CA1137368A - Mixed fiber length yarn - Google Patents

Mixed fiber length yarn

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Publication number
CA1137368A
CA1137368A CA000357055A CA357055A CA1137368A CA 1137368 A CA1137368 A CA 1137368A CA 000357055 A CA000357055 A CA 000357055A CA 357055 A CA357055 A CA 357055A CA 1137368 A CA1137368 A CA 1137368A
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Prior art keywords
fibers
length
yarn
percent
weight
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Application number
CA000357055A
Other languages
French (fr)
Inventor
Linda C. Sawyer
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Celanese Corp
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Celanese Corp
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Classifications

    • DTEXTILES; PAPER
    • D02YARNS; MECHANICAL FINISHING OF YARNS OR ROPES; WARPING OR BEAMING
    • D02GCRIMPING OR CURLING FIBRES, FILAMENTS, THREADS, OR YARNS; YARNS OR THREADS
    • D02G3/00Yarns or threads, e.g. fancy yarns; Processes or apparatus for the production thereof, not otherwise provided for
    • D02G3/22Yarns or threads characterised by constructional features, e.g. blending, filament/fibre

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Textile Engineering (AREA)
  • Yarns And Mechanical Finishing Of Yarns Or Ropes (AREA)

Abstract

ABSTRACT OF THE DISCLOSURE

A novel synthetic yarn is disclosed which com-prises fibers of different lengths (as specified). At least three groups of synthetic fibers are present in the yarn, with the synthetic fibers within each group being substantially uniform in length. The substantially uniform, length of each group of synthetic fibers present in the yarn differs from the substantially uniform length of the syn-thetic fibers in the other groups. The use of such mixtures of fiber lengths in a synthetic yarn enables the yarn to exhibit physical characteristics such as high bulk which more closely resemble the characteristics of natural fiber-containing yarns. Fabrics having improved physical charac-teristics may also be produced from the novel synthetic yarns disclosed.

Description

-, ~
~,f3 ~137;~

BACKGROUND OF THE INVENTION
-The present invention relates to synthetic fiber-containing yarns, especially novel yarns comprised of synthe-tic fibers having different lengths.
For many years natural fibers such as cotton and wool have been replaced, either wholly or in part, by synthe-tic fibers in the manufacture of yarns and fabrics. Signifi-cant improvements in the strength and processability of textile yarns have thus been achieved.
Synthetic fiber-containing yarns and fabrics do not, however, typically possess the appearance and physical characteristics of cotton or wool yarns and fabrics. Synthe-tic fiber-containing fabrics also do not generally attain the same level of comfort as natural fiber-containing fabrics.
Attempts have thus been made to improve the physi-cal characteristics of synthetic fiber-containing yarns and fabrics. For example, U.S. Patent 3,350,872 describes a textile yarn comprised of synthetic fibers whose physical characteristics are intended to simulate those of a wool fabric, which yarn consists of a crimped and uncrimped acrylic fiber. U.S. Patent No. 3,965,664 describes a yarn which is formed from a mixture of synthetic fibers including fibers having at least three different titers (titer sub-stantially corresponds to denier) and which is intended to have the feel of a natural fiber-containing yarn. U.S.
Patent 3,138,7g0 discloses yarns comprised of a blend of synthetic fibers (e.g., nylon or polyethylene tere~hthalate) and cotton fibers, with the synt!letic fibers being botn -;~ s`~ ~
l37~i8 crimped and uncrinlped. U.S. Patents 3,587,220 and 3,686,850 disclose yarns con~prised of synthetic fibers having high and low shrinkage characteristics. U.S. Patent 2,271,184 de-scribes a blend of fibers having both regular and irregular deniers. Differential fiber length is also a criterion taken into account in U.S. Patents 3,157,021; 3,371,47~; and 3,33S,466 in order to produce a bulky, high strength synthe-tic yarn.
A synthetic fiber-containing yarn has not been produced, however, which adequately exhi~its the advan-tageous physical characteristics (e.g., bulkiness and appear-ance) of natural fiber-containing yarns. A synthetic fiber-containing yarn having such characteristics while also possessing the strength and durability of synthetic fiber-containing yarns would thus be highly desirable. In addi-tion, a fabric conlprised of such a yarn would sinlilarly possess characteristics such as increased cover hereto~ore unattained by conventional synthetic fabrics. Such fabrics and yarns would have widespread application in shirting, un~erwear, sheeting, home furnishings, as well as in ~is-cellaneous te~tile uses.

