% concentrate of a nucleating agent composition, specifically Millad® 3988 (3,4-dimethyl dibenzylidiene sorbitol) in a 12 MFI polypropylene homopolymer (available from Standridge Color Corporation, Social Circle, Ga., USA), and a polyethylene homopolymer with a melt flow index of 12 (ava...

examples

[0100]“Hybrid” Composite yarn samples were formed by combination of a first yarn component and a second yarn component in a substantially parallel orientation using a controlled aerodynamic turbulence applied in a chamber to intermingle the first and second yarn components, using equipment such as the DS60 machinery made by Dietze & Schell for air-texturing of glass fibers.

[0101]A high-modulus polypropylene yarn, as described in Tables 1-3 above, was used as the First Yarn Component. First Yarn Components used were Innegra™ S yarns in 625 denier and 940 denier yarn sizes. Second Yarn Components used were E-glass, carbon, and basalt yarns. The E-glass yarn used was a resin-compatible yarn (RCY), size G75, with 0.7Z twist from AGY. In one embodiment, the E-glass is alumino-borosilicate glass with less than 1% w / w alkali oxides. The carbon yarn used was an AS4-GP-3k type from Hexcel. The carbon yarn can have one or more of the following physical properties: tensile strength of about 67...

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Abstract

This invention is a hybrid composite yarn comprising: a first polyolefin yarn having >about 80% crystallinity according to WAXS measuring techniques; a second yarn taken from the group consisting of: glass; quartz; carbon; poly(p-phenylene terephthalamide), poly(m-phenylene terephthalamide); poly(vinyl alcohol); poly(1,4-phenylene-2,14-benzibisoxazole) (PBO); poly(1,4-phenylene-2,14-benzobisthiazole) (PBT); poly(benzimidizole) (PBI); poly(ethylene-2,14-naphthalate) (PEN); lyotropic liquid crystalline polymers formed by polycondensation of aromatic organic monomers to form aromatic polyesters, polyamides, aluminia-silicates, basalt, regenerated cellulosic materials and ultra-high molecular weight polyethylene (UHMWPE); and, wherein the first polyolefin yarn and the second yarn are physically combined to form a composite yarn having at least one of the following properties: tenacity greater than about 100% of the expected tenacity based on the volume fraction of the second; an initial modulus >about 100% of the expected modulus based on the volume fraction of the second; elongation at break <about 320% of the elongation at break of the second.

Description

CLAIM OF PRIORITY[0001]This application is a Continuation in part of U.S. application Ser. No. 11 / 438,530 and U.S. Application 61 / 859,707 that are incorporated herein by reference.BACKGROUND OF THE INVENTION[0002]Yarns and fibers formed from polyolefins can offer many desirable characteristics. For example, they can possess good toughness and fatigue resistance, they can be resistant to chemical and biological degradation, and the raw materials are readily available. As such, monofilament fibers as well as multifilament yarns have been formed from various polyolefins such as polypropylene. More recently, multifilament polyolefin fibers with high tenacity and modulus have been developed. However, these high-tenacity and high-modulus polyolefin multifilament yarns have seen little application in the field of fiber-reinforced composites, due largely to the difficulty in combining these yarns with other high-modulus reinforcing fibers. As such, there remains room for improvement and var...

Claims

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Application Information

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Patent Type & Authority Applications(United States)
IPC IPC(8): D02G3/04D02J1/08D02G3/22
CPCD02G3/045D02G3/22D02J1/08D10B2101/06D10B2101/12D10B2101/02D10B2321/022D10B2401/10D10B2401/00D10B2505/12D10B2505/10D10B2501/00D10B2507/00D01D5/0885D01D5/098D01F1/10D01F6/06E04C5/073H04N21/4335D06N3/0011D06N3/0004D02G3/16Y10T428/2929
Inventor ETTIN, JEFFREYCATES, ELIZABETH
Owner INNEGRITY C
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