CN112639183A - Spun yarn comprising polyester staple fibers and fabric comprising said spun yarn - Google Patents
Spun yarn comprising polyester staple fibers and fabric comprising said spun yarn Download PDFInfo
- Publication number
- CN112639183A CN112639183A CN201980056390.5A CN201980056390A CN112639183A CN 112639183 A CN112639183 A CN 112639183A CN 201980056390 A CN201980056390 A CN 201980056390A CN 112639183 A CN112639183 A CN 112639183A
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- Prior art keywords
- fabric
- spun
- poly
- pet
- spun yarn
- Prior art date
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- 239000000835 fiber Substances 0.000 title claims abstract description 621
- 239000004744 fabric Substances 0.000 title claims abstract description 437
- 229920000728 polyester Polymers 0.000 title claims description 36
- 229920000642 polymer Polymers 0.000 claims abstract description 212
- 239000005020 polyethylene terephthalate Substances 0.000 claims abstract description 170
- 229920000139 polyethylene terephthalate Polymers 0.000 claims abstract description 169
- 229920001707 polybutylene terephthalate Polymers 0.000 claims abstract description 123
- 229920000742 Cotton Polymers 0.000 claims abstract description 121
- QQVIHTHCMHWDBS-UHFFFAOYSA-N isophthalic acid Chemical compound OC(=O)C1=CC=CC(C(O)=O)=C1 QQVIHTHCMHWDBS-UHFFFAOYSA-N 0.000 claims abstract description 67
- 239000000178 monomer Substances 0.000 claims abstract description 55
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- 238000000034 method Methods 0.000 claims description 118
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- 239000002964 rayon Substances 0.000 claims description 57
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- 238000007655 standard test method Methods 0.000 claims description 19
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- 238000011084 recovery Methods 0.000 claims description 15
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- VNGOYPQMJFJDLV-UHFFFAOYSA-N dimethyl benzene-1,3-dicarboxylate Chemical compound COC(=O)C1=CC=CC(C(=O)OC)=C1 VNGOYPQMJFJDLV-UHFFFAOYSA-N 0.000 description 1
- PBOFFNYRKURMFP-UHFFFAOYSA-L dipotassium;5-sulfobenzene-1,3-dicarboxylate Chemical compound [K+].[K+].OS(=O)(=O)C1=CC(C([O-])=O)=CC(C([O-])=O)=C1 PBOFFNYRKURMFP-UHFFFAOYSA-L 0.000 description 1
- 238000004090 dissolution Methods 0.000 description 1
- 238000011143 downstream manufacturing Methods 0.000 description 1
- 229920006240 drawn fiber Polymers 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 239000003063 flame retardant Substances 0.000 description 1
- 239000001530 fumaric acid Substances 0.000 description 1
- 238000004817 gas chromatography Methods 0.000 description 1
- 150000004820 halides Chemical class 0.000 description 1
- 239000012760 heat stabilizer Substances 0.000 description 1
- WGCNASOHLSPBMP-UHFFFAOYSA-N hydroxyacetaldehyde Natural products OCC=O WGCNASOHLSPBMP-UHFFFAOYSA-N 0.000 description 1
- 230000010354 integration Effects 0.000 description 1
- JVTAAEKCZFNVCJ-UHFFFAOYSA-N lactic acid Chemical group CC(O)C(O)=O JVTAAEKCZFNVCJ-UHFFFAOYSA-N 0.000 description 1
- 239000007788 liquid Substances 0.000 description 1
- 239000000314 lubricant Substances 0.000 description 1
- VZCYOOQTPOCHFL-UPHRSURJSA-N maleic acid Chemical compound OC(=O)\C=C/C(O)=O VZCYOOQTPOCHFL-UPHRSURJSA-N 0.000 description 1
- 239000011976 maleic acid Substances 0.000 description 1
- 239000003550 marker Substances 0.000 description 1
- 238000005259 measurement Methods 0.000 description 1
- 229910052751 metal Inorganic materials 0.000 description 1
- 239000002184 metal Substances 0.000 description 1
- OJURWUUOVGOHJZ-UHFFFAOYSA-N methyl 2-[(2-acetyloxyphenyl)methyl-[2-[(2-acetyloxyphenyl)methyl-(2-methoxy-2-oxoethyl)amino]ethyl]amino]acetate Chemical compound C=1C=CC=C(OC(C)=O)C=1CN(CC(=O)OC)CCN(CC(=O)OC)CC1=CC=CC=C1OC(C)=O OJURWUUOVGOHJZ-UHFFFAOYSA-N 0.000 description 1
- 125000002496 methyl group Chemical group [H]C([H])([H])* 0.000 description 1
- LVHBHZANLOWSRM-UHFFFAOYSA-N methylenebutanedioic acid Natural products OC(=O)CC(=C)C(O)=O LVHBHZANLOWSRM-UHFFFAOYSA-N 0.000 description 1
- VLKZOEOYAKHREP-UHFFFAOYSA-N n-Hexane Chemical group CCCCCC VLKZOEOYAKHREP-UHFFFAOYSA-N 0.000 description 1
- 239000002667 nucleating agent Substances 0.000 description 1
- 238000007383 open-end spinning Methods 0.000 description 1
- 230000003287 optical effect Effects 0.000 description 1
- 235000006408 oxalic acid Nutrition 0.000 description 1
- 238000012856 packing Methods 0.000 description 1
- 239000000049 pigment Substances 0.000 description 1
- 239000004014 plasticizer Substances 0.000 description 1
- 229920002239 polyacrylonitrile Polymers 0.000 description 1
- 229920002647 polyamide Polymers 0.000 description 1
- 229920001223 polyethylene glycol Polymers 0.000 description 1
- 229920000098 polyolefin Polymers 0.000 description 1
- 239000000843 powder Substances 0.000 description 1
- 238000011160 research Methods 0.000 description 1
- 235000009566 rice Nutrition 0.000 description 1
- 238000005096 rolling process Methods 0.000 description 1
- 229920006395 saturated elastomer Polymers 0.000 description 1
- 238000007493 shaping process Methods 0.000 description 1
- 229910052708 sodium Inorganic materials 0.000 description 1
- 239000011734 sodium Substances 0.000 description 1
- 230000003595 spectral effect Effects 0.000 description 1
- 238000001228 spectrum Methods 0.000 description 1
- 230000006641 stabilisation Effects 0.000 description 1
- 238000011105 stabilization Methods 0.000 description 1
- 229920001059 synthetic polymer Polymers 0.000 description 1
- HQHCYKULIHKCEB-UHFFFAOYSA-N tetradecanedioic acid Natural products OC(=O)CCCCCCCCCCCCC(O)=O HQHCYKULIHKCEB-UHFFFAOYSA-N 0.000 description 1
- ZIBGPFATKBEMQZ-UHFFFAOYSA-N triethylene glycol Chemical compound OCCOCCOCCO ZIBGPFATKBEMQZ-UHFFFAOYSA-N 0.000 description 1
- DTQVDTLACAAQTR-DYCDLGHISA-N trifluoroacetic acid-d1 Chemical compound [2H]OC(=O)C(F)(F)F DTQVDTLACAAQTR-DYCDLGHISA-N 0.000 description 1
- 238000007382 vortex spinning Methods 0.000 description 1
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Classifications
-
- D—TEXTILES; PAPER
- D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
- D01F—CHEMICAL FEATURES IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS; APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OF CARBON FILAMENTS
- D01F6/00—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof
- D01F6/88—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof from mixtures of polycondensation products as major constituent with other polymers or low-molecular-weight compounds
- D01F6/92—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof from mixtures of polycondensation products as major constituent with other polymers or low-molecular-weight compounds of polyesters
-
- D—TEXTILES; PAPER
- D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
- D01F—CHEMICAL FEATURES IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS; APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OF CARBON FILAMENTS
- D01F6/00—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof
- D01F6/78—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof from copolycondensation products
- D01F6/84—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof from copolycondensation products from copolyesters
-
- D—TEXTILES; PAPER
- D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
- D01F—CHEMICAL FEATURES IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS; APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OF CARBON FILAMENTS
- D01F8/00—Conjugated, i.e. bi- or multicomponent, artificial filaments or the like; Manufacture thereof
- D01F8/04—Conjugated, i.e. bi- or multicomponent, artificial filaments or the like; Manufacture thereof from synthetic polymers
- D01F8/14—Conjugated, i.e. bi- or multicomponent, artificial filaments or the like; Manufacture thereof from synthetic polymers with at least one polyester as constituent
-
- D—TEXTILES; PAPER
- D02—YARNS; MECHANICAL FINISHING OF YARNS OR ROPES; WARPING OR BEAMING
- D02G—CRIMPING OR CURLING FIBRES, FILAMENTS, THREADS, OR YARNS; YARNS OR THREADS
- D02G3/00—Yarns or threads, e.g. fancy yarns; Processes or apparatus for the production thereof, not otherwise provided for
- D02G3/02—Yarns or threads characterised by the material or by the materials from which they are made
- D02G3/04—Blended or other yarns or threads containing components made from different materials
-
- D—TEXTILES; PAPER
- D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
- D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
- D10B2331/00—Fibres made from polymers obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. polycondensation products
- D10B2331/04—Fibres made from polymers obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. polycondensation products polyesters, e.g. polyethylene terephthalate [PET]
Landscapes
- Engineering & Computer Science (AREA)
- Textile Engineering (AREA)
- Chemical & Material Sciences (AREA)
- Chemical Kinetics & Catalysis (AREA)
- General Chemical & Material Sciences (AREA)
- Mechanical Engineering (AREA)
- Yarns And Mechanical Finishing Of Yarns Or Ropes (AREA)
- Artificial Filaments (AREA)
- Nonwoven Fabrics (AREA)
- Knitting Of Fabric (AREA)
- Woven Fabrics (AREA)
Abstract
Disclosed herein is a spun yarn comprising melt-spun staple fiber comprising a first polymer and a second polymer, wherein the first polymer comprises poly (1, 3-trimethylene terephthalate) or poly (tetramethylene terephthalate), and the second polymer comprises poly (ethylene terephthalate) or Co-PET, wherein Co-PET is a poly (ethylene terephthalate) copolymer comprising isophthalic acid monomers; and wherein the first polymer comprises poly (1, 3-trimethylene terephthalate) and the weight ratio of the poly (1, 3-trimethylene terephthalate) to the second polymer is in the range of about 80: 20 to about 10: 90; or the first polymer comprises poly (butylene terephthalate), and the weight ratio of the poly (butylene terephthalate) to the second polymer is in the range of about 90: 10 to about 10: 90. The spun yarn may further comprise a second staple fiber, such as cotton or wool. The spun yarn can be used to make fabrics with advantageous properties.
Description
Cross Reference to Related Applications
The priority and benefit of U.S. provisional application No. 62/691066 entitled "Fabrics and Spun Yarns Comprising Polyester Staple fibers" filed on 28.6.2018 and U.S. provisional application No. 62/747999 entitled "Fabrics and Spun Yarns Comprising Polyester Staple fibers" filed on 19.10.2018, the disclosures of both provisional applications being incorporated herein by reference in their entirety.
Technical Field
The present disclosure relates to a spun yarn comprising meltspun staple fibers comprising a first polymer and a second polymer; and to a fabric comprising said spun yarn. The first polymer comprises poly (1, 3-trimethylene terephthalate) or poly (butylene terephthalate) and the second polymer comprises poly (ethylene terephthalate) or Co-PET, wherein Co-PET is a poly (ethylene terephthalate) copolymer comprising isophthalic acid monomers.
Background
Poly (1, 3-trimethylene terephthalate) (PTT) is a commercial fiber that provides desirable characteristics such as easy disperse dyeability at atmospheric pressure, relatively low flexural modulus, and relatively high degree of elastic recovery and resilience. Processes for producing PTT staple fibers are known, however, during storage prior to drawing, crimping and cutting, shrinkage of the partially oriented strands often prevents consistent processing of PTT into staple fibers. Shrinkage is affected by storage time and storage temperature, and uncontrolled shrinkage leads to titer non-uniformity and stretch breaks during the stretching process. Therefore, commercialization of the PTT staple fibers or blends of PTT staple fibers and natural fibers is limited.
In certain textile end uses, staple fibers are preferred over continuous filaments. For example, staple spinning for apparel fabrics requires discontinuous fibers rather than continuous fibers to allow the use of textile staple processing equipment. Staple fibers additionally allow blending of synthetic fibers with natural fibers such as wool, cotton, and cellulose. The manufacture of staple fibers suitable for use in fabrics can present particular problems, particularly in conventional split-filament spinning/drawing processes where drawing is performed in a separate step, and the characteristics of the undrawn fiber (e.g., dry heat shrinkage) can change as the undrawn fiber ages during storage.
There is a continuing need for PTT-based staple fibers having good uniformity and tenacity, as well as an economical process for producing such staple fibers. There is a continuing need for spun yarns comprising PTT-based staple fibers and having good tenacity and elongation at break, and which can impart desirable qualities to fabrics comprising such spun yarns.
Disclosure of Invention
Melt spun staple fibers, spun yarns comprising the melt spun staple fibers, and fabrics comprising the spun yarns are disclosed. In one embodiment, a spun yarn is disclosed comprising melt spun staple fiber comprising a first polymer comprising poly (1, 3-trimethylene terephthalate) or poly (tetramethylene terephthalate) and a second polymer comprising poly (ethylene terephthalate) or Co-PET, wherein Co-PET is a poly (ethylene terephthalate) copolymer comprising isophthalic acid monomers; and wherein the first polymer comprises poly (1, 3-trimethylene terephthalate) and the weight ratio of the poly (1, 3-trimethylene terephthalate) to the second polymer is in the range of about 80: 20 to about 10: 90; or the first polymer comprises poly (butylene terephthalate), and the weight ratio of the poly (butylene terephthalate) to the second polymer is in the range of about 90: 10 to about 10: 90. In another embodiment of the spinning, the weight ratio of the poly (1, 3-trimethylene terephthalate) or the poly (butylene terephthalate) to the second polymer is in the range of about 70: 30 to 30: 70. In another embodiment, the spun yarn has a scouring shrinkage (boil off shrinkage) of at least about 6% as determined according to ASTM D2259.
In one embodiment of the spinning, the meltspun staple fibers comprise poly (1, 3-trimethylene terephthalate) and poly (ethylene terephthalate). In another embodiment of the spinning, the meltspun staple fiber comprises poly (1, 3-trimethylene terephthalate) and Co-PET. In one embodiment of the spun yarn, the first polymer comprises poly (1, 3-trimethylene terephthalate) and the second polymer comprises Co-PET, and the Co-PET contains about 0.5 mole percent to about 10 mole percent of isophthalic acid monomer based on total copolymer composition. In another embodiment of the spinning, the meltspun staple fibers comprise poly (butylene terephthalate) and poly (ethylene terephthalate). In yet another embodiment of the spinning, the meltspun staple fibers comprise poly (butylene terephthalate) and Co-PET. In one embodiment of the spun yarn, the first polymer comprises poly (butylene terephthalate), and the second polymer comprises Co-PET, and the Co-PET contains about 0.5 to about 10 mole percent of isophthalic acid monomers based on total copolymer composition. In another embodiment of the spinning, the second polymer comprises Co-PET, and the Co-PET contains about 0.5 mole percent to about 10 mole percent isophthalic acid monomer based on total copolymer composition.
In one embodiment, the spun yarn further comprises a second staple fiber in an amount of about 5 wt% to about 95 wt% based on the total weight of the spun yarn. In another embodiment, the second staple fiber comprises polylactic acid, acrylic, nylon, olefin, acetate, rayon, or polyester. In another embodiment, the second staple fibers comprise at least one natural fiber selected from cotton, flax, wool, angora, mohair, alpaca, or cashmere (Cashmere). In another embodiment, the second staple fibers comprise polylactic acid, acrylic, nylon, olefins, acetate, rayon, polyester, cotton, flax, wool, angora, mohair, alpaca, cashmere, or mixtures thereof. In yet another embodiment, the second staple fibers comprise cotton or wool.
In one embodiment, the second staple fibers comprise cotton. In one embodiment, the spun yarn further comprises a second staple fiber, the second staple fiber comprises cotton, and the cotton is present in an amount of about 5 wt% to about 95 wt% based on the total weight of the spun yarn. In another embodiment, the spun yarn further comprising cotton has a cotton yarn count of about 4Ne to about 80 Ne.
In another embodiment, the second staple fibers comprise wool. In one embodiment, the spun yarn further comprises a second staple fiber, the second staple fiber comprises wool, and the wool is present in an amount of about 5 wt% to about 95 wt% based on the total weight of the spun yarn. In another embodiment, the spun yarns further comprising wool have a worsted count in the range of 7Nm to 120 Nm.
In another embodiment, a fabric is disclosed comprising the spun yarn as disclosed herein. In one embodiment, the fabric has a softer hand and better drape than a fabric of the same fabric construction consisting of rayon, polyethylene terephthalate, cotton, or a combination thereof. In one embodiment, the fabric has at least one of the following compared to a fabric of the same fabric construction consisting of polyethylene terephthalate, cotton, rayon, or a combination thereof: i) better wear resistance as determined according to ASTM D4966 standard test method; ii) a higher pilling note value as determined according to ASTM D4970 standard test method; or iii) greater loft as determined according to ASTM D1777 standard test method. In another embodiment, the fabric has better dyeability than a fabric of the same construction consisting of polyethylene terephthalate, cotton, rayon, or a combination thereof. In yet another embodiment, the fabric has better abrasion resistance than a fabric of the same fabric construction consisting of polyethylene terephthalate, cotton, rayon, or a combination thereof. In another embodiment, the fabric has less pilling (higher pilling note value) than a fabric of the same fabric construction consisting of polyethylene terephthalate, cotton, rayon, or a combination thereof. In another embodiment, the fabric has greater loft than a fabric of the same fabric construction consisting of polyethylene terephthalate, cotton, rayon, or a combination thereof.