-~ 1~l37;~fi8 The present invention is directed to providing a syntnetic fiber-containing yarn which possesses some of the physical characteristics of natural fiber-containing yarns, such as cotton or wool fiber-containing yarns and which exhibits increased bulk.
According to the present invention there is provided in a textile yarn comprised of a blend of cotton and polyester staple fibers wnerein the polyester staple fibers present in said yarn comprise at least about 50 percent by weight of the fibers in the yarn, the improvement wherein said polyester staple fibers consist of a mixture of fibers of at least three different lengths within the range of about 1/4 to about 6 inches whereby a fabric comprised of said yarn has improved comfort in comparison to a corresponding fabric comprised of a blend of cotton and polyester staple fibers wherein the polyester fibers are of uniform length of about 1 1/2 inches.
In another aspect of the present invention there is provided a yarn comprised of a blend of polyester fibers and cotton fibers, the improvement wherein the polyester fibers present in the yarn comprise at least about 50 percent by weight of the fibers within said yarn and consist of a mixture of at least three groups of polyester fibers, each 1~l3~;~68 group consisting of polyester fibers of a substantially uniform length which differs from the substantially uniform length of the polyester fibers in the other groups, and wherein the polyester fibers contained within said at least three groups of polyester fibers are distributed among each of the following ranges based upon the weigAt of the fibers present in said at least three groups:
(a) up to about 75 percent by weight of fibers having a length of about X, wherein X
represents the lengtn of the longest polyester fiber in said groups;
(b) up to about 75 percent by weight of fibers having a length greater than about l/2X
up to about not including said length of about X;
and (c) up to about 35 percent hy weight of fibers having a length less than or equal to said length of about l/2X.
In another aspect of the present invention, there is provided in a fabric containing a yarn comprised of a blend of polyester fibers and cotton fibers, the improvement wherein the polyester fibers present in the yarn comprise at least about 50 percent by weight of the fibers within said yarn and consist of a mixture of at least three groups of polyester fibers, each group consisting of polyester fibers of a substantially uniform length which differs from the substantially uniform length of the polyester fibers in the other groups, and wherein the polyester ~l37368 fibers are distributed among each of the following ranges based upon the weight of the fibers present in said at least three groups:
(a) up to about 75 percent by weight of fibers having a length of about X, wherein X
represents the length of the longest polyester fiber in said groups;
(b) up to about 75 percent by weight of fibers having a length greater than about l/2X up to but not including said length of about X; and (c~ up to about 35 percent by weight of fibers having a length less than or equal to said length of about l/2X.

:l~l37368 BRIEF DESCRIPTIO~ OF T~E DRA1~7INGS

Figure 1 is a photograph of a yarn comprised of cotton fibers (20X magnification).
Figure 2 is a photograph of a fabric produced from a conventional cotton yarn (20X magnification).
Figure 3 is a photograph of a yarn comprised of uniform length polyethylene terephthalate fibers (20X
magnification).
Figure 4 is a photograph of a fabric produced from a conventional polyester yarn (20X magnification).
Figure 5 is a photograph of a yarn comprised of polyethylene terephthalate fibers of mixed length according to the present invention (20X magnification).
Figure 6 is a photograph of a yarn comprised of polyethylene terephthalate fibers of mixed length according to the present invention (20X magnification).
Figure 7 is a photograph of a yarn comprised of polyethylene terephthalate fibers of mixed length according to the present invention (20X magnification).
Figure 8 is a photograph of a fabric produced from a yarn according to the presen~ invention comprised of polyethylene terep'nthalate fibers of mixed length (20X
magni_ication).

~l37~}61~

DETAILED DESCRIPTION OF THE INVENTION

The novel yarns of this invention are conlprised of a blend of synthetic fibers of different lengths, wherein the synt~:etic fibers present in the yarn conlprise at least about 50 percent by weight of the fibers within the yarn and consist of a n~ixture of at least three groups of synthetic fibers, each group consisting of synthetic fibers of a substantially unifornl length which differs fron, the sub-stantially uniforn~ length of the synthetic fibers in the other groups, and wherein the fihers contained within said at least three groups of synthetic fibers are distributed an,ong each of the following ranges based upon the weight of the fibers in the at least three groups:
(a) up to about 75 percent by weight of fibers havin~ a lensth of about X, wherein X represents the length of the longest synthetic fiber in the groups;
(b) up to about 75 percent by weight of fibers having a length greater than about l/2X up to but not includ-ing said length of about X; and (c) up to about 35 percent by weig31t o~ fibers having a length less than or equal to said leng~h of about 1/2X.
A preferred distribution of synthetic fibers within the above ranges consists of between about 25 and about 50 percent by ~eight of synthetic fioers having a length of about X, between about 25 and about 50 percent by weight of synthetic fibers having a length greater than about 1~2X up to but not including said length of about X, ~37;~Ç;8 and up to about 30 percent by weight of synthetic fibers havin~ a length less than or equal to said length of about 1/2X. Most preferably the yarn contains less than about 20 percent by weight of synthetic fibers having a length less than or equal to said length of about 1~2X.
It has been found that yarns which contain synthe-tic fibers in these lengths and proportions possess charac-teristics closely paralleling those of natural fiber-containin~
yarns (e.g., cotton or wool yarns). These characteristics relate to aesthetic factors as well as to the thern,al and tactile comfort of fabrics containing such yarns.
Fabrics containing yarns conlprised of natural fibers such as cotton ~enerally exhibit n con~fort" character-istics which are superior to those exhibited by fabrics which contain conventional synthetic fiber-containing yarns.
Generally, natural fiber-containing yarns exhibit a greater bulk density than synthetic yarns (i.e. the yarns consist of loosely packed fibers). Natural fiber-containing yarns consist of a ~lixture of fibers of differing length, thus providin~ a yarn having a nlultitu~e of protruding ends along the longitldinal axis of the yarn. The nlultitude of protruding ends provided by such a fiber len~th distribution is clearly shown in the photograph of a cotton yarn denoted as Figure ~. This characteristic of natural fiber-containing yarns is due, an,ong other factors, to the differential length character-istics of the individual fibers within the yarn.
rhe high bulk density of natural fiber-containing yarns enables fabrics to be produced whicn exhibit low air pernleability and satisfactory covering characteristics. The ~l37~68 high degree of fiber end protrudence also enhances the conlfort of the fabric. A typical cotton fabric is shown in the photograph denoted in Figure 2.
The significant degree of protrudence of fiber ends fronl the yarn in such fabrics provides for greater tactile conlfort in con,parison to conventional synthetic yarn-containing fabrics. Conventional synthetic yarns typi-cally consist of fibers having a unifornl length, therefore providing a lessened an,ount of protruding ends resulting in a sn,oother tactile sensation, high degree of air pern,e-ability, and low bulk. Note, for example, the low degree of protruding ends exhibited by a conventional polyethylene terephthalate yarn consisting of unifornl fiber lengths shown in Figure 3. Fabrics produced fron~ such yarns provide less cover than conventional cotton fabrics. Note, for exanlple, the decreased cover exhibited by the conventional polyester fabric shown in Figure 4 in conlparison to the cotton fabric of Figure 2. In contrast thereto, con,pare the high degree of fiber end protrudence exhibited by the nlixed fiber length polyet~ylene terephthalate yarns of this invention as shown in Figures 5, 6, and 7. Fabrics produced fron, the n,ixed synthetic fiber length yarns of the present invention will accordingly provide greater cover as shown in the photograph denoted as ~igure 8.
The novel synthetic fiber-containing yarns and fabrics o~ the present invention thus n,ore nearly sinlulate natural fi~er-containing yarns and fabrics, while addi-tionally exhibiting the advantageous characteristiss of synthetic fiber containing yarns. Such advantages are 1~l37;~

