Hybrid Composite Yarn

1 . A hybrid composite yarn comprising:

a first polyolefin yarn having greater than about 80% crystallinity according to WAXS measuring techniques;

a second yarn differing from the first polyolefin yarn taken from the group consisting of glass, carbon, poly(p-phenylene terephthalamide) and basalt yarns; 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 physical properties: 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.

2 . The composite yarn of claim 1 wherein the first polyolefin yarn is a multifilament having at least one of the following physical properties: a melt flow index between about 0.2 and about 50; a denier of less than about 300 grams/900 meters; a modulus equal to or greater than 40 g/d, an elongation of less than about 10% as measured by ASTM D2256; at least one of the filaments has a ratio of equatorial intensity to meridonal intensity greater than about 1.0 obtained from known small angle x-ray scattering (SAXS) measuring techniques.

3 . The composite yarn of claim 1 wherein the first polyolefin yarn is polypropylene.

4 . The composite yarn of claim 1 wherein the first polyolefin yarn is a blend of a first polyolefin and a second polymer taken from the group consisting of: thermoplastic, thermoset, and non-olefinic polymer.

5 . The composite yarn of claim 1 wherein the second yarn is E-glass in a quantity in the range of 20% to 80% by weight.

6 . The composite yarn of claim 5 wherein the second yarn is E-glass in a quality of about 60% by weight and at least one of the following physical properties: tenacity 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.

7 . The composite yarn of claim 1 wherein the second yarn is carbon yarn in a quantity in the range of 30% to 80% by weight.

8 . The composite yarn of claim 7 wherein the second yarn is carbon yarn in a quantity of about 75% by weight and at least one of the following properties: tenacity 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; elongation at break less than about 320% of the elongation at break of the second yarn.

9 . The composite yarn of claim 1 wherein the second yarn is basalt in a quantity of about 50% by weight and at least one of the following properties: tenacity 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.

10 . The composite yarn of claim 1 having:

filaments included in the first polyolefin yarn; and,

a plurality of microfibrils included in at least one of the filaments wherein the filament includes a plurality of voids interspersed within the microfibrils, wherein both said microfibrils and voids are aligned substantially parallel to the longitudinal axis of the first polyolefin yarn.

11 . A hybrid composite yarn comprising:

a first polyolefin yarn having greater than about 80% crystallinity according to WAXS measuring techniques;

a second yarn differing from the first polyolefin 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 yarn; an initial modulus greater than about 100% of the expected modulus based on the volume fraction of the second yarn; elongation at break less than about 320% of the elongation at break of the second yarn.

12 . The hybrid composite yarn of claim 11 wherein the first polyolefin yarn and the second yarn are physically combined to form a composite yarn having a tenacity in the range of 4.6 to 7.9 grams per denier.

13 . The hybrid composite yarn of claim 11 wherein the first polyolefin yarn and the second yarn are physically combined to form a composite yarn having an elongation break in the range of 2.9 to 6.6 percent.

14 . The hybrid composite yarn of claim 11 wherein the first polyolefin yarn and the second yarn are physically combined to form a composite yarn having a modulus in the range of 162 to 539 games per denier.

15 . A hybrid composite yarn comprising:

a multifilament polyolefin yarn wherein at least one of the filaments has a ratio of equatorial intensity to meridonal intensity greater than about 1.0 according to SAXS measuring techniques

a second yarn differing from the first multifilament polyolefin yarn taken from the group consisting of glass, carbon and basalt yarns;

wherein the first multifilament polyolefin yarn and the second yarn are physically combined to form a composite yarn.

16 . The composite yarn of claim 15 having a tenacity in the range of 4.6 to 7.9 grams per denier, an elongation break in the range of 2.9 to 6.6 percent and a modulus in the range of 162 to 539 games per denier.

17 . The composite yarn of claim 15 wherein the second yarn is at least 90% carbon and the modulus of the composite yarn is in the range of 1.8 to 2.76 time the modulus of the first multifilament polyolefin yarn.

18 . The composite yarn of claim 17 wherein the modulus of the first multifilament yarn is about 195 grams per denier.

19 . The composite yarn of claim 15 wherein the second yarn is at least 90% carbon and the elongation at break of the composite yarn is in the range of 32% to 43% that of the first multifilament polyolefin yarn.

20 . The composite yarn of claim 15 having:

filaments included in the first polyolefin yarn; and,

a plurality of microfibrils included in at least one of the filaments wherein the filament includes a plurality of voids interspersed within the microfibrils, wherein both said microfibrils and voids are aligned substantially parallel to the longitudinal axis of the first polyolefin yarn.

21 . The composite yarn of claim 15 wherein the second yarn is at least 90% carbon and the tenacity of the composite yarn is in the range of 74% to 83% that of the first multifilament polyolefin yarn.