In one embodiment, the fabric is a woven fabric having warp and weft yarns. In one embodiment, the fabric is a woven fabric having warp yarns and weft yarns, and the warp yarns, the weft yarns, or both the warp yarns and the weft yarns each comprise a spun yarn as disclosed herein. In another embodiment, the warp yarns comprise spun yarns as disclosed herein. In another embodiment, the weft yarn comprises a spun yarn as disclosed herein. In yet another embodiment, the warp yarns and the weft yarns each comprise a spun yarn as disclosed herein. In another embodiment, the fabric is a knitted fabric. In one embodiment, the knitted fabric has a higher degree of recovery than a knitted fabric of the same fabric construction consisting of polyethylene terephthalate, cotton, rayon, or a combination thereof. Also disclosed herein are articles, such as garments, comprising the fabrics as disclosed herein.
In yet another embodiment, melt spun staple fibers are disclosed, the fibers comprising a first polymer and a second polymer, the first polymer comprising poly (1, 3-trimethylene terephthalate) or poly (tetramethylene terephthalate), and the second polymer comprising poly (ethylene terephthalate) or Co-PET, wherein Co-PET is a poly (ethylene terephthalate) copolymer comprising isophthalic acid monomers, the staple fibers having a weight ratio of the first polymer to the second polymer in the range of about 70: 30 to about 30: 70, and a dry heat shrinkage of less than 6% as determined by dry heat shrinkage. In one embodiment, the melt-spun staple fibers comprise poly (1, 3-trimethylene terephthalate) and poly (ethylene terephthalate). In another embodiment, the melt-spun staple fibers comprise poly (1, 3-trimethylene terephthalate) and Co-PET. In another embodiment, the meltspun staple fibers comprise poly (butylene terephthalate) and poly (ethylene terephthalate). In yet another embodiment, the meltspun staple fibers comprise poly (butylene terephthalate) and Co-PET. In another embodiment, the second polymer comprises Co-PET, and the Co-PET contains about 0.5 mole percent to about 10 mole percent of isophthalic monomer based on total copolymer composition. In yet another embodiment of the meltspun staple fibers, the weight ratio of the first polymer to the second polymer is in the range of about 70: 30 to 50: 50.
Detailed Description
All patents, patent applications, and publications cited herein are incorporated by reference in their entirety.
As used herein, the terms "embodiment" or "disclosed" are not meant to be limiting, but generally apply to any embodiment defined in the claims or described herein. These terms are used interchangeably herein.
In this disclosure, a number of terms and abbreviations are used. The following definitions apply unless specifically stated otherwise.
The articles "a," "an," and "the" preceding an element or component are intended to be non-limiting with respect to the number of instances (i.e., occurrences) of the element or component. As used herein, "a", "an" and "the" are to be read as including one or at least one and the singular forms of the element or component also include the plural unless the number clearly indicates the singular.
The term "comprising" means the presence of stated features, integers, steps or components as referred to in the claims, but does not preclude the presence or addition of one or more other features, integers, steps, components or groups thereof. The term "comprising" is intended to include embodiments encompassed by the term "consisting essentially of. Similarly, the term "consisting essentially of is intended to include embodiments encompassed by the term" consisting of.
Where present, all ranges are inclusive and combinable. For example, when a range of "1 to 5" is recited, the recited range should be interpreted to include the ranges of "1 to 4", "1 to 3", "1 to 2 and 4 to 5", "1 to 3 and 5", and the like.
As used herein in connection with numerical values, the term "about" refers to a range of +/-0.5 of the numerical value, unless the term is otherwise specifically defined in context. For example, the phrase "a pH of about 6" refers to a pH of 5.5 to 6.5 unless the pH is otherwise specifically defined.
Every maximum numerical limitation given throughout this specification is intended to include every lower numerical limitation, as if such lower numerical limitations were expressly written herein. Every minimum numerical limitation given throughout this specification will include every higher numerical limitation, as if such higher numerical limitations were expressly written herein. Every numerical range given throughout this specification will include every narrower numerical range that falls within such broader numerical range, as if such narrower numerical ranges were all expressly written herein.
The features and advantages of the present disclosure will become more readily apparent to those of ordinary skill in the art from a reading of the following detailed description. It is to be understood that certain features of the disclosure, which are, for clarity, described above and below in the context of separate embodiments, may also be provided in combination in a single element. Conversely, various features of the disclosure which are, for brevity, described in the context of a single embodiment, may also be provided separately or in any subcombination.
The use of numerical values in the various ranges specified in this application are stated as approximations, as if the minimum and maximum values in the stated ranges were all preceded by the word "about," unless expressly specified otherwise. In this manner, slight variations above and below the stated ranges can be used to achieve substantially the same results as values within those ranges. Moreover, the disclosure of these ranges is intended as a continuous range including every value between the minimum and maximum values.
As used herein:
by "poly (1, 3-trimethylene terephthalate)" or PTT is meant a polymer comprising repeat units derived from 1, 3-propanediol and terephthalic acid (or equivalent). As used herein, the term "poly (1, 3-trimethylene terephthalate) homopolymer" refers to a polymer of essentially only 1, 3-propanediol and terephthalic acid (or equivalent). As used herein, the term "poly (1, 3-trimethylene terephthalate)" also includes PTT copolymers, which refers to polymers comprising repeat units derived from 1, 3-propanediol and terephthalic acid (or equivalent) and also containing at least one other unit derived from other monomers. Examples of PTT copolymers include copolyesters made using 3 or more reactants each having two ester-forming groups. For example, a co (1, 3-trimethylene terephthalate) may be used, wherein the co-monomers used to prepare the copolyester are selected from the group consisting of: linear, cyclic and branched aliphatic dicarboxylic acids having 4 to 12 carbon atoms (e.g., succinic acid, glutaric acid, adipic acid, dodecanedioic acid, and 1, 4-cyclo-hexanedicarboxylic acid); aromatic dicarboxylic acids other than terephthalic acid and having 8 to 12 carbon atoms (e.g., isophthalic acid and 2, 6-naphthalenedicarboxylic acid); linear, cyclic and branched aliphatic diols having 2 to 8 carbon atoms (other than 1, 3-propanediol, for example, ethylene glycol, 1, 2-propanediol, 1, 4-butanediol, 3-methyl-1, 5-pentanediol, 2-dimethyl-1, 3-propanediol, 2-methyl-1, 3-propanediol and 1, 4-cyclohexanediol); and aliphatic and aromatic ether glycols having 4 to 10 carbon atoms (e.g., hydroquinone bis (2-hydroxyethyl) ether or poly (vinyl ether) glycols having a molecular weight of less than about 460, including diethylene ether glycol). The comonomer is typically present in the copolyester at a level in the range of about 0.5 mol% to about 15 mol%, and may be present in an amount up to about 30 mol%.
As used herein, the term "poly (butylene terephthalate)" or PBT refers to a polymer derived substantially only from 1, 4-butanediol and terephthalic acid, and is also referred to as a poly (butylene terephthalate) homopolymer. As used herein, the term "poly (butylene terephthalate) copolymer" refers to a polymer comprising repeat units derived from 1, 4-butanediol and terephthalic acid and also containing at least one other unit derived from other monomers (e.g., co-monomers of a PTT copolymer as disclosed herein).
As used herein, the term "poly (ethylene terephthalate)" or PET refers to a polymer derived substantially only from ethylene glycol and terephthalic acid (or an equivalent, such as dimethyl terephthalate), and is also referred to as a poly (ethylene terephthalate) homopolymer. As used herein, the term "poly (ethylene terephthalate) copolymer" refers to a polymer comprising repeat units derived from ethylene glycol and terephthalic acid (or equivalent) and also containing at least one other unit derived from another monomer.
As used herein, the term "Co-PET" refers to a poly (ethylene terephthalate) copolymer in which the other monomer is isophthalic acid (or an ester equivalent). Thus, Co-PET is a poly (ethylene terephthalate) copolymer comprising ethylene terephthalate and isophthalic acid monomers.
"staple fibers" refers to natural fibers or lengths cut from filaments. The term "staple fibers" is used in the textile industry to distinguish natural fibers or man-made fibers cut from filaments. Rayon fibers are cut to a specific length, for example, as long as 8 inches or as short as 1.5 inches or less, so they can be processed or flocked on cotton, wool, or worsted spinning systems.
The term "meltspun staple fibers" refers to staple fibers obtained by the process of: melting the fiber-forming substance, extruding it through a spinneret, and then solidifying it by cooling; this meltspun fiber was stored, combined with other batches of similarly obtained meltspun fiber, and co-drawn, crimped, heat treated to achieve stabilization, and cut to obtain staple fiber.
The term "spun yarn" refers to a yarn produced by the process of: the tows of cut staple fibers are aligned in steps in which they are drawn sequentially into successive strands of progressively lower denier and bonded together by twisting.
"undrawn yarn" is a term commonly applied to undrawn fibers and is not intended herein to include fibers that have been drawn and processed into yarn products, such as those yarns used in knitted or woven fabrics. After melt spinning, undrawn yarn is accumulated until a total denier suitable for the drawing machine is produced. Accumulation may take up to 24 hours or more, including sleep or storage time between steps. For example, it typically takes 6 hours or more to make enough undrawn yarn to economically draw on a draw line. Due to production planning and other practical considerations, the fiber may be stored for several days. Fibers that have been exposed to such storage times are referred to as "aged" or "aged undrawn yarns".
"draw ratio" or "spin draw ratio" is the amount of filament that is stretched after melt spinning. As used herein, "draw ratio" refers to the machine draw ratio, which is the ratio of the surface speeds of the pulling roll to the advancing roll (the roll that moves the fiber). Some stretching occurs due to the pulling.
"carding" is the process of opening, singulating, aligning and forming a continuous untwisted yarn (called a sliver) from a staple bundle. The carding machine consists of a series of rollers, the surface of which is covered with a number of protruding metal teeth or pins.
"tow" means a large strand of continuously manufactured fiber filaments without definite twist, collected in loose rope form, and then cut into staple fibers or formed into sliver.
A "sliver" is a continuous strand of loosely assembled staple fibers without twist. The sliver is transported by a carding machine or drawing frame. The production of sliver is the first step of a textile operation, which converts staple fibers into a form that can be drawn and ultimately twisted into a spun yarn.
The term "fabric" refers to a planar textile structure produced by interlacing yarns, fibers or filaments.
The term "woven fabric" refers to a fabric comprised of interwoven warp and fill yarns (wefts). During the weaving process, the longitudinal warp yarns are held in tension on the frame or loom, while the drawn crosswise weft yarns (which may also be called weft yarns) pass through and are inserted into the warp yarns above and below.
The term "knit fabric" refers to a fabric produced by interlinking one or more ends of yarns to form loops.
The term "fabric construction" refers to details of the structure of the fabric, including the pattern, width, type of weaving or knitting, number of yarns per inch in the warp and weft, and weight of the goods.
The term "dtex" is a measure of the linear mass density of a fiber or yarn and is defined as the mass in grams/10,000 meters.
The term "sliver linear density" refers to the weight (in grams) of a sliver having a length of one meter.
The term "sliver linear density" (after the carding step) refers to the number of strands cut at 840 yards in a pound of weight, expressed in english count Ne, or the weight of the strands in grams in a 1000 meter length, expressed in grams/meter.
The term "final sliver linear density" (after the drawing step) refers to the number of strands of 840 yards cut length in one pound of weight expressed in english count Ne or the weight of the strands in grams per meter in one meter expressed in grams/meter.
The term "% unevenness" refers to the average deviation in weight, expressed as a percentage, of a 400 meter long spun yarn or a 50 meter long roving or 50 meter long sliver as measured by the Uster evenness tester-3 (UT 3). Measurements were carried out by an industrially established method using UT-3 and a yarn of length 400m or a sliver or roving of length 25m or 50 m.
The term "defect" in reference to spinning refers to the sum of the number of thick areas, the number of thin areas and the number of neps in a yarn of 1000 meters in length as determined using the Uster uniformity tester. As used herein, the term "thick zone" refers to a location on the yarn having a mass greater than or equal to + 150% of the average mass of the yarn in a cut length of 8 mm. As used herein, the term "thin zone" refers to a location on the yarn having a mass of less than or equal to 50% of the average mass of the yarn in a cut length of 8 mm. As used herein, the term "neps" refers to locations on the spun yarn having a mass greater than or equal to 200% of the average mass of the yarn in a cut length of 1 mm.
The term "hairiness index" refers to the average, expressed in normalized units, of the total length of protruding fibers per 1cm of length of yarn, measured optically in a 400 cm length yarn using a UT3 tester.
The present disclosure relates to a spun yarn comprising a melt-spun staple fiber comprising a first polymer and a second polymer, the first polymer comprising poly (1, 3-trimethylene terephthalate) or poly (tetramethylene terephthalate), and the second polymer comprising poly (ethylene terephthalate) or Co-PET, wherein Co-PET is a poly (ethylene terephthalate) copolymer comprising isophthalic acid monomers; and wherein the first polymer comprises poly (1, 3-trimethylene terephthalate) and the weight ratio of the poly (1, 3-trimethylene terephthalate) to the second polymer is in the range of about 80: 20 to about 10: 90; or the first polymer comprises poly (butylene terephthalate), and the weight ratio of the poly (butylene terephthalate) to the second polymer is in the range of about 90: 10 to about 10: 90. The meltspun staple fibers lack any distinct interface between the first polymer and the second polymer. The spun yarn has a scouring shrinkage of at least about 6% as determined according to ASTM D2259. Optionally, the spun yarn may comprise a second staple fiber, such as cotton or wool. Fabrics with the desired properties can be made from the spun yarns.
It has been found that the meltspun staple fibers disclosed herein have improved tenacity, crimpability, and stability compared to PTT meltspun staple fibers, and the characteristics of the meltspun staple fibers advantageously enable processing under conditions typically used for PET during conversion of the staple fibers to spun yarns. In addition, the spun yarns disclosed herein comprising meltspun staple fibers (whether further comprising secondary staple fibers or consisting essentially only of meltspun staple fibers) can produce woven, knitted, and nonwoven fabrics having cotton-like aesthetics, good strength, and other desirable attributes.
In one embodiment, the spun melt spun staple fiber comprises a first polymer comprising poly (1, 3-trimethylene terephthalate). Poly (1, 3-trimethylene terephthalate) suitable for melt spinning staple fibers is well known in the art and can be prepared, for example, by polycondensation of 1, 3-propanediol with terephthalic acid or terephthalic acid equivalent. Optionally, the 1, 3-propanediol may be biochemically obtained from a renewable source ("biologically derived" 1, 3-propanediol). Poly (1, 3-trimethylene terephthalate) can be trademarked
Commercially available from e.i. intra moore dupont, Wilmington, DE, Wilmington, wil. Optionally, the PTT or monomers thereof may be obtained by recycling post-industrial or post-consumer materials (i.e., fiber or plastic waste).
By "terephthalic acid equivalent" is meant a compound that behaves substantially as terephthalic acid when reacted with a polymeric diol, as would be generally recognized by one of ordinary skill in the relevant art. Terephthalic acid equivalents include, for example, esters (such as dimethyl terephthalate) and ester-forming derivatives (such as acid halides (e.g., acid chlorides) and anhydrides). Terephthalic acid and terephthalic esters (e.g., dimethyl ester) are suitable. Processes for the preparation of poly (1, 3-trimethylene terephthalate) are disclosed in, for example, US 6277947, US 6326456, US 6657044, US6353062, US 6538076 and US 7531617.
Preferably, the 1, 3-propanediol used as a reactant or as a component of a reactant in the preparation of poly (1, 3-trimethylene terephthalate) has a purity of greater than about 99 wt.% (e.g., greater than about 99.9 wt.%), as determined by gas chromatography analysis. Purified 1, 3-propanediol is disclosed in US 7038092, US 7098368, US 7084311 and US 7919658.
Poly (1, 3-trimethylene terephthalate) suitable for use in melt spinning fibers can be poly (1, 3-trimethylene terephthalate) homopolymers (derived substantially from 1, 3-propanediol and terephthalic acid and/or equivalents) and copolymers. In one embodiment, the poly (1, 3-trimethylene terephthalate) contains about 70 mole% or more of repeat units derived from 1, 3-propanediol and terephthalic acid (and/or its equivalents, such as dimethyl terephthalate). The poly (1, 3-trimethylene terephthalate) can contain at least about 85 mole%, or at least about 90 mole%, or at least about 95 mole%, or at least about 99 mole%, or about 100 mole% of repeat units derived from 1, 3-propanediol and terephthalic acid (or equivalent).
The poly (1, 3-trimethylene terephthalate) can contain small amounts of other co-monomers, and such co-monomers are typically selected such that they do not have a significant adverse effect on properties. Such other comonomers include, for example, sodium 5-sulfoisophthalate at levels in the range of about 0.2 to 5 mol%. Very small amounts of trifunctional comonomers, such as trimellitic acid, can be incorporated to control viscosity.
The poly (1, 3-trimethylene terephthalate) can contain up to 30 mole% of repeat units made from other diols or diacids. Other diacids include, for example, isophthalic acid, 1, 4-cyclohexanedicarboxylic acid, 2, 6-naphthalenedicarboxylic acid, 1, 3-cyclohexanedicarboxylic acid, succinic acid, glutaric acid, adipic acid, sebacic acid, 1, 12-dodecanedioic acid, and derivatives thereof, such as the dimethyl, diethyl, or dipropyl esters of these dicarboxylic acids. Other glycols include ethylene glycol, 1, 4-butanediol, 1, 2-propanediol, diethylene glycol, triethylene glycol, 1, 3-butanediol, 1, 5-pentanediol, 1, 6-hexanediol, 1, 2-, 1, 3-, and 1, 4-cyclohexanedimethanol, and long chain diols and polyols made from the reaction product of a diol or polyol and an alkylene oxide.