provided ~y the use of synthetic fibers of specified lengths and in specific proportions in the pro~uction of the yarn, and eventually, in the synthetic fabrics produced therefron~.
The yarns of this invention contain at least three groups of synthetic fibers with the synthetic fibers within each group being of substantially the sanle length. It is recognized that the fi~er lengths within each group will normally not be exactly the san,e due to the lack of pre-cision which exists when large an,ounts of such fibers are cut, but the fiber lengths within each group will generally only differ by a factor of about 5 percent or less. For exan~ple, if the longest length X of the synthetic fibers in the groups is intended to be 3 inches, the group of fibers which is cut to that length will generally contain synthetic fibers differing fronl the desired 3 inch length ~y a factor of about plus or nlinus 5 percent or less. This group of fibers will, for purposes of the invention, be deenled to contain fibers of about 3 inches in length (i.e., a length of about X). Sin,ilarly, the phrase "about 1/2X" is intended to include lengths of l/2X plus or n,inus about 5 percent.
That is, if the longest length X of the syn~hetic fibers in the groups is intended to be 3 inches, then fibers having a length of about 1/2X will differ fronl a length of 1 1/2 inches by only ~bout plus or n,inus 5 percent.
The substantially uniforn~ length of the synthetic fibers of each of the groups present in the yarn will also differ fronl the substantially uniforn, length of the syn-thetic fibers in the other groups present in the yarn.
~enerally it will be advantageous to enlploy groups o~ syn-~37;}~t3 thetic fibers whose substantially unifornl lengths differfron, the substantially uniforn, lengths of the synthetic fibers in the other ~roups by at least about 15 percent and preferably between about 15 percent and about 30 percent in order to provide a unifornl and high degree of fiber end pro-trudence alon~ the longitudinal axis of the yarn. It should be noted, however,.that less significant differences between the substantially unifornl lengths of the groups of synthetic fibers within the yarn will also provide the desired results, although the advantages of e~lploying groups of synthetic fibers of differing lengths clearly din~inish as the lengths of the synthetic fibers within the yarn beconle n,ore nearly equal. Generally, the substantially uniforn, length of the synthetic fibers of each group should differ fron, the substantially uniforn~ length of the synthetic fibers of the other groups by a factor of at least a~out 5 percent in order to ensure that the fiber lengths differ significantly enough to provide the desired results. ~
The synthetic fibers within the yarn nlust consist of a n,ininlu~, of three groups of synthetic fibers in order to o~tain the desired charac~eristics. ~.~ore than three groups of synthetic fibers ~(ay be present as long as the lengths of all of the fibers present in the yarn are distributed in the required proportions. Generally, the actual lengths of the synthetic fibers are considered to be less in,portant than the ratio of the lengths of the individual fibers to each other. ~owever, yarn production considerations (e.g., the problen,s which arise fron, handling n,ultiple lengths of fi`~ers) discourage th- use of an excessive nun,~er of qroups of ~37;~fi8 synthetic fibers of differing lengths. The advantages of the present invention may generally be achieved by employing any-where from three to six groups of synthetic fibers of such lengths and in such proportions consistent with the required distribution of the synthetic fibers within the yarns of this invention. However, it may be desirable to have a wide dis-tribution of lengths of fibers within each group.
In order to attain the full benefit of the yarn of the present inventi~n, each of the groups of synthetic fibers contained in the yarn should be present in a significant amount.
That is, each group should preferably comprise at least about 5 percent by weight of the total weight of the synthetic fibers contained within said groups. However, the percentage of syn-thetic fibers in any group may be less than about 5 percent by weight in certain instances, such as when more than three groups of synthetic fibers are present in the yarn. Note, for example, the proportions of the various groups employed in the yarn de-picted in Figure 5.
For purposes of illustration, the yarn of Figure 5 contains six groups of fibers of different lengths ranging from about 1-1/2 inches to about 1/4 inch. The yarn contains 19.4 percent by weight (based on the synthetic fibers in the yarn) of fibers having a length of about X (i.e., X being l-l/2 inches which is the longest length of the synthetic fibers in the groups), 62.1 percent by weight of fibers having a length greater than about 1~2X (i.e., 3/4 of an inch) and up to but not including said length of about X, and 18.S percent by weight of fibers having a length less than or equal to said length of about l/2X.

