High tenacity or high load bearing nylon fibers and yarns and fabrics thereof

Abstract

High strength or load bearing nylon fiber with break tenacity greater than 7.5 g/den and/or a tenacity at 10% elongation of greater than 4.0 g/den as well as yarns, fabrics and articles of manufacture thereof and methods for their production are provided.

What is claimed is: 
     
         1 . A nylon staple fiber comprising a nylon polymer, said fiber having a break tenacity greater than 7.5 g/den. 
     
     
         2 . The nylon staple fiber of  claim 1  wherein the nylon polymer is nylon 6,6. 
     
     
         3 . The nylon staple fiber of  claim 1  wherein the tenacity at 10% elongation of greater than 4.0 g/den. 
     
     
         4 . A yarn spun from the nylon staple fiber of any of  claims 1 - 4 . 
     
     
         5 . The yarn of  claim 5  further comprising at least one companion staple fiber. 
     
     
         6 . The yarn of  claim 6  wherein the companion staple fiber is selected from the group consisting of cellulosics, modified cellulosics, animal fibers, fire resistant polyester, fire resistant nylon, fire resistant rayon, fire resistant treated cellulose, m-aramid, p-aramid, modacrylic, novoloid, melamine, polyvinyl chloride, antistatic fiber, PBO (1,4-benzenedicarboxylic acid, polymer with 4,6-diamino-1,3-benzenediol dihydrochloride) and PBI (polybenzimidazole), and combinations thereof. 
     
     
         7 . A fabric comprising nylon staple fiber of any of  claims 1  through  4  or yarn of any of  claims 5  through  7 . 
     
     
         8 . The fabric of  claim 8  with a weight of less than 6.0 oz./yd 2 . 
     
     
         9 . The fabric of  claim 8  which meets or exceeds military fabrics strength and tear specifications established for fabrics that weigh less than 6.0 oz./yd 2 . 
     
     
         10 . An article of manufacture at least a portion of which comprises nylon staple fiber of  claim 1 . 
     
     
         11 . A non-woven fabric composite comprising high tenacity fiber and cellulosic or recycled synthetic or natural fiber. 
     
     
         12 . The non-woven composite of  claim 12  wherein the high tenacity fiber comprises load bearing nylon fiber with break tenacity greater than 7.5 g/den and/or a tenacity at 10% elongation of greater than 4.0/den. 
     
     
         13 . The non-woven composite of  claim 12  or  13  wherein the cellulosic or recycled synthetic or natural fiber comprises recycled denim. 
     
     
         14 . A method for producing high strength or load bearing nylon fiber, said method comprising melt-spinning nylon polymer into filaments, uniformly quenching the filaments and forming a tow from a multiplicity of these quenched filaments, subjecting the tow to drawing in the presence of steam, annealing, and converting the resulting drawn and annealed tow into staple fibers. 
     
     
         15 . The method of  claim 15  wherein annealing is performed under tension. 
     
     
         16 . The method of  claim 15  or  16  wherein the nylon fiber has a break tenacity greater than 7.5 g/den. 
     
     
         17 . The method of  claim 15  or  16  wherein the nylon fiber has a tenacity at 10% elongation of greater than 4.0 g/den.