The poly (1, 3-trimethylene terephthalate) can also include functional monomers, such as up to about 5 mole% of sulfonate compounds for imparting cationic dyeability. Specific examples of preferred sulfonate compounds include lithium 5-sulfoisophthalate, sodium 5-sulfoisophthalate, potassium 5-sulfoisophthalate, 4-sodium sulfo-2, 6-naphthalenedicarboxylate, tetramethylphosphine 3, 5-dicarboxybenzenesulfonate, tetrabutylphosphine 3, 5-dicarboxybenzenesulfonate, tributyl-methylphosphine 3, 5-dicarboxybenzenesulfonate, tetrabutylphosphine 2, 6-dicarboxynaphthalene-4-sulfonate, tetramethylphosphine 2, 6-dicarboxynaphthalene-4-sulfonate, ammonium 3, 5-dicarboxybenzenesulfonate, and ester derivatives thereof, such as methyl or dimethyl esters.
The intrinsic viscosity of poly (1, 3-trimethylene terephthalate) is typically about 0.5 deciliters per gram (dl/g) or more, and typically about 2dl/g or less. In one embodiment, the poly (1, 3-trimethylene terephthalate) has an intrinsic viscosity of about 0.7dl/g or more, such as 0.8dl/g or more or such as 0.9dl/g or more, and typically about 1.5dl/g or less, such as 1.4dl/g or less, and the currently available commercial product has an intrinsic viscosity of 1.2dl/g or less.
In another embodiment, the spun meltspun staple fiber comprises a first polymer comprising poly (butylene terephthalate). Poly (butylene terephthalate) s suitable for melt spinning staple fibers are also well known in the art and can be prepared, for example, by polycondensation of 1, 4-butanediol with terephthalic acid. Poly (butylene terephthalate) s can be trademarked
Commercially available from dupont, e.i. intra-moore, wilmington, te.
Poly (butylene terephthalate) s suitable for use in melt spinning fibers can be homopolymers (derived substantially from 1, 4-butanediol and terephthalic acid and/or equivalents) and copolymers. In one embodiment, the poly (butylene terephthalate) contains about 80 mole percent or more of repeat units derived from 1, 4-butanediol and terephthalic acid. In other embodiments, the poly (butylene terephthalate) may contain at least about 85 mole%, or at least about 90 mole%, or at least about 95 mole%, or at least about 99 mole%, or about 100 mole% of repeat units derived from 1, 4-butanediol and terephthalic acid (or equivalent). The poly (1, 3-trimethylene terephthalate) may contain small amounts of other co-monomers or functional monomers. Optionally, the PBT or monomers thereof can be obtained by recycling post-industrial or post-consumer materials (i.e., fiber or plastic waste).
Polyethylene terephthalate (PET) is a polyester that can be prepared by the condensation polymerization of ethylene glycol and terephthalic acid (or dimethyl terephthalate or other terephthalate). Processes for the preparation of poly (ethylene terephthalate) are known, for example, as disclosed in US 3398124 and US 3487049. Poly (ethylene terephthalate) suitable for use in preparing the melt spun staple fibers disclosed herein are also commercially available. In one embodiment, the poly (ethylene terephthalate) is a homopolymer and is derived substantially from ethylene glycol and terephthalic acid and/or equivalents. Optionally, the PET or its monomers may be obtained by recycling post-industrial or post-consumer materials (i.e. fibers or plastic waste).
In many applications, it may be desirable to alter the properties of the poly (ethylene terephthalate) by adding a third monomer. For example, copolymers of polyethylene terephthalate can be prepared from dimethyl terephthalate or monomers of terephthalic acid in combination with cyclohexanedimethanol or in combination with cyclohexanedimethanol and ethylene glycol. In other cases, isophthalic acid may be used to replace a portion of the terephthalic acid monomer, which can disrupt crystallinity and lower the melting point of the copolymer (referred to herein as "Co-PET").
As used herein, "Co-PET" refers to a poly (ethylene terephthalate) copolymer that can be prepared by the condensation polymerization of ethylene glycol, terephthalic acid (or dimethyl terephthalate or other terephthalate), and isophthalic acid (or dimethyl isophthalate or other terephthalate), as known in the art. Co-PET can also be produced in the following process: recycled poly (ethylene terephthalate) bottles are shredded, melted, purified and re-pelletized to produce fiber grade post-consumer recycled Co-PET. Isophthalic monomer is typically present in the Co-PET at a level in the range of from about 0.5 to about 15 mole%, based on the total copolymer composition, and may be present in an amount up to about 30 mole%. For example, the Co-PET may contain about 0.5, 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, or 30 mole% of isophthalic acid monomers. In one embodiment, the Co-PET useful in the melt spun staple fibers disclosed herein contains from about 1 mol% to about 5 mol% or up to about 10 mol% or up to about 15 mol% isophthalic monomer based on total copolymer composition. In another embodiment, useful Co-PET contains about 0.5 mol% to about 3 mol% isophthalic acid monomers. The amount of Co-PET isophthalic acid monomer can be selected to provide the desired properties to the Co-PET. It is believed that the lower melting point of Co-PET improves the compatibility of Co-PET with poly (1, 3-trimethylene terephthalate) during melt spinning. Co-PET is commercially available.
In some embodiments, polyethylene terephthalate copolymers containing monomers other than isophthalic acid may be used. For example, polyethylene terephthalate copolymers comprising ethylene glycol, terephthalic acid (or equivalents) and dicarboxylic acids such as succinic acid, adipic acid, azelaic acid, sebacic acid, glutaric acid, 1, 10-decanedicarboxylic acid, phthalic acid, dodecanedioic acid, sulfonated isophthalic acid, oxalic acid, fumaric acid, maleic acid, itaconic acid, 1, 4-cyclohexanedicarboxylic acid, 1, 3-cyclohexanedicarboxylic acid, 1, 2-cyclohexanedicarboxylic acid, and mixtures thereof may be used to prepare melt-spun staple fibers. Alternatively, polyethylene terephthalate copolymers and diols comprising ethylene glycol, terephthalic acid (or equivalents), such as diethylene glycol, polyethylene glycol, butanediol, 1, 4-cyclohexanedimethanol, 1, 2-cyclohexanediol, 1, 4-cyclohexanediol, 1, 3-cyclohexanediol, 1, 5-pentanediol, 1, 6-hexanediol, and mixtures thereof, can be used to make melt-spun staple fibers.
In one embodiment, the Co-PET is a poly (ethylene terephthalate) copolymer comprising ethylene terephthalate and isophthalic acid monomers. In another embodiment, the Co-PET is a poly (ethylene terephthalate) copolymer consisting essentially of poly (ethylene terephthalate) and isophthalic acid monomers. In another embodiment, the Co-PET is a poly (ethylene terephthalate) copolymer composed of poly (ethylene terephthalate) and isophthalic monomers.
Melt-spun staple fibers comprise a first polymer and a second polymer, the first polymer comprising poly (1, 3-trimethylene terephthalate) or poly (tetramethylene terephthalate), and the second polymer comprising poly (ethylene terephthalate) or Co-PET; and wherein the first polymer comprises poly (1, 3-trimethylene terephthalate) and the weight ratio of the poly (1, 3-trimethylene terephthalate) to the second polymer is in the range of about 80: 20 to about 10: 90; or the first polymer comprises poly (butylene terephthalate), and the weight ratio of the poly (butylene terephthalate) to the second polymer is in the range of about 90: 10 to about 10: 90. In one embodiment, the melt-spun staple fibers comprise poly (1, 3-trimethylene terephthalate) (PTT) and poly (ethylene terephthalate) (PET), and the melt-spun staple fibers comprise about 80 wt.% PTT and about 20 wt.% PET. In one embodiment, the melt spun staple fibers comprise about 75 wt.% PTT and about 25 wt.% PET. In one embodiment, the melt spun staple fibers comprise about 70 wt% PTT and about 30 wt% PET. In another embodiment, the staple fibers comprise about 65 wt% PTT and about 35 wt% PET. In yet another embodiment, the staple fibers comprise about 60 wt% PTT and about 40 wt% PET. In another embodiment, the staple fibers comprise about 55 wt% PTT and about 45 wt% PET. In another embodiment, the staple fibers comprise about 50 wt% PTT and about 50 wt% PET. In another embodiment, the staple fibers comprise about 45 wt% PTT and about 55 wt% PET. In a separate embodiment, the staple fibers comprise about 40 wt% PTT and about 60 wt% PET. In another embodiment, the staple fibers comprise about 35 wt% PTT and about 65 wt% PET. In yet another embodiment, the staple fibers comprise about 30 wt% PTT and about 70 wt% PET. In one embodiment, the melt spun staple fibers comprise about 25 wt% PTT and about 75 wt% PET. In one embodiment, the meltspun staple fibers comprise about 20 wt.% PTT and about 80 wt.% PET. In one embodiment, the meltspun staple fibers comprise about 15 wt.% PTT and about 85 wt.% PET. In one embodiment, the melt spun staple fibers comprise about 10 wt% PTT and about 90 wt% PET.
In one embodiment, the melt-spun staple fiber comprises poly (1, 3-trimethylene terephthalate) (PTT) and poly (ethylene terephthalate) copolymer comprising isophthalic acid monomers (Co-PET), and the weight ratio of PTT to Co-PET is in the range of about 80: 20 to about 10: 90. In one embodiment, the melt spun staple fibers comprise about 80 wt% PTT and about 20 wt% Co-PET. In another embodiment, the melt spun staple fibers comprise about 75 wt.% PTT and about 25 wt.% Co-PET. In one embodiment, the melt spun staple fibers comprise about 70 wt% PTT and about 30 wt% Co-PET. In another embodiment, the melt spun staple fibers comprise about 65 wt.% PTT and about 35 wt.% Co-PET. In yet another embodiment, the meltspun staple fibers comprise about 60 wt.% PTT and about 40 wt.% Co-PET. In another embodiment, the melt spun staple fibers comprise about 55 wt% PTT and about 45 wt% Co-PET. In another embodiment, the melt spun staple fibers comprise about 50 wt% PTT and about 50 wt% Co-PET. In another embodiment, the melt spun staple fibers comprise about 45 wt% PTT and about 55 wt% Co-PET. In a separate embodiment, the meltspun staple fibers comprise about 40 wt.% PTT and about 60 wt.% Co-PET. In another embodiment, the melt spun staple fibers comprise about 35 wt.% PTT and about 65 wt.% Co-PET. In yet another embodiment, the meltspun staple fibers comprise about 30 wt.% PTT and about 70 wt.% Co-PET. In one embodiment, the melt spun staple fibers comprise about 25 wt% PTT and about 75 wt% Co-PET. In another embodiment, the melt spun staple fibers comprise about 20 wt.% PTT and about 80 wt.% Co-PET. In yet another embodiment, the meltspun staple fibers comprise about 15 wt.% PTT and about 85 wt.% Co-PET. In another embodiment, the melt spun staple fibers comprise about 10 wt% PTT and about 90 wt% Co-PET.
In one embodiment, the melt-spun staple fiber comprises poly (butylene terephthalate) (PBT) and poly (ethylene terephthalate) (PET), and the melt-spun staple fiber comprises about 90 wt.% PBT and about 10 wt.% PET. In another embodiment, the melt spun staple fibers comprise about 85 wt.% PBT and about 15 wt.% PET. In one embodiment, the melt spun staple fibers comprise about 80 wt.% PBT and about 20 wt.% PET. In one embodiment, the melt spun staple fibers comprise about 75 wt.% PBT and about 25 wt.% PET. In one embodiment, the melt spun staple fibers comprise about 70 wt.% PBT and about 30 wt.% PET. In another embodiment, the staple fiber comprises about 65 wt.% PBT and about 35 wt.% PET. In yet another embodiment, the staple fiber comprises about 60 wt.% PBT and about 40 wt.% PET. In another embodiment, the staple fibers comprise about 55 wt.% PBT and about 45 wt.% PET. In another embodiment, the staple fibers comprise about 50 wt.% PBT and about 50 wt.% PET. In another embodiment, the staple fibers comprise about 45 wt.% PBT and about 55 wt.% PET. In a separate embodiment, the staple fibers comprise about 40 wt.% PBT and about 60 wt.% PET. In another embodiment, the staple fiber comprises about 35 wt.% PBT and about 65 wt.% PET. In yet another embodiment, the staple fiber comprises about 30 wt.% PBT and about 70 wt.% PET. In one embodiment, the melt spun staple fibers comprise about 25 wt.% PBT and about 75 wt.% PET. In one embodiment, the melt spun staple fibers comprise about 20 wt.% PBT and about 80 wt.% PET. In one embodiment, the melt spun staple fibers comprise about 15 wt.% PBT and about 85 wt.% PET. In one embodiment, the melt spun staple fibers comprise about 10 wt.% PBT and about 90 wt.% PET.
In one embodiment, the melt-spun staple fiber comprises poly (butylene terephthalate) (PBT) and a poly (ethylene terephthalate) copolymer comprising isophthalic acid monomers (Co-PET), and the weight ratio of PBT to Co-PET is in the range of about 90: 10 to about 10: 90. In one embodiment, the melt spun staple fibers comprise about 85 wt.% PBT and about 15 wt.% Co-PET. In another embodiment, the melt spun staple fibers comprise about 80 wt.% PBT and about 20 wt.% Co-PET. In another embodiment, the melt spun staple fibers comprise about 75 wt.% PBT and about 25 wt.% Co-PET. In one embodiment, the melt spun staple fibers comprise about 70 wt.% PBT and about 30 wt.% Co-PET. In another embodiment, the melt spun staple fibers comprise about 65 wt.% PBT and about 35 wt.% Co-PET. In yet another embodiment, the melt spun staple fibers comprise about 60 wt.% PBT and about 40 wt.% Co-PET. In another embodiment, the melt spun staple fibers comprise about 55 wt.% PBT and about 45 wt.% Co-PET. In another embodiment, the melt spun staple fibers comprise about 50 wt.% PBT and about 50 wt.% Co-PET. In another embodiment, the melt spun staple fibers comprise about 45 wt.% PBT and about 55 wt.% Co-PET. In a separate embodiment, the melt spun staple fibers comprise about 40 wt.% PBT and about 60 wt.% Co-PET. In another embodiment, the melt spun staple fibers comprise about 35 wt.% PBT and about 65 wt.% Co-PET. In yet another embodiment, the melt spun staple fibers comprise about 30 wt.% PBT and about 70 wt.% Co-PET. In one embodiment, the melt spun staple fibers comprise about 25 wt.% PBT and about 75 wt.% Co-PET. In another embodiment, the melt spun staple fibers comprise about 20 wt.% PBT and about 80 wt.% Co-PET. In yet another embodiment, the melt spun staple fibers comprise about 15 wt.% PBT and about 85 wt.% Co-PET. In another embodiment, the melt spun staple fibers comprise about 10 wt.% PBT and about 90 wt.% Co-PET.
The meltspun staple fibers may be formed in a two-stage process. In the first stage, the polymers are combined, melted, extruded to form filaments comprising the polymers, the filaments are cooled and collected as a tow. In the second stage, the tow may be processed through at least one of drawing, crimping, annealing, and cutting to produce staple fibers. Processes for making polyester staple fibers are known, for example, as disclosed in US 5, 308, 564.
The first polymer (PTT or PBT) and the second polymer (PET or Co-PET) can be combined by any known technique. The polymers can be combined in a variety of ways, for example, they can be (a) heated and mixed simultaneously, (b) pre-mixed in a separate apparatus prior to heating, or (c) heated and then mixed. Mixing, heating and shaping can be carried out by conventional equipment designed for this purpose, such as extruders. The temperature should be above the melting point of each polymer, but below the minimum decomposition temperature. Suitable temperatures may range from about 140 ℃ to about 240 ℃, for example at least about 200 ℃ and up to about 230 ℃. In one embodiment, the melting temperature is less than 280 ℃.
In one embodiment, the polymer may be compounded, for example, in the compounding screw in the desired proportions to form pellets, which are then fed into the spinner extruder. In another embodiment, pellets can be made from each polymer separately and then blended together as a salt and pepper mixture into the spin machine extruder using up to two feeders. Alternatively, pellets may be made from each polymer separately and pre-blended together before feeding the pellets to the spinning machine extruder. In yet another embodiment, each polymer may be melted to form a molten polymer stream, and the molten polymer streams may then be combined and pellets formed from the molten mixture. The term "pellet" is used generically herein, and is used regardless of shape, such that it includes products sometimes referred to as "chips" or "flakes".
Additives may be added to the poly (1, 3-trimethylene terephthalate), poly (butylene terephthalate), poly (ethylene terephthalate), Co-PET, or mixtures of polymers, if desired. Useful additives may include, for example, delustrants, nucleating agents, heat stabilizers, tackifiers, optical brighteners, antioxidants, antimicrobials, plasticizers, antistatic agents, lubricants, processing aids, flame retardants, dyes, TiO2Or a pigment.
The combined first and second polymers (i.e., a PTT and PET mixture, a PTT and Co-PET mixture, a PBT and PET mixture, or a PBT and Co-PET mixture) are extruded through a spinneret at a temperature of about 250 ℃ to about 275 ℃ (e.g., at least about 255 ℃ and up to about 270 ℃). The spun filaments are extruded in bundles, each threadline in these bundles comprising at least about 34 filaments, for example from about 175 filaments to about 6800 filaments, or even 6900 filaments or more. The undrawn filaments typically have a denier per filament of from about 3 to about 8, or more. The spinneret holes are typically circular for circular fibre cross-sections, but holes of various shapes may be used as desired, for example for trilobal or triangular cross-sections. The spun filaments have a denier in the range of about 3 to about 8dpf and are collected as bundles (tows). Typically, the dry heat shrinkage of the tow is less than 6%, as determined by the dry heat shrinkage method disclosed herein in the examples.