~37;~6~

T~e different fiber lengths to be used within the groups present in the yarn can vary greatly depending upon the desired yarn characteristics as well as the intended use of the yarn. For exanlple, textile fabrics whose prinlary use is in shirts and sin~ilar wearing apparel typically will be conlprised of a yarn which contains synthetic fibers having a longest length of about 1 1/2 inches. Yarns which are to be used in the production of sweaters, however, will typically contain synthetic fibers having a longest length of about 3 to 6 inches. The deternlination of the longest length to be used in a yarn which is intended for a specific use is well within the skill of the artisan.
Thus, in accordance with the required fiber distri-bution of the present invention, a yarn whose prin,ary use lies in the shirting field could contain up to about 75 percent by weight of synthetic fibers of about 1 1/2 inches in length, u~ to about 75 percent by weight of synthetic fibers having a length greater than about 3/4 of an inch up to but not including said length of about 1 1/2 inches, and up to about 35 percent by weight of synthetic fibers having a lenath less than or equal to said length of ahout 3/4 of an inch, based upon the weight of the fibers in those three groups.
The synthetic fibers in each of the above ranges n,ay be provided by nlore than one group of fibers, with the substantially unifornl lenyth of the synthetic fibers of one group differing fron, the substantially uniforn, length of the synthetic fibers of the other group. However, the total weight percentaae of the synthetic fibers in the group n,us~
not exceed the allowable proportion for fibers of those ]engths.

~l37;~i8 For exanlple, in a yarn which contains S0 percent by weight of synthetic fi~ers of about 1 1/2 inches in length, 40 percent by weight of synthetic fibers having a length greater than about 3/4 of an inch and up to but not including said length of about 1 1/2 inches, and 10 percent by weight of synthetic fibers having a length less than or equal to said length of about 3/4 of an inch (based upon the weight of the fibers in those groups), the synthetic fibers having a length of between about 3/4 and about 1 1/2 inches could be evenly distributed between fibers 1 inch in length and fibers 1 1/4 inches in length (i.e., 20 percent by weight of each based on the total weight of ~he synthetic fibers present).
It should be understood that the length of the longest synthetic fibers to be used in the groups contained within the novel yarn of this invention n,ay be n~uch greater than 1 1/2 inches, and n,ay indeed be 3 or 6 inches or greater in length. G~nerally the length of the longest synthetic fiber will range between about 1 and 6 inches for conventional textile applications. However, the n,inin,un, length of the fibers ~resent will necessarily be n,ore closely controlled, since it n~ay becon,e very in,practical to incorporate any fiber length of less than about 1/4 inch in length into the yarn during the production se~uence. The shortest length of any syntnetic fibers present will thus generally he at least 1/2 inch.
The prol~uction of a synthetic fiber-containing yarn which contains synthetic fibers of lengths which vary over a wide range ~.ay ~lso present problen,s during the l37368 production of the yarn. It is thus also advantageous to en~ploy groups of synthetic fibers which have significantly differiny lengths but which lengths do not differ too greatly.
For exanlple, a yarn containing synthetic fibers having lengths of about 3 inches, about 1 3/4 inches, and about ~/4 of an inch would be acceptable both with respect to lenqth differential an~ong the groups as well as the n~inin,un~ length present.
A preferred distribution of synthetic fibers within a yarn includes about 20 percent by weight of synthe-tic fibers of about l l/4 inches in length, ahout 40 percent by weight of synthetic fibers having a length ranging fron, about 1 up to but not including said length of about 1 l/4 inches, about 25 percent by weight of synthetic fibers having a length ranging fronl about 3/4 up to but not includ-ing said length of about l inch, and about 15 percent by weight of synthetic fibers having a length less than said length of about 3/4 inch (e.g., about 1/2 inch or less), based upon the weight of synthetic fibers present in the different groups.
n,ost ?referred dis~ribution of synthetic fibers ~ithin a yarn contains about 20 percent by weight of synth~tic fibers of about 1 1~4 inches in length, about 40 percent by weight of synthetic fibers having a length of about 1 inch, about 25 percent by weight of synthetic fibers having a length of about 3/4 of an inch and about 15 ?ercent by weight of synthetic fibers having a length of about 1/2 of an inch. Such a yarn is shown in Figure 6.
Other physical characteristics of the synthetic fibers used in the novel yarns of this invention n,ay be ~37;~i8 varie~ in order to further increase the overall bulk of the yarn. For exan,ple, at least a portion of the synthetic fibers niay be crinlped prior to being incorporated into the yarn. Mixtures of shrinkable and non-shrinkable synthetic fibers n,ay also be used to increase yarn bulk. At least a portion of the synthetic fibers n(ay also have an irregular-ly-shaped or non-circular cross-section. Fibers of nlixed deniers nlay also be used with the yarns of the present invention.
The synthetic fibers used in the novel yarns and fabrics of this invention n,ay consist of any suitable con~en-tional polynleric nlaterial. Suitable polyn,eric nlaterials include cellulose acetate, rayon, polyanlides (e.g., aranlids~, polyesters, acrylics, and polyolefins. Nylon 66 (e.g., poly(hexan~ethylene adipanlide)), linear terephthalate polyesters (e.g., polyethylene terephthalate), polyacrylonitrile, polypropylene, and poly(n,etaphenylene isothala~,ide) are exen~plary nlaterials. Mixtures of the above n,aterials n,ay also be enlployed in the yarns of the present invention.
Polyethylene terephthalate and cellulose acetate are preferred 201y~eric niaterials~
The synthetic fihers present ~n the yarn con,prise at least about 50 percent by weight of the total fibers ~present in the yarn and consist of a nlixture of at least three groups of synthetic fihers oE substantially uniforn.
length, with the synthetic fibers contained within the at least three groups bein~ present in the re~uire~ proportions in or~er to ensure that the henefits of the present invention are attained. Preferably, the synthetic fibers contained ~l37;~68 within the at least three grou~s are present in the yarn in amounts ranging from about 65 to 100 percent by weight based on the total weight of the fibers present in the yarn.
The yarns of this invention may also contain natural fibers such as cotton or wool fibers in conventional weight ratios which typically range from about 50:50 to 90:10 syn-thetic fiber/natural fiber, with preferred ratios being 65:35 and 80:20. It should be noted, however, that when the yarn contains both synthetic and natural fibers, the natural fibers need not be present in the required number of groups or the specified ranges set forth for the synthetic fibers. In addi-tion, the yarn of this invention may also contain other synthetic fibers such as rayon or nylon instead of or in mixture with the natural fibers. Thus, for example, the yarn could comprise ~5%
mixed length polyester and 35% rayon or nylon.
The novel synthetic fiber-containing yarns of this invention may be formed into novel fabrics which exhibit im-proved comfort characteristics as compared to conventional synthetic fiber-containing fabrics. The fabrics may be pro-duced by conventianal processes (e.g., by knitting or weaving).
Due to the increased bulk and protruding end count of the novel yarns of this invention, fabrics produced therefrom will exhibit improved covering characteristics as well as an im-proved tactile sensation. Such fabrics will therefore more closely possess the "look and feel" of natural fiber-containing fabrics, such as cotton and wool fabrics.
Fabrics may also be prepared which comprise a mixture of the novel synthetic fiber-containing yarns of the present invention and conventional natural fiber-containing yarns or synthetic fiber-containing yarns. The novel yarns of this invention may be blended with such natural or synthetic fiber-containing yarns in conventional weight ratios.