In the second stage of the process for making staple fibers, the tow is fed from a set of tanks or racks containing undrawn meltspun yarn. A finish may be applied to facilitate downstream processing. The tow is then drawn by immersion in a heated dilute finishing water bath. Generally, the feed roll is maintained at room temperature while the draw roll may be heated. The drawn tow is stabilized by passing it through a saturated steam chamber and may optionally be further drawn and annealed on a plurality of heated draw roll modules before passing it through a room temperature roll module. Various simplifications may be made to the draw zone using fewer or more heaters or room temperature draw modules to optimally draw and stabilize the yarn in preparation for crimping. Crimping modules typically use a steam box that reduces the yarn modulus in preparation for crimping, and typically the crimper is a mechanical stuffer box crimper with a flapper door, which is subjected to pneumatic pressure. Drawing the yarn tows into a crimper box body through a group of driving rollers; the yarn bends and forms a crimp as it exits the box, which is controlled by the back pressure on the flapper. The crimped tow passes through an annealer section and is then cut into staple fibers.
The final denier per filament of the melt-spun staple fiber may be in the range of 1 to 2 for cotton system processing and 2 to 3 for wool system processing.
The meltspun staple fibers disclosed herein have processing advantages. For example, in the preparation of spun yarns, staple fibers can be processed with good productivity through opening, carding and drawing steps. The melt spun staple disclosed herein can be run on a staple spinning process using conditions typical for PET staple spinning.
The drawn fiber may be cut into staple fibers of any desired length. If the staple fibers are too short, carding can be difficult. If the staple is too long, it may be difficult to spin on cotton or wool system equipment. For use in cotton spinning systems, the length of the staple fibers is typically in the range of about 32mm to about 51mm, for example in the range of about 38mm to 40 mm. For use in a spinning system, the staple fibers typically have a plurality of cut lengths, with an average cut length in the range of about 70mm to about 100mm, for example in the range of about 80mm to about 90 mm. The staple fibers may be crimped to have about 10 to about 18 (e.g., about 11 to about 15) full sinusoidal arcs per inch. For cotton spinning systems, the melt spun staple fibers typically have a denier per filament of 1 to 2, a tenacity greater than 4 g/denier, and an elongation at break of 20% to 60%, as determined using the method disclosed in the examples below. For worsted systems, the melt spun staple fibers typically have a denier per filament of 2 to 4, a tenacity greater than 4 g/denier, and an elongation at break of 30% to 90%.
The meltspun staple fibers disclosed herein may be used to make spun yarns. In one embodiment, the spun yarns consist essentially of meltspun staple fibers and do not contain any other type of staple fibers. In another embodiment, the spun yarn comprises the melt spun staple fiber disclosed herein. In another embodiment, the spun yarn further comprises a second staple fiber in an amount of about 5 weight percent to about 95 weight percent based on the total weight of the spun yarn. In one embodiment, the second staple fibers may comprise at least one natural fiber. In another embodiment, the second staple fibers comprise at least one natural fiber selected from the group consisting of cotton, flax, wool, angora, mohair, alpaca, or cashmere. In another embodiment, the second staple fibers may comprise at least one synthetic fiber. In another embodiment, the second staple fiber comprises polylactic acid, acrylon, nylon, olefin, acetate, rayon, or polyester. In yet another embodiment, the second staple fibers may comprise at least one regenerated cellulose fiber. As used herein, the term "regenerated cellulose fiber" refers to textile fibers made from regenerated cellulose, also known as rayon, and includes lyocell, viscose, rayon, and the like,
And
a fiber. As used herein, "lyocell fibers" refers to a form of rayon consisting of cellulose fibers made from dissolving bleached wood pulp using dry-jet wet-spinning. As used herein, "viscose" refers to regenerated manufactured fibers made from cellulose and obtained by the viscose process. As used herein, the term "a" or "an" refers to,
refers to fibers made from beech pulp. As used herein, the term "a" or "an" refers to,
refers to fibers made from eucalyptus.
In one embodiment, the spun yarn comprises melt spun staple fibers comprising a first polymer and a second polymer, the first polymer comprising PTT or PBT and the second polymer comprising PET or Co-PET, wherein the weight ratio of the first polymer to the second polymer is in the range of about 80: 20 to about 10: 90 or about 70: 30 to about 30: 70 or about 60: 40 to about 40: 60 or about 70: 30 to about 50: 50 and the spun yarn further comprises a second staple fiber comprising cotton. In another embodiment, the first polymer comprises poly (butylene terephthalate), and the weight ratio of poly (butylene terephthalate) to the second polymer is in a range of about 90: 10 to about 10: 90 (e.g., about 90: 10 to about 80: 20), and the spun yarn further comprises a second staple fiber comprising cotton. The cotton may be present in the spun yarn in an amount of about 5 wt% to about 95 wt% and the meltspun staple fiber may be present in the spun yarn in an amount of about 95 wt% to about 5 wt%, based on the total weight of the spun yarn. For example, the spun yarn may contain about 5 wt% cotton and about 95 wt% meltspun staple fiber, or about 10 wt% cotton and about 90 wt% meltspun staple fiber, or about 15 wt% cotton and about 85 wt% meltspun staple fiber, or about 20 wt% cotton and about 80 wt% meltspun staple fiber, or about 25 wt% cotton and about 75 wt% meltspun staple fiber, or about 30 wt% cotton and about 70 wt% meltspun staple fiber, or about 35 wt% cotton and about 65 wt% meltspun staple fiber, or about 40 wt% cotton and about 60 wt% meltspun staple fiber, or about 45 wt% cotton and about 55 wt% meltspun staple fiber, or about 50 wt% cotton and about 50 wt% meltspun staple fiber, or about 55 wt% cotton and about 45 wt% meltspun staple fiber, or about 60 wt% cotton and about 40 wt% meltspun staple fiber, or about 65 wt% cotton and about 35 wt% meltspun staple fiber, based on the total weight of the spun yarn, Or about 70 wt% cotton and about 30 wt% meltspun staple fiber, or about 75 wt% cotton and about 25 wt% meltspun staple fiber, or about 80 wt% cotton and about 20 wt% meltspun staple fiber. In another embodiment, the spun yarn may comprise greater than 95 wt% meltspun staple fiber and less than 5 wt% of a second staple fiber comprising cotton. The relative amounts of cotton and meltspun staple fibers are selected to provide desired characteristics to the spun yarn and fabrics made from the yarn. The spun yarn may have a cotton count (Ne) of about 4 to about 70 (e.g., about 4 to about 60, or about 4 to about 50, or about 10 to about 60, or about 20 to about 60). The spun yarn comprising cotton may have a fracture toughness of at least 10 cN/tex. In some embodiments, the spun yarn comprising cotton may have a fracture toughness of at least 10 cN/tex. The spun yarn comprising cotton may have an elongation at break of at least 4%. Methods for determining fracture toughness and elongation are provided in the examples below.
In another embodiment, the spun yarn comprises melt spun staple fibers comprising a first polymer and a second polymer, the first polymer comprising PTT or PBT and the second polymer comprising PET or Co-PET, wherein the weight ratio of the first polymer to the second polymer is in the range of about 80: 20 to about 10: 90 or about 70: 30 to about 30: 70 or about 60: 40 to about 40: 60 or about 70: 30 to about 50: 50 and the spun yarn further comprises a second staple fiber comprising wool. In another embodiment, the first polymer comprises poly (butylene terephthalate), and the weight ratio of poly (butylene terephthalate) to the second polymer is in a range of about 90: 10 to about 10: 90 (e.g., about 90: 10 to about 80: 20), and the spun yarn further comprises a second staple fiber comprising wool. The term "wool" refers to fibers made from sheep or lamb wool. Wool may be present in an amount of about 5 wt% to about 95 wt%, and meltspun staple fiber may be present in an amount of about 95 wt% to about 5 wt%, based on the total weight of the spun yarn. For example, the spun yarn may contain about 5 wt% wool and about 95 wt% meltspun staple fiber, or about 10 wt% wool and about 90 wt% meltspun staple fiber, or about 15 wt% wool and about 85 wt% meltspun staple fiber, or about 20 wt% wool and about 80 wt% meltspun staple fiber, or about 25 wt% wool and about 75 wt% meltspun staple fiber, or about 30 wt% wool and about 70 wt% meltspun staple fiber, or about 35 wt% wool and about 65 wt% meltspun staple fiber, or about 40 wt% wool and about 60 wt% meltspun staple fiber, or about 45 wt% wool and about 55 wt% meltspun staple fiber, or about 50 wt% wool and about 50 wt% meltspun staple fiber, or about 55 wt% wool and about 45 wt% meltspun staple fiber, or about 60 wt% and about 40 wt% meltspun staple fiber, or about 65 wt% meltspun staple fiber and about 35 wt% meltspun staple fiber, based on the total weight of the spun yarn, Or about 70 wt% wool and about 30 wt% meltspun staple fiber, or about 75 wt% wool and about 25 wt% meltspun staple fiber, or about 80 wt% wool and about 20 wt% meltspun staple fiber, or about 85 wt% wool and about 15 wt% meltspun staple fiber, or about 90 wt% wool and about 10 wt% meltspun staple fiber, or about 95 wt% wool and about 5 wt% meltspun staple fiber. The relative amounts of wool and meltspun staple fibers are selected to provide desired characteristics to the spun yarns and fabrics made from the yarns. The spun yarn may have a spinning count (Nm) of about 7 to about 120 (e.g., about 7 to about 110, or about 7 to about 100, or about 10 to about 120, or about 10 to about 100, or about 10 to about 75).
In another embodiment, the spun yarn comprises melt spun staple fibers comprising a first polymer and a second polymer, the first polymer comprising PTT or PBT and the second polymer comprising PET or Co-PET, wherein the weight ratio of the first polymer to the second polymer ranges from about 80: 20 to about 10: 90 or about 70: 30 to about 30: 70 or about 60: 40 to about 40: 60 or about 70: 30 to about 50: 50And the spun yarn further comprises a second staple fiber comprising rayon. In another embodiment, the first polymer comprises poly (butylene terephthalate), and the weight ratio of poly (butylene terephthalate) to the second polymer is in a range of about 90: 10 to about 10: 90 (e.g., about 90: 10 to about 80: 20), and the spun yarn further comprises a second staple fiber comprising rayon. As used herein, "rayon" refers to textile fibers made from regenerated cellulose and includes lyocell, viscose, rayon, and rayon,
And
a fiber. In spinning, the rayon may be present in an amount of about 5 wt% to about 95 wt% and the meltspun staple fiber may be present in an amount of about 95 wt% to about 5 wt%, based on the total weight of the spun yarn. For example, the spun yarn may contain about 5 wt% rayon and about 95 wt% meltspun staple fiber, or about 10 wt% rayon and about 90 wt% meltspun staple fiber, or about 15 wt% rayon and about 85 wt% meltspun staple fiber, or about 20 wt% rayon and about 80 wt% meltspun staple fiber, or about 25 wt% rayon and about 75 wt% meltspun staple fiber, or about 30 wt% rayon and about 70 wt% meltspun staple fiber, or about 35 wt% rayon and about 65 wt% meltspun staple fiber, or about 40 wt% rayon and about 60 wt% meltspun staple fiber, or about 45 wt% rayon and about 55 wt% meltspun staple fiber, or about 50 wt% rayon and about 50 wt% meltspun staple fiber, or about 55 wt% rayon and about 45 wt% meltspun staple fiber, or about 60 wt% rayon and about 40 wt% meltspun staple fiber, Or about 65 wt% rayon and about 35 wt% meltspun staple fiber, or about 70 wt% rayon and about 30 wt% meltspun staple fiber, or about 75 wt% rayon and about 25 wt% meltspun staple fiber, or about 80 wt% rayon and about 20 wt% meltspun staple fiber, or about 85 wt% rayon and about 15 wt% meltspun staple fiber, or about 90 wt% rayonThe filaments and about 10 wt% of the meltspun staple fibers, or about 95 wt% rayon and about 5 wt% of the meltspun staple fibers. The relative amounts of rayon and meltspun staple fiber are selected to provide desired characteristics to the spun yarn and fabrics made from the yarn. The spun yarn may have a cotton count (Ne) of about 4 to about 80 (e.g., about 10 to about 60, or about 12 to about 40).
In another embodiment, the spun yarn comprises meltspun staple fiber comprising a first polymer and a second polymer, the first polymer comprising PTT or PBT and the second polymer comprising PET or Co-PET, wherein the weight ratio of the first polymer to the second polymer is in the range of about 80: 20 to about 10: 90 or about 70: 30 to about 30: 70 or about 60: 40 to about 40: 60 or about 70: 30 to about 50: 50 and the spun yarn further comprises a second staple fiber comprising acrylic. In another embodiment, the first polymer comprises poly (butylene terephthalate), and the weight ratio of poly (butylene terephthalate) to the second polymer is in a range of about 90: 10 to about 10: 90 (e.g., about 90: 10 to about 80: 20), and the spun yarn further comprises a second staple fiber comprising acrylic fibers. As used herein, "acrylic fiber" refers to a synthetic fiber made of polyacrylonitrile having an average molecular weight of about 100,000 and a monomer unit number of about 1900. The acrylic fiber may be present in an amount of about 5 wt% to about 95 wt% and the meltspun staple fiber may be present in an amount of about 95 wt% to about 5 wt%, based on the total weight of the spun yarn. For example, the spun yarn may contain about 5 wt% acrylic fiber and about 95 wt% meltspun staple fiber, or about 10 wt% acrylic fiber and about 90 wt% meltspun staple fiber, or about 15 wt% acrylic fiber and about 85 wt% meltspun staple fiber, or about 20 wt% acrylic fiber and about 80 wt% meltspun staple fiber, or about 25 wt% acrylic fiber and about 75 wt% meltspun staple fiber, or about 30 wt% acrylic fiber and about 70 wt% meltspun staple fiber, or about 35 wt% acrylic fiber and about 65 wt% staple fiber, or about 40 wt% acrylic fiber and about 60 wt% meltspun staple fiber, or about 45 wt% acrylic fiber and about 55 wt% staple fiber, or about 50 wt% acrylic fiber and about 50 wt% staple fiber, or about 55 wt% acrylic fiber and about 45 wt% staple fiber, based on the total weight of the spun yarn, Or about 60 wt% acrylic fiber and about 40 wt% meltspun staple fiber, or about 65 wt% acrylic fiber and about 35 wt% meltspun staple fiber, or about 70 wt% acrylic fiber and about 30 wt% meltspun staple fiber, or about 75 wt% acrylic fiber and about 25 wt% meltspun staple fiber, or about 80 wt% acrylic fiber and about 20 wt% meltspun staple fiber, or about 85 wt% acrylic fiber and about 15 wt% meltspun staple fiber, or about 90 wt% acrylic fiber and about 10 wt% meltspun staple fiber, or about 95 wt% acrylic fiber and about 5 wt% meltspun staple fiber. The relative amounts of acrylic fiber and meltspun staple fiber are selected to provide the desired characteristics for spinning and fabrics made from the yarn. The spun yarn may have a cotton count (Ne) of about 4 to about 80 (e.g., about 10 to about 60, or about 12 to about 40).
In another embodiment, the spun yarn comprises melt-spun staple fiber comprising a first polymer and a second polymer, the first polymer comprising PTT or PBT and the second polymer comprising PET or Co-PET, wherein the weight ratio of the first polymer to the second polymer is in the range of about 80: 20 to about 10: 90 or about 70: 30 to about 30: 70 or about 60: 40 to about 40: 60 or about 70: 30 to about 50: 50 and the spun yarn further comprises a second staple fiber comprising polylactic acid (PLA). In another embodiment, the first polymer comprises poly (butylene terephthalate), and the weight ratio of poly (butylene terephthalate) to the second polymer is in a range of about 90: 10 to about 10: 90 (e.g., about 90: 10 to about 80: 20), and the spun yarn further comprises a second staple fiber comprising PLA. As used herein, "polylactic acid fiber" refers to a manufactured fiber in which the fiber-forming substance is composed of at least 85% by weight of lactate units derived from a natural sugar. PLA can be present in an amount of about 5 wt% to about 95 wt%, and meltspun staple fiber can be present in an amount of about 95 wt% to about 5 wt%, based on the total weight of the spun yarn. For example, the spun yarn may contain about 5 wt% PLA and about 95 wt% meltspun staple fiber, or about 10 wt% PLA and about 90 wt% meltspun staple fiber, or about 15 wt% PLA and about 85 wt% meltspun staple fiber, or about 20 wt% PLA and about 80 wt% meltspun staple fiber, or about 25 wt% PLA and about 75 wt% meltspun staple fiber, or about 30 wt% PLA and about 70 wt% meltspun staple fiber, or about 35 wt% PLA and about 65 wt% meltspun staple fiber, or about 40 wt% PLA and about 60 wt% meltspun staple fiber, or about 45 wt% PLA and about 55 wt% meltspun staple fiber, or about 50 wt% PLA and about 50 wt% meltspun staple fiber, or about 55 wt% PLA and about 45 wt% meltspun staple fiber, or about 60 wt% PLA and about 40 wt% meltspun staple fiber, or about 65 wt% PLA and about 35 wt% meltspun staple fiber, based on the total weight of the spun yarn, Or about 70 wt% PLA and about 30 wt% meltspun staple fiber, or about 75 wt% PLA and about 25 wt% meltspun staple fiber, or about 80 wt% PLA and about 20 wt% meltspun staple fiber, or about 85 wt% PLA and about 15 wt% meltspun staple fiber, or about 90 wt% PLA and about 10 wt% meltspun staple fiber, or about 95 wt% PLA and about 5 wt% meltspun staple fiber. The relative amounts of PLA and meltspun staple fiber are selected to provide desired characteristics to the spun yarn and fabrics made from the yarn.
In another embodiment, the spun yarn comprises melt spun staple fibers comprising a first polymer and a second polymer, the first polymer comprising PTT or PBT and the second polymer comprising PET or Co-PET, wherein the weight ratio of the first polymer to the second polymer is in the range of about 80: 20 to about 10: 90 or about 70: 30 to about 30: 70 or about 60: 40 to about 40: 60 or about 70: 30 to about 50: 50 and the spun yarn further comprises a second staple fiber comprising nylon. In another embodiment, the first polymer comprises poly (butylene terephthalate), and the weight ratio of poly (butylene terephthalate) to the second polymer is in a range of about 90: 10 to about 10: 90 (e.g., about 90: 10 to about 80: 20), and the spun yarn further comprises a second staple fiber comprising nylon. As used herein, "nylon fiber" refers to a manufactured fiber in which the fiber-forming substance is a long chain synthetic polyamide, with less than 85% of the amide linkages being directly attached to two aliphatic groups. The nylon can be present in an amount of about 5 wt% to about 95 wt% and the meltspun staple fiber can be present in an amount of about 95 wt% to about 5 wt%, based on the total weight of the spun yarn. For example, the spun yarn may contain about 5 wt% nylon and about 95 wt% meltspun staple fiber, or about 10 wt% nylon and about 90 wt% meltspun staple fiber, or about 15 wt% nylon and about 85 wt% meltspun staple fiber, or about 20 wt% nylon and about 80 wt% meltspun staple fiber, or about 25 wt% nylon and about 75 wt% meltspun staple fiber, or about 30 wt% nylon and about 70 wt% meltspun staple fiber, or about 35 wt% nylon and about 65 wt% meltspun staple fiber, or about 40 wt% nylon and about 60 wt% meltspun staple fiber, or about 45 wt% nylon and about 55 wt% meltspun staple fiber, or about 50 wt% nylon and about 50 wt% meltspun staple fiber, or about 55 wt% nylon and about 45 wt% meltspun staple fiber, or about 60 wt% nylon and about 40 wt% meltspun staple fiber, or about 65 wt% nylon staple fiber and about 35 wt% meltspun staple fiber, based on the total weight of the spun yarn, Or about 70 wt% nylon and about 30 wt% meltspun staple fiber, or about 75 wt% nylon and about 25 wt% meltspun staple fiber, or about 80 wt% nylon and about 20 wt% meltspun staple fiber, or about 85 wt% nylon and about 15 wt% meltspun staple fiber, or about 90 wt% nylon and about 10 wt% meltspun staple fiber, or about 95 wt% nylon and about 5 wt% meltspun staple fiber. The relative amounts of nylon and melt-spun staple fibers are selected to provide the desired characteristics for the spun yarn and fabrics made from the yarn.
In another embodiment, the spun yarn comprises melt-spun staple fibers comprising a first polymer and a second polymer, the first polymer comprising PTT or PBT and the second polymer comprising PET or Co-PET, wherein the weight ratio of the first polymer to the second polymer is in the range of about 80: 20 to about 10: 90 or about 70: 30 to about 30: 70 or about 60: 40 to about 40: 60 or about 70: 30 to about 50: 50 and the spun yarn further comprises a second staple fiber comprising an olefin. In another embodiment, the first polymer comprises poly (butylene terephthalate), and the weight ratio of poly (butylene terephthalate) to the second polymer is in a range of about 90: 10 to about 10: 90 (e.g., about 90: 10 to about 80: 20), and the spun yarn further comprises a second staple fiber comprising an olefin. As used herein, "olefin fiber" refers to any long chain synthetic polymer in which the fiber-forming substance is composed of at least 85 weight percent of ethylene, propylene, or other olefin units, with the exception of amorphous (non-crystalline) polyolefins that qualify as rubber fibers. The olefin may be present in an amount of about 5 wt% to about 95 wt% and the meltspun staple fiber may be present in an amount of about 95 wt% to about 5 wt%, based on the total weight of the spun yarn. For example, the spun yarn may contain about 5 wt% olefin fiber and about 95 wt% meltspun staple fiber, or about 10 wt% olefin fiber and about 90 wt% meltspun staple fiber, or about 15 wt% olefin fiber and about 85 wt% meltspun staple fiber, or about 20 wt% olefin fiber and about 80 wt% meltspun staple fiber, or about 25 wt% olefin fiber and about 75 wt% meltspun staple fiber, or about 30 wt% olefin fiber and about 70 wt% meltspun staple fiber, or about 35 wt% olefin fiber and about 65 wt% melt spun staple fiber, or about 40 wt% olefin fiber and about 60 wt% meltspun staple fiber, or about 45 wt% olefin fiber and about 55 wt% meltspun staple fiber, or about 50 wt% olefin fiber and about 50 wt% meltspun staple fiber, or about 55 wt% olefin fiber and about 45 wt% meltspun staple fiber, based on the total weight of the spun yarn, Or about 60 wt% olefin fibers and about 40 wt% meltspun staple fibers, or about 65 wt% olefin fibers and about 35 wt% meltspun staple fibers, or about 70 wt% olefin fibers and about 30 wt% meltspun staple fibers, or about 75 wt% olefin fibers and about 25 wt% meltspun staple fibers, or about 80 wt% olefin fibers and about 20 wt% meltspun staple fibers, or about 85 wt% olefin fibers and about 15 wt% meltspun staple fibers, or about 90 wt% olefin fibers and about 10 wt% meltspun staple fibers, or about 95 wt% olefin fibers and about 5 wt% meltspun staple fibers. The relative amounts of the olefin fibers and the meltspun staple fibers are selected to provide desired characteristics to the spun yarn and fabrics made from the yarn.
In another embodiment, the spun yarn comprises melt spun staple fibers comprising a first polymer and a second polymer, the first polymer comprising PTT or PBT and the second polymer comprising PET or Co-PET, wherein the weight ratio of the first polymer to the second polymer is in the range of about 80: 20 to about 10: 90 or about 70: 30 to about 30: 70 or about 60: 40 to about 40: 60 or about 70: 30 to about 50: 50 and the spun yarn further comprises a second staple fiber comprising an acetate ester. In another embodiment, the first polymer comprises poly (butylene terephthalate), and the weight ratio of poly (butylene terephthalate) to the second polymer is in a range of about 90: 10 to about 10: 90 (e.g., about 90: 10 to about 80: 20), and the spun yarn further comprises a second staple fiber comprising an acetate ester. As used herein, "cellulose acetate fibers" refers to manufactured fibers in which the fiber-forming substance is cellulose acetate and includes diacetate and triacetate. Diacetate is defined as cellulose acetate fiber in which more than 74% and less than 92% of the hydroxyl groups are acetylated (degree of esterification higher than 2.22 and lower than 2.76). Triacetate is defined as a cellulose acetate fiber in which more than 92% of the hydroxyl groups are acetylated (degree of esterification higher than 2.76 and lower than 3.00). The cellulose acetate may be present in an amount of about 5 wt% to about 95 wt% and the meltspun staple fibers may be present in an amount of about 95 wt% to about 5 wt%, based on the total weight of the spun yarn. For example, the spun yarn may contain about 5 wt% acetate fiber and about 95 wt% meltspun staple fiber, or about 10 wt% acetate fiber and about 90 wt% meltspun staple fiber, or about 15 wt% acetate fiber and about 85 wt% meltspun staple fiber, or about 20 wt% acetate fiber and about 80 wt% meltspun staple fiber, or about 25 wt% acetate fiber and about 75 wt% meltspun staple fiber, or about 30 wt% acetate fiber and about 70 wt% meltspun staple fiber, or about 35 wt% acetate fiber and about 65 wt% staple fiber, or about 40 wt% acetate fiber and about 60 wt% meltspun staple fiber, or about 45 wt% acetate fiber and about 55 wt% meltspun staple fiber, or about 50 wt% acetate fiber and about 50 wt% spun staple fiber, or about 55 wt% acetate fiber and about 45 wt% melt spun staple fiber, based on the total weight of the spun yarn, Or about 60 wt% acetate fiber and about 40 wt% meltspun staple fiber, or about 65 wt% acetate fiber and about 35 wt% meltspun staple fiber, or about 70 wt% acetate fiber and about 30 wt% meltspun staple fiber, or about 75 wt% acetate fiber and about 25 wt% meltspun staple fiber, or about 80 wt% acetate fiber and about 20 wt% meltspun staple fiber, or about 85 wt% acetate fiber and about 15 wt% meltspun staple fiber, or about 90 wt% acetate fiber and about 10 wt% meltspun staple fiber, or about 95 wt% acetate fiber and about 5 wt% meltspun staple fiber. The relative amounts of acetate fibers and meltspun staple fibers are selected to provide desired characteristics to the spun yarn and fabrics made from the yarn.
In another embodiment, the spun yarn comprises melt-spun staple fibers comprising a first polymer and a second polymer, the first polymer comprising PTT or PBT and the second polymer comprising PET or Co-PET, wherein the weight ratio of the first polymer to the second polymer is in the range of about 80: 20 to about 10: 90 or about 70: 30 to about 30: 70 or about 60: 40 to about 40: 60 or about 70: 30 to about 50: 50 and the spun yarn further comprises a second staple fiber comprising a polyester, such as poly (ethylene terephthalate), poly (1, 3-trimethylene terephthalate), or poly (butylene terephthalate). In another embodiment, the first polymer comprises poly (butylene terephthalate), and the weight ratio of poly (butylene terephthalate) to the second polymer is in a range of about 90: 10 to about 10: 90 (e.g., about 90: 10 to about 80: 20), and the spun yarn further comprises a second staple fiber comprising polyester. The polyester may be present in an amount of about 5 wt% to about 95 wt% and the meltspun staple fibers may be present in an amount of about 95 wt% to about 5 wt%, based on the total weight of the spun yarn. For example, the spun yarn may contain about 5 wt% polyester fiber and about 95 wt% meltspun staple fiber, or about 10 wt% polyester fiber and about 90 wt% meltspun staple fiber, or about 15 wt% polyester fiber and about 85 wt% meltspun staple fiber, or about 20 wt% polyester fiber and about 80 wt% meltspun staple fiber, or about 25 wt% polyester fiber and about 75 wt% meltspun staple fiber, or about 30 wt% polyester fiber and about 70 wt% meltspun staple fiber, or about 35 wt% polyester fiber and about 65 wt% meltspun staple fiber, or about 40 wt% polyester fiber and about 60 wt% meltspun staple fiber, or about 45 wt% polyester fiber and about 55 wt% meltspun staple fiber, or about 50 wt% polyester fiber and about 50 wt% meltspun staple fiber, or about 55 wt% polyester fiber and about 45 wt% spun staple fiber, or about 45 wt% polyester fiber and about 45 wt% spun staple fiber, Or about 60 wt% polyester fiber and about 40 wt% meltspun staple fiber, or about 65 wt% polyester fiber and about 35 wt% meltspun staple fiber, or about 70 wt% polyester fiber and about 30 wt% meltspun staple fiber, or about 75 wt% polyester fiber and about 25 wt% meltspun staple fiber, or about 80 wt% polyester fiber and about 20 wt% meltspun staple fiber, or about 85 wt% polyester fiber and about 15 wt% meltspun staple fiber, or about 90 wt% polyester fiber and about 10 wt% meltspun staple fiber, or about 95 wt% polyester fiber and about 5 wt% meltspun staple fiber. The relative amounts of polyester fibers and meltspun staple fibers are selected to provide desired characteristics to the spun yarn and fabrics made from the yarn. The spun yarn may have a cotton count (Ne) of about 4 to about 80 (e.g., about 10 to about 60, or about 12 to about 40).
The melt spun staple fibers are cut to a desired length for blending with a second fiber and subsequently processed on a cotton or wool spinning system. For example, a spun yarn comprising meltspun staple fibers and cotton, flax, polylactic acid, acrylon, nylon, olefin, acetate, polyester, or rayon fibers may generally be processed on a cotton spinning system. Spun yarns comprising melt-spun staple fibers and wool, angora, mohair or cashmere fibers can be processed on a wool spinning system in general.
To form a spun yarn, the meltspun staple fibers and optionally at least one second staple fiber are first blended, for example by stack mixing (a process in which a bundle of fibers is opened, mixed and laid down in layers). A series of coarse and fine opening machines can be used in succession, for example to open the fiber bundles into fiber tufts of smaller size in a blowing chamber. The smaller fiber bundles are then carded to form a continuous strand of fibers (called a sliver) in which substantially all of the fibers are oriented along the sliver axis. The sliver from the carding machine can have very high quality/length variation, so multiple carded slivers (i.e., 6) are typically combined and drafted simultaneously by the same amount (i.e., 6 times) to further orient the fibers in the resulting sliver, for example, using a draw frame or other methods known in the art. The sliver delivered from the final draw frame has minimal mass/length variation but has a higher linear density than that required in the final spinning, thus reducing the linear density of the sliver during drawing. Typically, the drawing process operates in two steps, where partial drafting and twisting are performed to make the roving. The roving is converted into a spun yarn by further drawing it on a final spinning machine using known processes such as ring spinning, open end spinning, air jet spinning and vortex spinning. The spun yarn can be wound in ring spinning onto small packages called "cop"; several cop tubes may be spliced and wound onto a larger final package called a "cone".
Woven and knitted fabrics can be made from the spun yarns disclosed herein. Examples of stretch fabrics include circular, flat and warp knit fabrics, and plain, twill and satin woven fabrics. Articles such as garments can be made from fabrics comprising the spun yarns disclosed herein. The nonwoven fabric can be made from the staple fibers disclosed herein and can be used in articles such as wipes, diapers, napkins, and personal care articles. Nonwoven fabrics can also be used as base materials for coated fabrics, and in various other applications, such as apparel and home textiles.
The spun yarns disclosed herein may be used to make fabrics, such as woven or knitted fabrics. In one embodiment, the fabric containing the spun yarns disclosed herein is a woven fabric having warp yarns and weft yarns. In one embodiment, the warp yarns comprise spun yarns as disclosed herein. In another embodiment, the weft yarn comprises a spun yarn as disclosed herein. In another embodiment, the warp and weft yarns each comprise a spun yarn as disclosed herein. The woven fabric may further comprise other yarns or continuous filaments, for example in the warp, in the weft or in both the warp and the weft. In another embodiment, the spun yarns disclosed herein are used in the warp and the spun yarns comprising natural fibers are used in the weft. In another embodiment, the spun yarns disclosed herein are used in the warp and the spun yarns comprising synthetic fibers are used in the weft. In yet another embodiment, spun yarns containing natural fibers are used in the warp and the spun yarns disclosed herein are used in the weft. In another embodiment, comprising synthetic fibersSpinning is used in the warp and the spinning disclosed herein is used in the weft. In yet another embodiment, the spinning disclosed herein is used in the warp as well as in the weft. Knitted fabrics can be made using the spun yarns disclosed herein alone or in combination with spun yarns comprising natural or synthetic fibers. Woven fabrics containing the spun yarns disclosed herein may have, for example, about 80g/m2To about 600g/m2Fabric weights within the range.
Fabrics comprising the spun yarns disclosed herein can provide advantages over fabrics composed of spun yarns of PET, cotton, rayon, PTT, or combinations thereof and lacking the same construction of the meltspun staple fibers disclosed herein. For example, a fabric comprising a spun yarn disclosed herein comprising meltspun staple fibers may have a softer hand (i.e., feel softer) than a fabric of PET, cotton, rayon, or a combination thereof, and greater loft as indicated by greater fabric thickness. Fabrics comprising the spun yarns disclosed herein may have better dyeability than fabrics of the same construction consisting of PET, cotton, rayon, or combinations thereof. The fabrics disclosed herein can be dyed darker, darker and at lower temperatures than similarly constructed PET fabrics. The fabrics disclosed herein can have better dye absorption than PET fabrics when dyed at lower temperatures, which reduces cost by conserving energy. For example, a fabric comprising the spun yarns disclosed herein can be dyed more deeply (i.e., have a lower L value when measured under a D65 light source) than a simultaneously dyed PET fabric, even when dyed under conditions of 100 ℃ and can also be dyed more deeply than a PET fabric as compared to a PET fabric dyed at 130 ℃. The property of absorbing more dye, absorbing dye at lower temperature and dyeing deeper may be referred to as "better dyeability" of the fabric. The woven fabrics disclosed herein may also have improved drape, as evidenced, for example, by higher drape areas and drape coefficient values (e.g., as determined by method BS 5058). A combination of softer hand and improved drape is particularly desirable in fabrics. Additionally, the fabrics disclosed herein exhibit less pilling (higher pilling rating value), e.g., as determined by the ASTM D4970 method, and better abrasion resistance, as compared to fabrics of the same construction consisting of PET, cotton, rayon, or combinations thereof. The fabrics disclosed herein have better tear strength in the warp and/or weft direction compared to fabrics of the same construction consisting of PET, cotton, rayon, or combinations thereof. A knit fabric comprising the spun yarn disclosed herein can have a higher degree of recovery than a knit fabric of the same construction consisting of polyethylene terephthalate, cotton, rayon, or a combination thereof.
Non-limiting examples of embodiments disclosed herein include:
1. a spun yarn, comprising: melt-spun staple fiber comprising a first polymer comprising poly (1, 3-trimethylene terephthalate) (PTT) or poly (butylene terephthalate) (PBT) and a second polymer comprising poly (ethylene terephthalate) (PET) or Co-PET, wherein the Co-PET is a poly (ethylene terephthalate) copolymer comprising isophthalic acid monomers; and wherein the first polymer comprises poly (1, 3-trimethylene terephthalate) and the weight ratio of the poly (1, 3-trimethylene terephthalate) to the second polymer is in the range of about 80: 20 to about 10: 90; or the first polymer comprises poly (butylene terephthalate), and the weight ratio of the poly (butylene terephthalate) to the second polymer is in the range of about 90: 10 to about 10: 90.
2. The spun yarn of embodiment 1, wherein the first polymer comprises poly (1, 3-trimethylene terephthalate) and the second polymer comprises poly (ethylene terephthalate).
3. The spun yarn of embodiment 1 or 2, wherein the first polymer comprises poly (1, 3-trimethylene terephthalate) and the second polymer comprises Co-PET.
4. The spun yarn of embodiment 1, wherein the first polymer comprises poly (butylene terephthalate) and the second polymer comprises poly (ethylene terephthalate).
5. The spun yarn of embodiment 1 or 4, wherein the first polymer comprises poly (butylene terephthalate) and the second polymer comprises Co-PET.