~l37;~68 The yarns of this invention ~ay be produced in any conventional manner. Any desired blending, cardinq, draft-ing and spinning sequence may be used to produce the yarns.
When it is initially determined what distribution of synthe-tic fiber lengths is desired in the yarn to be produced, groups of synthetic fibers are cut on a cutting wheel set to the appropriate lengths. The cut fibers are then blended and carded whereupon the various len~ths become randomly distributed. The yarn which is then spun from the mixture of fibers will contain the specified lengths of synthetic fibers in the required proportions. The fibers of each of the groups become randomly distributed and dispersed through-out the yarn during the yarn production process and are not actually grouped or segregated as to fiber lengths within the yarn which is produced.
In order to demonstrate the advantages to be gained from the present invention, several different yarns were prepared as set forth below:

Yarn Yarn Com~osition A Polyethylene terephthalate ~ibers of uniform lengtl;l (i.e. l 1/2 inches~
B Conventional cotton fiber yarn C 50:50 blend o~ uniform le~gth PET fibers~cotton fibers Mixed PET fiber length yarn (i.e. 50~ 1 1/2 inches, 15% l 1/4 inches, 15% l inch, 10% 3/~
inch, 10~ 1/2 inch) "-- ~
~l37;~68 Fabrics prepared from each of the yarns A, B, C
and D were tested using a Mitex Bendinq Tester to determine the bending rigidity of the yarns from which they were prepared. The b~ndin~ rigidity of a yarn is indicative of how a fabric or garment containing that yarn will drape or hang from a person. The relative softness of a fabric is related to the bending rigidity of the yarn within the fabric, with a high value for bending rigidity being indi-cative of a high degree of fiber end protrudence within the yarn since the presence of protruding ends provides fric-tional resistence to bending.
Table II sets forth the bending rigidity for the various yarns identified above.
TABLE II
-Bending RigiditY
Yarn (millivolts/radian-inch) A (Uniform length PET) 3.5 B (Cotton) 9.6 C (50:50 PET/Cotton) 7.7 D (Mixed fiber length) 8.4 As may be seen from the above ~ata, the cotton yarn exhibits the highest bending rigidity o~ the yarns tested. ~owever, the mixed Eiber length yarn which falls within the scope of the present inven.ion (yarn D) exhibits a bending rigidity which is greater than that e~hibited by any o~ the yarns except the cotton yarn. It is noted that the bending rigidity of the mixed liber length yarn is signiEicantly ~reater than the bending rigi~ity of the conventional polyethylene terep}lthalate yarn (i.e. varn A).
The fabrics prepared from yarns A, B, C and D were further tested to determine certain other of their ch~rac-teristics as set Eorth below:

1~l3~368 TABLE III

Fabric Fabric Fabric Bulk FabricThickness Weight Area Make-Up(Inxlo2) (Oz/Yd2) (nln~2/unit lenqth) Yarn A 1.40 4.6 1.77 Yarn B 1.81 5.1 1.92 Yarn C 1.69 4.8 1.69 Yarn D 1.52 S.0 2.00 The above data shows that a fabric produced fronl a synthetic nlixed fiber length PET yarn of the present inven-tion (i.e. yarn D) exhibits a bulk area (i.e. a n~easure of yarn bulk including loops and hairs) which is greater than the bulk area of a cotton fabric-produced fronl a conventional cotton yarn (i.e. yarn B). The bulk area n,easuren,ents of Table III were nlade on a Quantinlet 720 Inlage Analyzing Con,puter and consitute the average of over fifty n,easure-n,ents. The bulk area of the fabric produced fron, the niixed fiber length yarn of the present invention is significantly greater than the bulk area of the fabric produced fronl a conventional PET yarn (i.e. yarn A). Therefore, the fabric produced fronl yarn D, while having a thickness and weiynt that are not excessive, exhibits a significant increase in bulk area which is highly desirable since the bulk area of a fabric is directly related to the coverage to be afforded by that fabric per unit wei~ht. That is, an increase in the bulk area of a fabric will result in an increase in the covering characteristics of the fabric.