6. The spun yarn of embodiment 1, 3 or 5, wherein the second polymer comprises Co-PET, and the Co-PET contains about 0.5 to about 10 mole percent of isophthalic monomer based on total copolymer composition.
7. A spun yarn of embodiment 1, 2, 3, 4, 5 or 6 wherein the weight ratio is in the range of about 70: 30 to about 30: 70.
8. The spun yarn of embodiment 1, 2, 3, 4, 5 or 6 wherein the weight ratio is in the range of about 60: 40 to about 40: 60.
9. A spun yarn of embodiment 1, 2, 3, 4, 5 or 6 wherein the weight ratio is in the range of about 70: 30 to about 50: 50.
10. The spun yarn of embodiment 1, 2, 3, 4, 5, 6, or 7 wherein the weight ratio of the poly (1, 3-trimethylene terephthalate) or the poly (tetramethylene terephthalate) to the second polymer is in the range of about 70: 30 to about 30: 70.
11. The spun yarn of embodiments 1, 2, 3, 4, 5, 6, 7, 8, 9, or 10, wherein the spun yarn has a scouring shrinkage of at least about 6% as determined according to ASTM D2259.
12. The spun yarn of embodiment 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, or 11, further comprising a second staple fiber in an amount of from about 5 wt% to about 95 wt% based on the total weight of the spun yarn.
13. The spun yarn of embodiment 12, wherein the second staple fiber comprises polylactic acid, acrylic, nylon, olefin, acetate, rayon, polyester, cotton, flax, wool, angora, mohair, alpaca, cashmere, or mixtures thereof.
14. The spun yarn of embodiment 12, wherein the second staple fiber comprises cotton or wool.
15. The spun yarn of embodiment 12, 13, or 14, wherein the second staple fiber comprises cotton.
16. The spun yarn of embodiments 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, or 15, wherein the spun yarn has a cotton count of about 4Ne to about 80 Ne.
17. The spun yarn of embodiment 12, 13 or 14, wherein the second staple fiber comprises wool.
18. The spun yarn of embodiments 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, or 17, wherein the spun yarn has a worsted count in the range of 7Nm to 120 Nm.
19. A fabric comprising the spun yarn of embodiments 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, or 18.
20. The fabric of embodiment 19, wherein the fabric has a softer hand and better drape than a fabric of the same fabric construction consisting of rayon, polyethylene terephthalate, cotton, or a combination thereof.
21. The fabric of embodiment 19 or 20, wherein the fabric has better dyeability than a fabric of the same fabric construction consisting of polyethylene terephthalate, cotton, rayon, or a combination thereof.
22. The fabric of embodiment 19, 20, or 21, wherein the fabric has better abrasion resistance as determined according to ASTM D4966 standard test method as compared to a fabric of the same fabric construction consisting of polyethylene terephthalate, cotton, rayon, or a combination thereof.
23. The fabric of embodiment 19, 20, 21, or 22, wherein the fabric has less pilling (higher pilling rating value) as determined according to ASTM D4970 standard test method as compared to a fabric of the same fabric construction consisting of polyethylene terephthalate, cotton, rayon, or a combination thereof.
24. The fabric of embodiment 19, 20, 21, 22, or 23, wherein the fabric has greater bulk as determined according to ASTM D1777 standard test method as compared to a fabric of the same fabric construction consisting of polyethylene terephthalate, cotton, rayon, or a combination thereof.
25. The fabric of embodiments 19, 20, or 21, wherein the fabric has at least one of the following compared to a fabric of the same fabric construction consisting of polyethylene terephthalate, cotton, rayon, or a combination thereof:
i) better wear resistance as determined according to ASTM D4966 standard test method;
ii) a higher pilling note value as determined according to ASTM D4970 standard test method; or
iii) greater loft as determined according to ASTM D1777 standard test method.
26. The fabric of embodiment 19, 20, 21, 22, 23, 24, or 25, wherein the fabric is a woven fabric having warp and weft yarns.
27. The fabric of embodiment 26, wherein the warp yarns comprise the yarns of embodiments 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, or 18.
28. The fabric of embodiment 26 or 27, wherein the weft yarns comprise the spun yarns of embodiments 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, or 18.
29. The fabric of embodiment 26, 27 or 28, wherein both the warp and the weft yarns each comprise a spun yarn as described in embodiments 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17 or 18.
30. The fabric of embodiments 19, 20, 21, 22, 23, 24, or 25, wherein the fabric is a knitted fabric.
31. The fabric of embodiment 30, wherein the knit fabric has a higher degree of recovery as determined according to method BS 4294 as compared to a knit fabric of the same fabric construction consisting of polyethylene terephthalate, cotton, rayon, or a combination thereof.
32. An article comprising the fabric of embodiment 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, or 31.
33. The article of embodiment 32, wherein the article is a garment.
34. A melt-spun staple fiber comprising a first polymer comprising poly (1, 3-trimethylene terephthalate) or poly (tetramethylene terephthalate) and a second polymer comprising poly (ethylene terephthalate) or Co-PET, wherein Co-PET is a poly (ethylene terephthalate) copolymer comprising isophthalic acid monomers, said staple fiber having:
a) a weight ratio of poly (1, 3-trimethylene terephthalate) to the second polymer in the range of about 80: 20 to about 10: 90; or
A weight ratio of poly (butylene terephthalate) to the second polymer in a range of about 90: 10 to about 10: 90; and
b) a dry heat shrinkage of less than 6% as determined by dry heat shrinkage.
35. The meltspun staple fiber of embodiment 34, wherein the weight ratio of the poly (1, 3-trimethylene terephthalate) or the poly (butylene terephthalate) to the second polymer is in the range of about 70: 30 to about 30: 70.
36. The meltspun staple fiber of embodiment 34, wherein the weight ratio of the poly (1, 3-trimethylene terephthalate) or the poly (butylene terephthalate) to the second polymer is in the range of about 70: 30 to about 50: 50.
37. The melt spun staple fiber of embodiment 34, 35, or 36, wherein said first polymer comprises poly (1, 3-trimethylene terephthalate) and said second polymer comprises poly (ethylene terephthalate).
38. The melt spun staple fiber of embodiment 34, 35, or 36, wherein said first polymer comprises poly (1, 3-trimethylene terephthalate) and said second polymer comprises Co-PET.
39. The melt spun staple fiber of embodiment 34, 35, or 36, wherein said first polymer comprises poly (butylene terephthalate) and said second polymer comprises poly (ethylene terephthalate).
40. The melt spun staple fiber of embodiment 34, 35, or 36, wherein said first polymer comprises poly (butylene terephthalate) and said second polymer comprises Co-PET.
41. The melt spun staple fiber of embodiment 34, 35, 36, 38, or 40, wherein the second polymer comprises Co-PET, and the Co-PET contains from about 0.5 mole percent to about 10 mole percent of isophthalic monomer based on total copolymer composition.
Examples of the invention
As used herein, "comp.ex." refers to a comparative example; "ex." refers to examples; "rpm" means revolutions per minute; "wt%" means weight percent; "dL/g" is deciliter per gram; "g" is gram; "mg" is mg; "° c" means degrees celsius; "min" is minutes; "h" is hours; "s" is seconds; "lb" is pounds; "kg" is kg; "mm" is millimeters; "m" is rice; "gpl" is grams per liter; "m/min" is meters per minute; "mol" is a mole; "kg" is kg; "ppm" is parts per million; "Hz" is Hertz; "cN" is centiNewtons; "rpm" is revolutions per minute; "wt" is weight; "dpf" is the denier per filament; "g/d" is grams per denier; "Ne" refers to cotton count (english) and is a measure of linear density, defined as the henx number (850 yards or 770 meters) of a 1 pound (0.45 kilogram) weight of hank material; "Nm" refers to metric count and to the number of 1000 meter units in a kilogram of yarn; "dtex" refers to dtex; "AATCC" refers to the American Association of textile chemists and colorists; "ASTM" refers to the American society for testing and materials; and "BS" refers to the british standards institute.
Material
All materials were used as received unless otherwise indicated.
Containing 0.3% TiO2And poly (1, 3-trimethylene terephthalate) (PTT) having an inherent viscosity of 0.96dL/g was obtained from dupont, e.i. intra mool, wilmington, tera in combination with K2266.
Co-PET containing 1.7 mole% isophthalic acid (IPA) monomer, 48.4 mole% terephthalic acid (TPA) monomer and 49.9 mole% Ethylene Glycol (EG) monomer was obtained from southern Asia plastics, Inc. (Leikecheng S.C 29560, U.S.A., post office box 939). The Co-PET composition was determined by NMR analysis and is given based on the total copolymer composition. The intrinsic viscosity of Co-PET was 0.80 dL/g.
Post-consumer recycle Co-PET containing 1.1 mol% IPA monomer, 49.1 mol% TPA monomer, and 49.9 mol% EG monomer was obtained from wilkinson corporation (stephani s.c.29301, post office box 171898, usa). The Co-PET composition was determined by NMR analysis and is given based on the total copolymer composition. The intrinsic viscosity of Co-PET was 0.76 dL/g.
Method
The "Co-PET" composition was determined by NMR analysis using the following procedure. The Co-PET pellets were freeze-ground to a powder form, then approximately 18mg were weighed into an NMR tube and 5: 1CDCl was added3: TFA-D (5: 1 deuterated chloroform/deuterated trifluoroacetic acid) was added to a total volume of 0.6 mL. Vortex the sample to dissolve the Co-PET. Proton NMR spectra were obtained within 30 minutes after dissolution.
Proton NMR spectra were taken at 30 ℃ on a 500MHz Bruker Avance III HD NMR equipped with a 5mm CPQCI (indirect) cryoprobe. The following parameters were used for the acquisition: cycle delay was 30 seconds, acquisition time was 4 seconds, 90 degree pulse was 8.0 seconds, spectral window was 10000Hz, point 79998, and a total of 64 scans/transients were collected and averaged. The spectra were referenced to a residual proton signal of 7.24ppm chloroform-d and treated with 0.10Hz lb and then zero-filled to 512 k.
The co-PET composition was calculated from the integration of the signals at approximately 8.7ppm, 8.1ppm, and 4.8ppm, corresponding to isophthalic acid, terephthalic acid, and ethylene glycol between the terephthalic acid groups, respectively. The isophthalic signal used represents 1 mole of protons and therefore its integral is already relative. The terephthalic acid integral represents 4 moles of terephthalic acid protons and includes 2 moles of isophthalic acid protons; the relative integral of terephthalic acid was determined by the following procedure: the relative integral of isophthalic acid was subtracted by 2 times and the remainder was divided by 4. The integral associated with ethylene glycol corresponds to 4 moles of ethylene glycol protons, and the relative integral is determined by dividing the measured integral by 4. The three relative integrals are added, and then the relative mol% value is calculated as each corresponding relative integral divided by the sum, then multiplied by 100%.
The dry heat shrinkage of the undrawn meltspun fibers was determined using the following procedure, referred to herein as dry heat shrinkage. A skein having a diameter of 50cm and a loop number of 10 was prepared, and its length was measured with a weight of 20 g. Two such rings were shrunk by exposure to 40 ℃ for 20 hours at zero applied tension. The rings were cooled to 21 ℃ at 65% relative humidity and then the length was re-measured at a weight of 20 g. Percent dry heat shrinkage was calculated as follows:
for melt spun staple fibers, the fiber properties were determined using the automated single fiber testing system FAVIMAT + and using the following method. Denier is determined according to ASTM D1577 standard test method for linear density of textile fibers. Fracture toughness and elongation were determined according to the tensile properties of ASTM D3822 for individual textile fibers.
The crimp characteristics of staple fibers are characterized by crimp shrinkage, crimp stability, and crimp recovery. Crimp contraction is the difference in length of crimped fibers versus uncrimped fibers. Measuring the crimp length L0 at a low load of 0.001cN/dtex and the decurled length L1 at a heavy load of 0.1cN/dtex allows calculating the crimp contraction as [ (L1-L0)/L1 ]. 100.
Curl stability is a measure of curl stability under a given load. Crimp stability can be measured by determining the degree of recovery of the staple length when the load is removed. Crimp stability can be calculated as [ (L1-L2/(L1-L0) ] 100 60 seconds after 10 seconds of application of a heavier load of 0.1cN/dtex (to determine L1) with L2 as the length of the staple fiber (measured at 0.001 cN/dtex).
Crimp recovery refers to the difference in length L1 of the uncrimped fiber from the fiber length L2 after releasing the crimp removal force, expressed as a percentage of uncrimped fiber: [ (L1-L2)/L1 ]. 100.
Melt spun fiber examples
Comparative example A
Melt spun PTT fiber
Will contain 0.3% TiO2And poly (1, 3-trimethylene terephthalate) (PTT) having an inherent viscosity of 0.96dL/g was dried in a vacuum oven under a nitrogen blanket at 120 ℃ for 16 hours and melt-extruded into a bundle of 34 filament yarns of circular cross-section using a twin-screw extruder spinning machine. The extruder melt zone temperature was maintained between 180 ℃ and 255 ℃. The polymer throughput was 14.06g/min with a winder speed of 1250m/m, resulting in a spun denier per filament of 2.9.
The dry heat shrinkage of the yarn bundle was determined to be 47%.
Example 1
Undrawn melt spun fibers containing PTT and Co-PET
Will contain 0.3% TiO2And poly (1, 3-propylene terephthalate) having an inherent viscosity of 0.96dL/g was melt blended with poly (ethylene terephthalate) -Co-isophthalate (Co-PET) (from Nana Plastics, Inc. (Nan Ya Plastics)) having an inherent viscosity of 0.80dL/g in a twin screw extruder at a weight ratio of 50/50 to form composite pellets. The extruder throughput was 150 lb/hr (68.04 kg/hr, 0.0189kg/s) and the melt temperature at the extruder outlet was below 285 ℃ as measured by a hand-held thermocouple.
And (3) mixing the PTT: the Co-PET composite pellets were dried in a vacuum oven under a nitrogen blanket at 120 ℃ for 16 hours and melt extruded into a bundle of 34 filament yarns of circular cross-section using a twin screw extruder spinning machine. The extruder melt zone temperature was maintained between 180 ℃ and 255 ℃. The polymer throughput was 14.06g/min or 21.52 g/min. For each throughput, the winder speed was 750m/m or 1250m/m, such that the spun denier per filament was in the range of 3.3 to 7.7. The dry heat shrinkage of the yarn bundle (tow) was measured in the range of 1.2% to 3.1%. This amount of dry heat shrinkage in the undrawn fiber is very low and indicates the stability of the material during storage. The results are shown in the table below.
Table 1 example 1: spinning conditions and dry heat shrinkage of filament bundles
| Through the amount of water, g/min | Speed of the winder, m/m | Dry heat shrinkage ratio of% |
| 14.06 | 750 | 1.4 |
| 14.06 | 1250 | 3.1 |
| 21.52 | 750 | 1.2 |
| 21.52 | 1250 | 2.3 |
Example 2
Undrawn melt spun fibers containing PTT and Co-PET
Will contain 0.3% TiO2And poly (1, 3-propylene terephthalate) having an inherent viscosity of 0.96dL/g was melt blended with a fiber grade post consumer Co-PET containing 1.1 mol% IPA monomer, 49.1 mol% TPA monomer and 49.9 mol% EG monomer in a twin screw extruder at a weight ratio of 50/50 to form composite pellets. The intrinsic viscosity of Co-PET was 0.76 dL/g. The extruder throughput was 150lb/h (0.0189kg/s) and the melt temperature at the extruder outlet was below 285 ℃ as measured by a hand-held thermocouple.
And (3) mixing the PTT: the Co-PET composite pellets were dried in a vacuum oven under a nitrogen blanket at 120 ℃ for 16 hours and melt extruded into a bundle of 34 filament yarns of circular cross-section using a twin screw extruder spinning machine. The extruder melt zone temperature was maintained between 180 ℃ and 255 ℃. The polymer throughput was 14.06g/min or 21.52 g/min. For each throughput, the winder speed was 750m/m or 1250m/m, resulting in a spun denier per filament of 3.3 to 7.7. The dry heat shrinkage of the yarn bundle was measured in the range of 1.2% to 2.5%. This amount of dry heat shrinkage in the undrawn fiber is very low and indicates the stability of the material during storage. The results are shown in the table below.
Table 2 example 2: spinning conditions and dry heat shrinkage of filament bundles
| Through the amount of water, g/min | Speed of the winder, m/m | Dry heat shrinkage ratio of% |
| 21.52 | 750 | 1.2 |
| 21.52 | 1250 | 3 |
| 14.06 | 750 | 1.2 |
| 14.06 | 1250 | 2.5 |
Example 3
Melt spun staple fibers comprising PTT and Co-PET
Will contain 0.3% TiO2And poly (1, 3-propylene terephthalate) having an inherent viscosity of 0.96dL/g was melt blended with Co-PET (from south Asia plastics corporation) in a weight ratio of 50/50 in a twin screw extruder to form composite pellets. The extruder throughput was 150lb/h (0.0189kg/s) and the melt temperature at the extruder outlet was below 285 ℃ as measured by a hand-held thermocouple. The composite was left at 145 ℃ for 20 hours.
6800 round cross-section filaments were spun using a single extruder spinning machine with radial quench. The extruder melt zone temperature was maintained at 252 ℃ to 274 ℃. The polymer throughput was 0.379 g/min/hole and the feed roll speed was 1100 m/m. The spinning dpf is 3.0. The spun fibers were collected in a tank. Twenty-two cans, 448,800 denier total, feed the draw-crimp-cut/bale module. Staple melt spun fibers are produced using a typical cotton count staple process utilizing a multi-stage draw, crimper, annealer and cutter. The tow was immersed in a 22 ℃ finishing bath (0.5% strength, Seilacher, commercially available from schell + Seilacher). The tow was first drawn in a 0.5% strength finishing bath at 80 ℃ between a 22 ℃ feed roll running at 36m/m and a 75 ℃ heated draw roll running at 110.88m/m, resulting in a first stage draw ratio of 3.08. The drawn tow was pulled through a steam cabinet at 100 ℃ by a 165 ℃ downstream heated roller running at 110.88 m/m. The tow was passed through another set of 165 ℃ rolls running at 99.8 m/m. The finish (6% consistency) was sprayed and the tow was passed through a 25 ℃ chilled drum running at 99.8 m/m. The tow enters a steam box at 100 ℃ and then enters a 50mm crimper. The crimper speed was 100 m/m. The crimper rolls were at a temperature and pressure of 65 c and 0.8bar, respectively. The crimped tow was annealed in a plate and strip dryer at 100 ℃ for 8 minutes and finally cut to produce staple melt spun fibers having the following characteristics:
denier per filament (dpf) 1.2, Coefficient of Variation (CV) 8.79%
Toughness 4.89g/d, CV 8.79%
Elongation 45.97% and CV 19.59%
The length of the short fiber is 37-38mm
Curl number (full sine arc) of 12/inch
Crimp stability 67.09% and CV 22.1%
The yarn finishing degree is 0.26 percent
Example 4
Melt spun fibers comprising PTT and Co-PET
Will contain 0.3% TiO2And poly (1, 3-propylene terephthalate) having an inherent viscosity of 0.96dL/g was melt blended with Co-PET (from south Asia plastics corporation) in a weight ratio of 50/50 in a twin screw extruder to form composite pellets. The extruder throughput was 150lb/h (0.0189kg/s) and the melt temperature at the extruder outlet was below 285 ℃ as measured by a hand-held thermocouple. The composite was left at 145 ℃ for 20 hours.
6800 round cross-section filaments were spun using a single extruder spinning machine with radial quench. The extruder melt zone temperature was maintained at 252 ℃ to 274 ℃. The polymer throughput was 0.493 g/min/hole and the feed roll speed was 600 m/m. The spinning dpf is 7.2. The spun fibers were collected in a tank. Ten cans, 489 total, 600 denier, feed draw-crimp-cut/bale module. The melt spun staple fibers are produced using a typical staple count staple process utilizing a multi-stage draw, crimper, annealer and cutter. The tow was immersed in a 22 ℃ finishing bath (0.5% concentration, Seilacher, commercially available from hilsenehh corporation). The tow was first drawn in a conditioning bath at 80 ℃ with a concentration of 0.5% between a 22 ℃ feed roll running at 30m/m and a 75 ℃ heated draw roll running at 109.3m/m so that the first stage draw ratio was 3.64. The tow was pulled through a 165 ℃ downstream heated roller running at 103.9 m/m. The finish (6% consistency) was sprayed and the tow was passed through a 25 ℃ chilled drum running at 101.9 m/m. The tow enters a steam box at 100 ℃ and then enters a 50mm crimper. The crimper speed was 110.6 m/m. The crimper rolls were at a temperature and pressure of 65 c and 1.3bar, respectively. The crimped tow was annealed in a plate and strip dryer at 100 ℃ for 8 minutes and finally cut to produce staple fibers having the following characteristics:
dpf＝2.5，CV＝6.98％
toughness 3.83g/d, CV 8.74%
Elongation 69.72% and CV 25.26%
The length of the short fiber is 82-125mm and the average value is 84mm
Curl number (full sine arc) is 14/inch
Crimp stability 91.19% and CV 8.31%
The yarn finishing degree is 0.21%
Commercially available spun yarn
Table 3 lists the commercially available spun yarns and their abbreviations in the following table. Some of these yarns were used to prepare the fabrics of the comparative examples.
Table 3. abbreviation of commercially available spun yarn.
Examples of spun yarns made on cotton systems
The melt spun staple fibers from example 3 were used to prepare the spun yarns of examples 5-10. The spun yarn and intermediate material (such as sliver) obtained in the preparation of the spun yarn were evaluated using the following method:
toughness was measured at 5m/min using a CRE type tensile testing apparatus (such as Uster Tensorapid-3) with a nip speed of 5m/min and a sample length of 50 cm.
The% elongation at break is measured using a CRE type tensile testing apparatus (such as Uster Tensorapid-3) at a nip speed of 5m/min and a sample length of 50 cm.
Example 5
20s Ne spun yarn containing 100% melt spun fibers
A spun yarn was prepared using a cotton spinning system according to the following procedure.
The meltspun staple fibers from example 3 were removed from the package and hand mixed. The average staple length was 40mm and the denier was 1.2D. The fibers were mixed and placed in layers during stack mixing and then conditioned at 65% relative humidity and 25 ℃ for 24 hours. The mass of fibers is removed from the stack by vertically withdrawing the material and feeding it into a blow chamber line that is typically used for spinning synthetic fibers. During the process, the size of the fiber cluster was broken from about 150mg to about 30 mg. The following parameters were used:
setting of feed roll and beater blade is 1.7mm
Cotton lap linear density about 400g/m
All waste collection settings are close to "0"
The speed of the wide beater is 400rpm
Refiner speed 450rpm
Next, 30mg fiber bundles were carded into individual fibers and arranged into a strand of continuous fibers (sliver) with the fibers oriented along the length of the sliver. The following parameters were used:
machine type, model: carding machine, LRC1/3
M/c production speed 70M/min
Feed disc and licker-in gauge sheet 32thou (thousandths of an inch)
Cover gauge 14, 12 through
Bell mouth size of 4.0mm or more
Sliver linear density 4.5g/m
Licker-in speed 650rpm
Cylinder speed 350rpm
Cover plate speed 6in/min
Final sliver linear density 5.0g/m
In the draw frame, six carded slivers are combined together and simultaneously drawn by the same amount (6 times) to further orient the fibers in the resulting sliver. The first step is called breaker draw and the second step is called finisher draw. The following parameters were used:
machine type and model: drawing frame, LR RSB 851
Front/rear of bottom roller gauge sheet 44/48mm
Flare diameter 3.8mm
Sliver linear density 4.5g/m
Hardness of top rubber roller 83 °
Breaking draft 1.4 for the breaker and finishing draw 1.4 for the finisher
Web tension draft 1
Frame tension draft of 1.02
The conveying speed is 250MPM for I drawing frame, and 350MPM for II drawing frame
Draw frame I and II were 6
Final sliver linear density 5.00g/m
The percent non-uniformity is 1.88 for the finisher sliver
Next, a roving is prepared on a roving frame from the sliver delivered from the final draw frame. Partial twisting is also performed in the roving frame to impart strength to the roving. The following parameters were used:
machine type and model: roving frame, LF 4200
Gauge block size 5.5mm
Spindle speed 1000rpm
Twist factor of 0.70
Roving hench 0.75s Ne
Roll gauge sheet 48/55/62mm
The feeding frame is 36mm
The Uster value (unevenness) of the roving was found to be 3.16% and the Uster% (unevenness%) was 3.26.
The roving is further drawn on a ring spinning machine to produce a spun yarn with a yarn count of 20s Ne. The following parameters were used:
LR G5/1 ring-bar machine type and model
Roller gauge 42.5/65mm
51/66mm for saddle-gauge piece
Rubber roll hardness (front/rear F/B) ═ 68/83 °
Break draft of 1.22
Twist factor per inch/twist of 3.6/16.09
Bead ring size: 1/0M1HO
Spindle speed: 15500rpm
The spun yarn was wound on a ring machine in small packages called "cop" each weighing about 50 g. A number of cop were spliced and cleaned of any yarn defects, and finally wound into a cone on a winder using the following parameters:
speed 1000m/min
Yarn tension 5% -6% of yarn breaking load
Packing hardness-minimum
Cone weight 1.0kg or more
The final spun yarn was evaluated for tensile properties and% unevenness on a Uster tensorapid-3 and a Uster unevenness tester-3. The results are shown in Table 4.
The yarn wound in the final machine is very active and may be tangled by the twist created during spinning. Since entanglement can lead to yarn breakage during fabric manufacture, the yarn is structurally stabilized by adjusting the cone in an autoclave with a maximum temperature of 70 ℃ for 50 minutes.
Example 6
40s Ne yarn with 100% melt spun fibers
A spun yarn was prepared according to the procedure of example 5 using the melt spun staple fiber from example 3, with the following differences:
the final sliver had a linear density of 4.75g/m and a% non-uniformity of 1.75
Rovings were prepared as in example 5, except that the roving henry was 1.2s Ne.
In the step of drawing the roving, the twist factor/twist per inch was 3.6/22.6, the bead size was 4/0M1HO, and the spindle speed was 16500 rpm.
The spun yarn was wound onto a cone at a speed of 1500 m/min.
The spinning characteristics are given in table 4.
Example 7
20s Ne spun yarn containing 40/60 melt spun fiber/cotton (wt/wt)
A spun yarn was prepared using the melt spun staple fiber from example 3 and cotton (Shankar 6 variety indian cotton, obtained from north india bang (e.g., bypopo and harrisa bang). The average length of the cotton staple fibers was 31mm and the fineness (fiber linear density) was 4.1. mu.g/inch, which was measured using an air flow method. A spun yarn was prepared according to the procedure of example 5, with the following differences:
in the hand mixing step, two layers of sliver (taken from a 100% cotton spinning process after carding and broken into small tuft sizes of 25-30 mg) are laid on one layer of melt spun staple fiber.
The linear density of the final sliver from the carding step was 4.7 g/m.
Rovings were prepared as in example 5, except that the twist multiplier was 0.85 and the roving henry was 0.7s Ne.
The roving was further drawn as in example 5 except that the twist per inch was 16.99.
The spinning characteristics are given in table 4.
Example 8
40s Ne yarn containing 40/60 melt spun fiber/cotton (wt/wt)
A spun yarn was prepared using the melt spun staple fiber from example 3 and cotton (Shankar 6 variety indian cotton, commercially available from northern pont, india). The cotton staple fibers had an average length of 31mm and a linear density of 4.1 micrograms/inch. A spun yarn was prepared according to the procedure of example 5, with the following differences:
in the hand mixing step, two layers of sliver (taken from a 100% cotton spinning process after carding and broken into small tuft sizes of 25-30 mg) are laid on one layer of melt spun staple fiber.
The linear density of the final sliver from the carding step was 4.7 g/m.
After drawing, the final sliver linear density was 4.75 g/m.
Rovings were prepared as in example 5, except that the twist multiplier was 0.85 and the roving henry was 1.2s Ne.
The roving was further drawn as in example 5 except that the twist per inch was 24.02, the traveler size was 4/0M1HO, and the spindle speed was 16500 rpm.
The spun yarn was wound onto a cone at a speed of 1500 m/min.
The spinning characteristics are given in table 4.
Example 9
20s Ne spun yarn containing 40/60 melt spun fiber/Tencel
Using the melt-spun staple fiber from example 3 and commercially available
Spun yarns were prepared from staple fibers (Lenzing).
The staple fibers had an average length of 40mm and a denier of 1.2D. A spun yarn was prepared according to the procedure of example 5, with the following differences:
in the manual mixing step, the two layers are combined
The fibers (broken down to a small tuft size of 25-30 mg) were laid down on a layer of melt spun staple fibers.
The linear density of the final sliver from the carding step was 4.7 g/m.
A roving was prepared as in example 5, except that the twist multiplier was 0.85.
The roving was further drawn as in example 5 except that the twist per inch was 16.99.
The spinning characteristics are given in table 4.
Example 10
40s Ne yarn comprising 40/60 melt spun fiber/Tencel
Using the melt-spun staple fiber from example 3 and commercially available
Spun yarns were prepared from staple fibers (lanjing corporation).
The average length of the staple was 40mm and the denier was 1.2D. A spun yarn was prepared according to the procedure of example 5, with the following differences:
in the manual mixing step, the two layers are combined
The fibers (broken down to a small tuft size of 25-30 mg) were laid down on a layer of melt spun staple fibers.
The linear density of the final sliver from the carding step was 4.7 g/m.
After drawing, the final sliver linear density was 4.75 g/m.
Rovings were prepared as in example 5, except that the twist multiplier was 0.85 and the roving henry was 1.2s Ne. The roving was further drawn as in example 5 except that the twist per inch was 24.02, the traveler size was 4/0M1HO, and the spindle speed was 16500 rpm.
The spun yarn was wound onto a cone at a speed of 1500 m/min. The spinning characteristics are given in table 4.
TABLE 4 characterization of the spun yarns of examples 5-10 and the commercially available comparative spun yarns
Note that:
1see Table 3 for an abbreviation of commercially available spun yarn
2The speed is 5m/min
The results in Table 4 show that the compounds, alone or with cotton or cotton
The spun yarn combined with 100% meltspun staple fiber has sufficient tenacity and elongation at break for use in a weaving or knitting process.
Spun yarns consisting of only melt spun staple fiber of example 3, poly (ethylene terephthalate) staple fiber, or poly (1, 3-trimethylene terephthalate) staple fiber (examples 5 and 6) were subjected to the boiling water shrinkage test method according to ASTM D2259. The length of the skein with the indicated dead weight attached was measured before and after immersion in boiling water (30 min at 100 ℃, in an autoclave, MLR 1: 40, where "MLR" refers to the ratio of material to liquid), and in table 5 the skein length difference divided by the skein length before boiling is reported as the percent shrinkage. PET and PTT spun yarns are commercially available.
TABLE 5 boiling water shrinkage of spun yarn
Abbreviations are defined in table 3.
The highest boiling water shrinkage was observed for the spun yarn of example 6 containing only meltspun staple fibers, the lowest boiling water shrinkage was observed for the spun yarn containing PET, and the intermediate% shrinkage values were observed for the spun yarn containing PTT. This is desirable for fabrics based on meltspun staple fibers to impart more fabric loft after finishing.
Examples of woven fabrics
The fabric was evaluated using the following method:
fabric weight (grey and finished goods) -ASTM D3776 Standard test method for Fabric weight per Unit area
Dimensional stability (after 3 washes, warp and weft) -AATCC 135 dimensional Change in Fabric after Home Wash
wicking-AATCC 197 textile vertical wicking
Tear Strength (warp and weft) -ASTM D1424 Standard test method for tear Strength of fabrics, carried out by means of drop-hammer (Elmendorf type) apparatus
thickness-ASTM D1777 Standard test method for thickness of textile Material
Pilling rating (1000 rounds) -ASTM D4970 standard test method for pilling resistance and other related surface variations of textile fabrics: martindale tester
Abrasion (5000 wheels) -ASTM D4966 Standard test method for abrasion resistance of textile fabrics (Martindale abrasion tester method)
drape-BS 5058 fabric drape evaluation method
Friction color fastness-AATCC 8 Friction color fastness
Wash color fastness-AATCC 61-2A (49 ℃, 45min, 1.5gpl)
Burst Strength (Cylinder knit Fabric) -ASTM D3786 Standard test method for burst Strength of textile fabrics
Stretch and recovery (circular knit fabric) -BS 4294(5kg) fabric stretch and recovery characteristic test method
The shrinkage% (in the fabric, from the blank to the finished product) was determined as follows. Greige goods fabrics were marked with permanent markers to indicate 30cm lines in the fabric length (warp direction) and 30cm lines in the fabric width (weft direction). The fabric is then dyed and finished and the length of the permanent marker thread is measured again. For the length (warp) and width (weft) directions, the percent shrinkage was calculated by dividing the difference in the length of the threads before and after dyeing and finishing, respectively, by 30 and multiplying by 100. The method is referred to herein as the percent shrinkage method.
Softness assessment (also called subjective hand value) -subjective hand value assessment was performed by assessing the hand of the fabric by 12 experts in the field who were tested at south indian textile research institute (SITRA) of indian copenta. This is a widely used method in the textile industry to assess fabric softness. The fabrics were coded as a and B and the grade of the fabric was evaluated independently based on knowledge of the softness of the fabric. Each expert rated a softer fabric as "1" and a less soft fabric as "2". This was done for 100% PET fabric and the fabrics of examples 11 and 14. The final rating is derived by averaging 12 readings. The lower average grade fabric has a final grade of 1 (softer) and the higher average grade fabric has a grade of 2.
The spun yarns of examples 5 to 10 were used to prepare woven fabrics as shown in table 6. Woven twill (3/1) heavy-duty fabrics and plain woven (1/1) shirt fabrics were prepared using the spun yarns disclosed herein as warp and fill (fill) yarns; a comparative fabric was prepared using commercially available spun yarns in the warp and weft. For each woven fabric, the same yarns are used in the warp and weft. The fabric evaluation results are presented in tables 7 and 8. Unless otherwise stated, results for the finished fabric are reported.
Example 11
The spun yarn from example 5 was used as warp and weft to make a heavy woven twill fabric. The warp yarns were sized using an Elvanol-T25 PVA sizing agent and then warped using a CCI single head sizing machine. Using a 350m/min warper, a beam ending at 2150, 18 inches wide and 3.5 meters long was prepared. The following reeding scheme was used:
stretching: 4-shaft
Drawing type (straight drawing (1, 2, 3 and 4))
Reeding: 2 warp density/reed
Reed number: 75 reed/2 inch
An 3/1LHT twill fabric was woven on a CCI sample loom at a loom speed of 40 picks per minute. The pick count value was set to 63 picks/inch. A greige cloth fabric 2m long and 49.5cm wide was obtained.
The greige cloth was desized on an RBE lab jig dyeing machine as follows. The fabric samples were loaded into a jig dyeing machine filled with water (2L), NaOH (2gpl) and wetting agent; levocol CESR (wetting agent) (5gpl) was added and the bath temperature was raised to 90 ℃. The fabric was run in the bath for 60min, then the bath was drained, refilled with fresh water, and the bath temperature was raised to 85 ℃. The fabric was washed with hot water for 15min and the bath drained. The bath was again filled with water and the fabric was passed through it for 15min (cold water wash). The bath was drained, filled with water and neutralized by the addition of acetic acid (1 gpl); the fabric was run in the bath for 15 min. The bath was then drained, refilled with fresh water, and the fabric was run in a cold water bath for 15 min. The fabric was then discharged from the jig and dried under atmospheric conditions and then heat-set in an RBE tenter at 160 ℃ for 45 seconds.