~3736B

In addition, fabrics produced fronl the n~ixed fiber length yarns of the present invention exhibit a water vapor transnlission rate (WVTR) which is significantly lower than that exhibited by conventional synthetic fabrics while also approaching the values for cotton fabrics. The water vapor transmission rate is defined in accordance with ASTM test E96-66 and is indicative of the anlount of water vapor which passes through a unit area of fabric per unit tin,e at a vapor pressure difference of about 6.6 nln, Hg at 70F. and 65 percent relative hunlidity.

TABLE IV
-Fabric Water Vapor Transnlission Makeu~ Rate (gnl/24 hrs/nl2) Yarn A (Unifornl length PET) 2~83 Yarn B (Cotton) 1620 Yarn D (Mixed fiher length) 1923 The water vapor transn,ission rate of a fabric is indicative of the relative porosity and the covering charac-teristics of the fabric. That is, a fabric conlprised of a yarn having a large nu~,ber of protruding ends will necessarily be less porous than a fabric conlprised of a yarn having a lesser nun,ber of protruding ends.
The principles, preferred en~bodin(ents and n,o~es of operation of the present invention have been describea in the foregoing specification. The invention which.is intended to ~e protected herein, however, is not to b~ construed as lin,ited to the particular fornls disclosed, since these are to be regarded as illustrative rather than restrictive.
Variations and chan~es n,ay be nlade by those skilled in the art witllout de~arting ronl the spirit of the invention.

WHAT IS C~AIMED TS:
- _ ;L2.

Claims (64)

THE EMBODIMENTS OF THE INVENTION IN WHICH AN EXCLUSIVE
PROPERTY OR PRIVILEGE IS CLAIMED ARE DEFINED AS FOLLOWS:
1. In a textile fabric containing a yarn comprised of a blend of cotton and polyester staple fibers wherein the polyester staple fibers present in said yarn comprise at least about 50 percent by weight of the fibers in the yarn, the improvement wherein said polyester staple fibers consist of a mixture of fibers of at least three different lengths within the range of about 1/4 to about 6 inches whereby said fabric has improved comfort in comparison to a corresponding fabric comprised of a blend of cotton and polyester staple fibers wherein the polyester fibers are of uniform length of about 1 1/2 inches.
2. The fabric of claim 1 wherein said polyester fibers are comprised of a polymeric material consisting of linear tereph-thalate polyesters.
3. The fabric of claim 2 wherein said polymeric material is polyethylene terephthalate.
4. The fabric of claim 1 wherein said polyester staple fibers comprise at least about 65 percent by weight of the fibers present in the yarn.
5. The fabric of claim 1 wherein said polyester staple fibers comprise between about 50 and 90 percent by weight of the fibers present in the yarn.
6. The fabric of claim 1 wherein said polyester staple fibers comprise about 80 percent by weight of the fibers present in the yarn.
7. The fabric of claim 1 wherein at least a portion of said polyester fibers are crimped.
8. The fabric of claim 1 wherein at least a portion of said polyester fibers having an irregularly-shaped or non-circular cross section.
9. The fabric of claim 1 wherein said polyester staple fibers consist of a mixture of fibers of between about three to six differing lengths.
10. The fabric of claim 1 wherein the length of said polyester staple fibers ranges from about 1/4 to about 1 1/2 inches.
11. The fabric of claim 1 wherein said lengths differ from each other by a factor of at least about 15 percent.
12. The fabric of claim 1 wherein each of said different lengths is present in an amount of at least about 5 percent by weight based on the total weight of the polyester fibers in the yarn.
13. In a textile yarn comprised of a blend of cotton and polyester staple fibers wherein the polyester staple fibers present in said yarn comprise at least about 50 percent by weight of the fibers in the yarn, the improvement wherein said polyester staple fibers consist of a mixture of fibers of at least three different lengths within the range of about 1/4 to about 6 inches whereby a fabric comprised of said yarn has improved comfort in comparison to a corresponding fabric comprised of a blend of cotton and polyester staple fibers wherein the polyester fibers are of uniform length of about 1 1/2 inches.
14. The yarn of claim 13 wherein said polyester fibers are comprised of a polymeric material consisting of linear tereph-thalate polyesters.
15. The yarn of claim 14 wherein said polymeric material is polyethylene terephthalate.
16. The yarn of claim 13 wherein said polyester staple fibers comprise at least about 65 percent by weight of the fibers present in the yarn.
17. The yarn of claim 13 wherein said polyester staple fibers comprise between about 50 and 90 percent by weight of the fibers present in the yarn.
18. The yarn of claim 13 wherein said polyester staple fibers comprise about 80 percent by weight of the fibers present in the yarn.
19. The yarn of claim 13 wherein at least a portion of said polyester fibers are crimped.
20. The yarn of claim 13 wherein at least a portion of said polyester fibers have an irregularly-shaped or non-circular cross section.
21. The yarn of claim 13 wherein said polyester staple fibers consist of a mixture of fibers of between about three to six differing lengths.
22. The yarn of claim 13 wherein the length of said polyester staple fibers ranges from about 1/4 to about 1 1/2 inches.
23. The yarn of claim 13 wherein said lengths differ from each other by a factor of at least about 15 percent.
24. The yarn of claim 13 wherein each of said different lengths is present in an amount of at least about 5 percent by weight based on the total weight of the polyester fibers in the yarn.
25. In a fabric containing a yarn comprised of a blend of polyester fibers and cotton fibers, the improvement wherein the polyester fibers present in the yarn comprise at least about 50 percent by weight of the fibers within said yarn and consist of a mixture of at least three groups of polyester fibers, each group consisting of polyester fibers of a substantially uniform length which differs from the substantially uniform length of the polyester fibers in the other groups, and wherein the polyester fibers are distributed among each of the following ranges based upon the weight of the fibers present in said at least three groups:
(a) up to about 75 percent by weight of fibers having a length of about X, wherein X represents the length of the longest polyester fiber in said groups;
(b) up to about 75 percent by weight of fibers having a length greater than about l/2X up to but not including said length of about X; and (c) up to about 35 percent by weight of fibers having a length less than or equal to said length of about l/2X.
26. The fabric of claim 25 wherein the polyester fibers within said at least three groups are comprised of a polymeric material consisting of linear terephthalate polyesters.
27. The fabric of claim 26 wherein said polymeric material is polyethylene terephthalate.
28. The fabric of claim 25 wherein X ranges from about 1 to about 6 inches.
29. The fabric of claim 28 wherein X is about 6 inches.
30. The fabric of claim 28 wherein X is about 3 inches.
31. The fabric of claim 28 wherein X is about 1 1/2 inches.
32. The fabric of claim 25 wherein at least a portion of said polyester fibers within said at least three groups are crimped.
33. The fabric of claim 25 wherein at least a portion of said polyester fibers within said at least three groups have an irregularly-shaped or non-circular cross section.
34. The fabric of claim 25 wherein the polyester fibers within said at least three groups are distributed among each of the following ranges:
(a) between about 25 and about 50 percent by weight of fibers having a length of about X;
(b) between about 25 and about 50 percent by weight of fibers having a length greater than about l/2X up to but not including said length of about X; and (c) up to about 30 percent by weight of fibers having a length less than or equal to said length of about 1/2X.
35. The fabric of claim 34 wherein said polyester fibers having a length less than or equal to said length of about l/2X
are present in an amount of less than about 20 percent by weight.
36. The fabric of claim 25 wherein said length of about is about 1 1/4 inches and the polyester fibers within said at least three groups are distributed as follows:
(a) about 20 percent by weight of fibers having a length of about 1 1/4 inches;

(b) about 40 percent by weight of fibers having a length ranging from about 1 inch up to but not including said length of about 1 1/4 inches;
(c) about 25 percent by weight of fibers having a length ranging from about 3/4 of an inch up to but not including said length of about 1 inch; and (d) about 15 percent by weight of fibers having a length less than said length of about 3/4 of an inch.
37. The fabric of claim 36 wherein the polyester fibers within said at least three groups are distributed as follows:
(a) about 20 percent by weight of fibers having a length of about 1 1/4 inches;
(b) about 40 percent by weight of fibers having a length of about 1 inch;
(c) about 25 percent by weight of fibers having a length of about 3/4 of an inch; and (d) about 15 percent by weight of fibers having a length of about 1/2 of an inch.
38. The fabric of claim 25 wherein said length of X is about 1 1/2 inches and the polyester fibers within said at least three groups are distributed as follows:
(a) 19.4 percent by weight of fibers having a length of 1 1/2 inches;
(b) 41.7 percent by weight of fibers having a length of 1 1/4 inches;
(c) 20.4 percent by weight of fibers having a lenght of 1 inch;
(d) 12.5 percent by weight of fibers having a lenght of 3/4 inch;

(e) 4.6 percent by weight of fibers having a length of 1/2 inch; and (f) 1.4 percent by weight of fibers having a length of 1/4 inch.
39. The fabric of claim 25 wherein the substantially uniform length of the polyester fibers within each of the at least three groups present in the yarn differs from the substantially uniform length of the polyester fibers in the other groups by a factor of at least about 15 percent.
40. The fabric of claim 25 wherein the substantially uniform length of the polyester fibers within each of the at least three groups present in the yarn differs from the substantially uniform length of the synthetic fibers in the other groups by a factor of between about 15 percent and about 30 percent.
41. The fabric of claim 25 wherein the fibers within said at least three groups comprise at least about 65 percent, by weight of the fibers present in the yarn.
42. The fabric of claim 25 wherein said polyester fibers within said at least three groups comprise between about 50 and 90 percent by weight of the fibers present in the yarn.
43. The fabric of claim 25 wherein said polyester fibers comprise about 80 percent by weight of the fibers present in the yarn.
44. The fabric of claim 25 wherein each group of fibers of substantially uniform length is present in an amount of at least about 5 percent by weight based on the total weight of polyester fibers in the yarn.
45. In a yarn comprised of a blend of polyester fibers and cotton fibers, the improvement wherein the polyester fibers present in the yarn comprise at least about 50 percent by weight of the fibers within said yarn and consist of a mixture of at least three groups of polyester fibers, each group consisting of polyester fibers of a substantially uniform length which differs from the substantially uniform length of the polyester fibers in the other groups, and wherein the polyester fibers contained within said at least three groups of polyester fibers are distributed among each of the following ranges based upon the weight of the fibers present in said at least three groups:
(a) up to about 75 percent by weight of fibers having a length of about X, wherein X represents the length of the longest polyester fiber in said groups;
(b) up to about 75 percent by weight of fibers having a length greater than about l/2X up to but not including said length of about X; and (c) up to about 35 percent by weight of fibers having a length less than or equal to said length of about l/2X.
46. The yarn of claim 45 wherein the polyester fibers within said at least three groups are comprised of a polymeric material consisting of linear terephthalate polyesters.
47. The yarn of claim 46 wherein said polymeric material is polyethylene terephthalate.
48. The yarn of claim 45 wherein X ranges from about 1 to about 6 inches.
49. The yarn of claim 48 wherein X is about 6 inches.
50. The yarn of claim 48 wherein X is about 3 inches.
51. The yarn of claim 48 wherein X is about 1 1/2 inches.
52. The yarn of claim 45 wherein at least a portion of said polyester fibers within said at least three groups are crimped.
53. The yarn of claim 45 wherein at least a portion of said polyester fibers within said at least three groups have an irregularly-shaped or non-circular cross section.
54. The yarn of claim 45 wherein the polyester fibers within said at least three groups are distributed among each of the following ranges:
(a) between about 25 and about 50 percent by weight of fibers having a length of about X;
(b) between about 25 and about 50 percent by weight of fibers having a length greater than about 1/2X up to but not including said length of about X; and (c) up to about 30 percent by weight of fibers having a length less than or equal to said length of about 1/2,X.
55. The yarn of claim 54 wherein said polyester fibers having a length less than or equal to said length of about 1/2X are present in an amount of less than about 20 percent by weight.
56. The yarn of claim 45 wherein said length of X is about 1 1/4 inches and the polyester fibers within said at least three groups are distributed as follows:
(a) about 20 percent by weight of fibers having a length of about 1 1/4 inches;

(b) about 40 percent by weight of fibers having a length ranging from about l inch up to but not including said length of about l l/4 inches;
(c) about 25 percent by weight of fibers having a length ranging from about 3/4 of an inch up to but not including said length of about l inch; and (d) about 15 percent by weight of fibers having a length less than said length of about 3/4 of an inch.
57. The yarn of claim 56 wherein the polyester fibers within said at least three groups are distributed as follows:
(a) about 20 percent by weight of fibers having a length of about l l/4 inches;
(b) about 40 percent by weight of fibers having a length of about 1 inch;
(c) about 25 percent by weight of fibers having a length of about 3/4 of an inch; and (d) about 15 percent by weight of fibers having a length of about l/2 of an inch.
58. The yarn of claim 45 wherein said length of X is about l l/2 inches and the polyester fibers within said at least three groups are distributed as follows:
(a) 19.4 percent by weight of fibers having a length of l l/2 inches;
(b) 41.7 percent by weight of fibers having a length of l. l/4 inches;
(c) 20.4 percent by weight of fibers having a length of 1 inch;
(d) 12.5 percent by weight of fibers having a length of 3/4 inch;

(e) 4.6 percent by weight of fibers having a length of 1/2 inch; and (f) 1.4 percent by weight of fibers having a length of 1/4 inch.
59. The yarn of claim 45 wherein the substantially uniform length of the polyester fibers within each of the at least three groups present in the yarn differs from the substantially uniform length of the polyester fibers in the other groups by a factor of at least about 15 percent.
60. The yarn of claim 45 wherein the substantially uniform length of the polyester fibers within each of the at least three groups present in the yarn differs from the substantially uniform length of the polyester fibers in the other groups by a factor of between about 15 percent and about 30 percent.
61. The yarn of claim 45 wherein the fibers within said at least three groups comprise at least about 65 percent by weight of the fibers present in the yarn.
62. The yarn of claim 45 wherein said polyester fibers within said at least three groups comprise between about 50 and 90 percent by weight of the fibers present in the yarn.
63. The yarn of claim 45 wherein said polyester fibers comprise about 80 percent by weight of the fibers present in the yarn.
64. The yarn of claim 45 wherein each group of fibers of substantially uniform length is present in an amount of at least about 5 percent by weight based on the total weight of polyester fibers in the yarn.
CA000357055A 1979-08-13 1980-07-25 Mixed fiber length yarn Expired CA1137368A (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US6621679A 1979-08-13 1979-08-13
US066,216 1979-08-13

Publications (1)

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CA1137368A true CA1137368A (en) 1982-12-14

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EP (1) EP0024198B1 (en)
BR (1) BR8004913A (en)
CA (1) CA1137368A (en)
DE (1) DE3069296D1 (en)
MX (1) MX155684A (en)

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Publication number Priority date Publication date Assignee Title
CA2930568A1 (en) * 2013-12-10 2015-06-18 Optimer Performance Fibers, Inc. Fiber blends with improved moisture management properties

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Publication number Priority date Publication date Assignee Title
US3628219A (en) * 1968-12-13 1971-12-21 Osaka Kiko Co Ltd Method and apparatus for forming a combed sliver
US4041690A (en) * 1975-11-05 1977-08-16 Tuscarora Cotton Mill Novelty yarn and method for making same
AU529092B2 (en) * 1978-03-24 1983-05-26 Toray Industries, Inc. Fasciated yarn

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MX155684A (en) 1988-04-13
EP0024198A1 (en) 1981-02-25
BR8004913A (en) 1981-02-17
DE3069296D1 (en) 1984-10-31
EP0024198B1 (en) 1984-09-26

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