The fabric was then dyed with a mixture of disperse dyes using the following time and temperature profiles: heating to 70 deg.C and holding for 10min, then raising the temperature to 130 deg.C at 1.5 deg.C/min and holding for 30min, then lowering the temperature to 70 deg.C at 1.5 deg.C/min and draining. After dyeing, the fabric was reductively cleaned with hydro and NaOH (2gpl each) at 90 ℃ for 20 min. The fabric was then washed with cold water for 10min, contacted with acetic acid (2gpl) for 15min, and then washed with cold water for 10 min. The dyed fabric was filled with a finish (softener) and then heat set in an RBE lab tenter at 160 ℃ for 45 seconds.
The fabric construction is shown in table 6. The wicking test results were 100%. The fabric of example 11 was found to have a softer hand (i.e., better softness) than the fabric of comparative example B. Other fabric properties are presented in tables 7 and 8.
Comparative example B
A comparative heavy woven 3/1LHT twill fabric was prepared following the procedure of example 11 using commercially available 20s Ne 100% PET staple spun yarn ("P1") as the warp and fill yarns, except that the reed-reeding scheme used a 4-warp-density/reed and the reed count was 50 reed/2 inch. The greige goods fabric was dyed, finished and heat-set as in example 11.
The fabric construction is shown in table 6. The wicking test results were 100%. Other fabric properties are presented in tables 7 and 8.
Example 12
A thick woven twill fabric was prepared using the spun yarn from example 7 as the warp and fill yarns according to the procedure of example 11, but with the following exceptions. The greige goods fabric is desized and bleached in a jig dyeing machine, heat-set in a tenter, dyed with a mixture of disperse dyes, and then dyed with reactive dyes under cotton dyeing conditions.
The fabric construction is shown in table 6. The wicking test results were 100%. Other fabric properties are presented in tables 7 and 8.
Comparative example C
A comparative heavy woven 3/1LHT twill fabric was prepared as in example 12, except that a commercially available 20s Ne 40/60 PET/cotton staple spun yarn ("PC 1") was used as the warp and fill yarns.
The fabric construction is shown in table 6. The wicking test results were 100%. Other fabric properties are presented in tables 7 and 8.
Example 13
A heavy woven twill fabric was prepared according to the procedure of example 12 using the spun yarn from example 9 as warp and weft yarns, except that no hydrogen peroxide neutralizer was used at the end of the bleaching step.
The fabric construction is shown in table 6. The wicking test results were 100%. Other fabric properties are presented in tables 7 and 8.
Comparative example D
A comparative heavy woven 3/1LHT twill fabric was prepared following the procedure of example 12, except that a commercially available 20s Ne 40/60 was used
Spun staple yarn ("PT 1") was used as warp and weft yarns. Greige goods fabric was dyed, finished and heat-set as in example 12, except that the second dyeing step with reactive dye was carried out
Under dyeing conditions.
The fabric construction is shown in table 6. The wicking test results were 100%. Other fabric properties are presented in tables 7 and 8.
Example 14
The spun yarn from example 6 was used as warp and weft to make a plain woven shirt fabric. The procedure is as described in example 11 with the following differences: after warping, the beam contained 1680 ends and the reed count was 84 reed/2 inch.
The fabric construction is shown in table 6. The wicking test results were 100%. The fabric of example 14 was found to have a better (softer) hand compared to the fabric of comparative example E. Other fabric properties are presented in tables 7 and 8.
Comparative example E
A comparative plain woven shirt fabric was prepared following the procedure of example 11 except that a commercially available 40s Ne 100% PET staple spun yarn ("P2") was used as the warp and fill yarns. After warping, the beam contained 1680 ends and the reed count was 84 reed/2 inch. A greige cloth fabric 2m long and 47.7cm wide was obtained.
The fabric construction is shown in table 6. The wicking test results were 100%. Other fabric properties are presented in tables 7 and 8.
Example 15
The spun yarn from example 8 was used as warp and weft to make a plain woven shirt fabric. The procedure was as in example 12 except that no hydrogen peroxide neutralizer was used at the end of the bleaching step.
The fabric construction is shown in table 6. The wicking test results were 100%. Other fabric properties are presented in tables 7 and 8.
Comparative example F
A comparative plain woven shirt fabric was prepared following the procedure of example 11 except that a commercially available 40s Ne 40/60 PET/cotton spun yarn ("PC 2") was used as warp and weft yarns, and the following additional differences in the procedure were made: after warping, the beam contained 1748 ends and a reed count of 92 reed/2 inch. A greige cloth fabric 2m long and 48.7cm wide was obtained and dyed as described in example 12.
The fabric construction is shown in table 6. The wicking test results were 100%. Other fabric properties are presented in tables 7 and 8.
Example 16
The spun yarn from example 10 was used as warp and weft to make a plain woven shirt fabric. The procedure was as in example Wfab-1, except that after warping, the warp beam contained 1748 ends, reed count was 92 reed/2 inch, and pick count was set to 62 pick/inch. A greige cloth fabric 2m long and 48.7cm wide was obtained and dyed as described in example 12.
The fabric construction is shown in table 6. The wicking test results were 100%. Other fabric properties are presented in tables 7 and 8.
Comparative example G
According to example 11 except that a commercially available 40s Ne 40/60PET @, was used to prepare a comparative shirt fabric
Spun staple yarn ("PT 2") was used as warp and weft yarns, and the following additional differences in the procedure were made: after warping, the beam contained 1748 ends, had a reed count of 92 reed/2 inch, and the pick count was set to 62 pick/inch. A greige cloth fabric 2m long and 48.7cm wide was obtained and dyed as described in example 12.
The fabric construction is shown in table 6. The wicking test results were 100%. Other fabric properties are presented in tables 7 and 8.
The results in the foregoing table show that the fabrics containing the spun yarns disclosed herein have many advantages over the fabrics of the comparative examples. Woven fabrics containing the spun yarns disclosed herein may have greater loft, as indicated by the greater thickness of the example fabrics as compared to similarly constructed comparative example fabrics. The woven fabrics of the examples also showed less pilling (higher pilling rating value), better abrasion resistance (lower% weight loss) and better drape (higher drape coefficient value) than the fabrics of the comparative examples. Additionally, the example fabrics also stained more deeply (lower L values with a D65 illuminant). The combination of improved hand (softer feel) and better drapability is particularly desirable for fabrics.
Examples of tubular knitted fabrics
The spun yarns of examples 5 to 10 were used as knitting yarns to prepare circular knitted fabrics as shown in table 9; a comparative fabric was prepared using a commercially available spun yarn. The machine gauge was 20 inches for all circular knit fabrics made using 20s Ne yarns. The machine gauge was 24 inches for all circular knit fabrics made using 40s Ne yarns. The fabric evaluation results are presented in tables 9 and 10. Unless otherwise stated, results for the finished fabric are reported.
Example 17
The spun yarn from example 5 was used to prepare a circular knit fabric on a Mesdan laboratory knitting machine. The greige cloth fabric was heat-set in an RBE tenter frame at 160 ℃ for 45 seconds and then scoured in an HTHP baker dyeing machine using the following procedure. The fabric was scoured with NaOH (2gpl) at 90 ℃ for 60 minutes and the wetting agent Levocol CESR (5gpl) was added. The fabric was washed at 85 ℃ for 15 minutes, then with cold water for 15 minutes, then with a neutralizing solution containing acetic acid (1gpl) for 15 minutes, and then again with cold water for 15 minutes.
The scoured fabric was then dyed with a mixture of disperse dyes in the same machine using the following time and temperature profiles: heating to 70 deg.C and holding for 10min, then raising the temperature to 130 deg.C at 1.5 deg.C/min and holding for 30min, then lowering the temperature to 70 deg.C at 1.5 deg.C/min and draining. After dyeing, the fabric was reductively cleaned with hydro and NaOH (2gpl each) at 90 ℃ for 20 min. The fabric was then washed with cold water for 10min, neutralized with acetic acid (2gpl) for 15min, and then washed again with cold water for 10 min. The dyed fabric was filled with a finish (softener) and then heat-set in a laboratory tenter at 160 ℃ for 45 seconds.
The fabric construction is shown in table 9. The wicking test results were 100%. The fabric of example 17 was found to have a softer hand (i.e., better softness) than the fabric of comparative example H. Other fabric properties are presented in tables 9 and 10.
Comparative example H
A comparative knit fabric was prepared following the procedure of example 17, except that a commercially available 20s Ne 100% PET staple spun yarn ("P1") was used.
The fabric construction is shown in table 9. The wicking test results were 100%. Other fabric properties are presented in tables 9 and 10.
Example 18
A circular knit fabric was prepared according to the procedure of example 17 on a Mesdan laboratory knitting machine using the spun yarn from example 7, except that after dyeing with disperse dye, the fabric was dyed in the same machine with a reactive dye mixture with added salt (60gpl) using the following time and temperature profile: heat to 60 ℃ and hold for 30min, then add soda ash (15gpl) and hold for 30min, then drain. The fabric was then washed with cold water for 10min, acetic acid (1gpl) for 15min, and then heat soaped with Albatex AD (2gpl), during which the temperature was raised to 90 ℃ and held for 15 min. The fabric was then washed with hot water (85 ℃) for 15min and then with cold water for 10 min. The dye was fixed with Levocol HCF (0.5gpl), during which the temperature was raised to 50 ℃ and held for 20 min. The dyed fabric was filled with finish and then heat set in a laboratory tenter at 160 ℃ for 45 seconds.
The fabric construction is shown in table 9. The wicking test results were 100%. Other fabric properties are presented in tables 9 and 10.
Comparative example I
A comparative knit fabric was prepared following the procedure of example 18, except that a commercially available 20s Ne 40/60 PET/cotton spun yarn ("PC 1") was used.
The fabric construction is shown in table 9. The wicking test results were 100%. Other fabric properties are presented in tables 9 and 10.
Example 19
A circular knit fabric was prepared on a Mesdan laboratory knitting machine using the spun yarn from example 9 following the procedure of example 18.
The fabric construction is shown in table 9. The wicking test results were 100%. Other fabric properties are presented in tables 9 and 10.
Comparative example J
A comparative knit fabric was prepared following the procedure of example 18, except that a commercially available 20s Ne 40/60PET @wasused
Spun staple yarn ("PT 1").
The fabric construction is shown in table 9. The wicking test results were 100%. Other fabric properties are presented in tables 9 and 10.
Example 20
A circular knit fabric was prepared on a Mesdan laboratory knitting machine using the spun yarn from example 6 following the procedure of example 1, except that a different mixture of disperse dyes was used.
The fabric construction is shown in table 9. The wicking test results were 100%. The fabric of example 20 was found to have a better hand (i.e., better softness) than the fabric of comparative example K. Other fabric properties are presented in tables 9 and 10.
Comparative example K
A comparative knit fabric was prepared following the procedure of example 17, except using a commercially available 40s Ne 100% PET staple spun yarn ("P2") and a different disperse dye mixture.
The fabric construction is shown in table 9. The wicking test results were 100%. Other fabric properties are presented in tables 9 and 10.
Example 21
A circular knit fabric was prepared on a Mesdan laboratory knitting machine using the spun yarn from example 8 following the procedure of example 18, except that a different mixture of disperse dyes was used.
The fabric construction is shown in table 9. The wicking test results were 100%. Other fabric properties are presented in tables 9 and 10.
Comparative example L
A comparative knit fabric was prepared following the procedure of example 18, except using a commercially available 40s Ne 40/60 PET/cotton spun yarn ("PC 2"), a different disperse dye mixture, and a different reactive dye mixture.
The fabric construction is shown in table 9. The wicking test results were 100%. Other fabric properties are presented in tables 9 and 10.
Example 22
A circular knit fabric was prepared on a Mesdan laboratory knitting machine using the spun yarn from example 10 following the procedure of example 18, except that different mixtures of disperse dyes and different mixtures of reactive dyes were used.
The fabric construction is shown in table 9. The wicking test results were 100%. Other fabric properties are presented in tables 9 and 10.
Comparative example M
A comparative knit fabric was prepared following the procedure of example 18, except that a commercially available 40s Ne 40/60PET @
Spun staple yarn ("PT 2"), different disperse dye mixtures and different reactive dyes.
The fabric construction is shown in table 9. The wicking test results were 100%. Other fabric properties are presented in tables 9 and 10.
The results in tables 9 and 10 show that the example circular knit fabrics provide advantages over the fabrics of the comparative examples. For example, a circular knit fabric containing the spun yarns comprising meltspun staple fibers disclosed herein has greater loft as indicated by the greater thickness of the fabric as compared to the fabric of the comparative example. The example circular knit fabrics also exhibited less pilling (higher pilling rating value) and better abrasion resistance (lower% weight loss). In addition, the example fabrics had better stretch recovery than the comparative example fabrics, both at shorter and longer recovery times.
Example 23
2/64s Nm spun yarn containing 70/30 wool/melt spun staple fibers
A spun yarn was prepared using a worsted system according to the following procedure.
The spun yarn of example 23 was prepared using the meltspun staple fiber from example 4. Melt-spun staple fibers of 2.5 denier and an average length of 84mm were taken and converted to sliver in a cotton-card spinning system according to a conventional carding process commonly used in spinning mills. The sliver was blended with wool top (australian merino wool, 20.5 microns, average length 68mm) and spun in a worsted system at 70/30(wt/wt) wool/melt spun staple fiber blend ratio. The nominal spun count of the spun yarn was 2/64s Nm.
Example 24
The spun yarn from example 23 was used as warp and weft to make a heavy twill fabric. The warp yarns were sized using an Elvanol-T25 PVA sizing agent and softener and then beamed using a CCI single head sizing machine. Using a 350m/min warper, a beam ending at 1770, 18 inches wide and 3.5 meters long was prepared. The following reeding scheme was used:
stretching: 3 shaft
Drawing type (straight drawing (1, 2 and 3))
Reeding: 3 warp density/reed
Reed number: 60 reed/2 inch
2/1RHT twill was woven on a CCI sample loom at a loom speed of 40 picks per minute. The pick count value was set to 63 picks/inch. A greige cloth fabric 2m long and 50cm wide was obtained.
Greige goods fabric was sized in a jig dyeing machine using a procedure similar to that of example 11, except Albatex AD was used in conjunction with the Levocol CESR. The fabric was then subjected to a hot water wash (85 ℃, 15min), a cold water wash (15min), a neutralization step with acetic acid (15min) and another cold water wash (15 min). The fabric was allowed to flat dry at atmospheric conditions and then heat set at 170 ℃ for 45 seconds.
The fabric was then dyed with a mixture of disperse dyes using the following time and temperature profiles: heating to 70 deg.C and holding for 10min, then raising the temperature to 130 deg.C at 1.5 deg.C/min and holding for 30min, then lowering the temperature to 70 deg.C at 1.5 deg.C/min and draining. The fabric was rinsed with 90 ℃ Hydros and NaOH (1gpl each) for 20 min. The fabric was then washed with cold water for 10min, contacted with acetic acid (2gpl) for 15min, and then washed with cold water for 10 min.
The fabric was then dyed with a mixture of acid dyes using the following time and temperature profiles: heating to 70 deg.C and holding for 10min, then raising the temperature to 98 deg.C at 1.5 deg.C/min and holding for 45min, then lowering the temperature to 70 deg.C at 1.5 deg.C/min and draining. The fabric was washed in cold water (10min), treated with acetic acid (1gpl, 15min), then hot soaped with Albatex AD (90 ℃, 15min), washed with hot water (85 ℃, 15min), washed with cold water (10min), then contacted with levacol HCF (0.5gpl) at 50 ℃ for 20min to fix the dye.
The fabric was steamed in an autoclave (130 ℃, 3min), then filled with finish, then heat-set in a laboratory tenter at 160 ℃ for 45 seconds, then steamed again in an autoclave (130 ℃, 3 min).
The greige goods and finished fabric were evaluated. The results are as follows:
the structure of the grey fabric: 96 × 54 (warp density/inch × weft density/inch)
And (3) construction of a finished fabric: 114 x 63 (warp density/inch x weft density/inch)
Weight of grey fabric: 198g/m2
Weight of finished fabric: 249g/m2
Dimensional stability (%):
length-2.8%;
width-1.7%
Wicking test: 100 percent
Tear strength: warp yarn 1984g, weft yarn 896g
Stretch%: 42.7
1 minute recovery,%: 83.1
30min recovery,%: 90.9
Degree of recovery after 60 minutes,%: 93.51
Example 25
Undrawn melt spun fibers containing PTT and Co-PET
Will contain 0.3% TiO2And poly (1, 3-trimethylene terephthalate) (PTT) pellets having an inherent viscosity of 0.96dL/gPellets of the stock and polyethylene terephthalate Co-isophthalate (Co-PET) (from south Asia plastics Inc.) having an inherent viscosity of 0.80dL/g were dried in a vacuum oven under a nitrogen blanket at 120 ℃ for 16 hours, respectively. The dried pellets of PTT and the dried pellets of Co-PET were blended together in the proportions given in Table 11 in a small roller by the action of hand shaking and the roller. Each salt and pepper blend thus formed was melt extruded into a 34 filament yarn bundle of circular cross-section using a twin screw extruder spinner. The extruder melt zone temperature was maintained between 180 ℃ and 265 ℃. Polymer throughput, winder speed, spun denier per filament and dry heat shrinkage of the yarn bundle (tow) are provided in table 11.
Table 11 example 25: spinning conditions and dry heat shrinkage of filament bundles
Example 26
Unstretched melt-spun fibers comprising Co-PET and PBT
Pellets of polyethylene terephthalate Co-isophthalate (Co-PET) (from south Asia plastics Inc.) having an inherent viscosity of 0.80dL/g and pellets of inherent viscosity of 1.15dL/g were combined
Pellets of 6130C NC010 polybutylene terephthalate (PBT) were dried in a vacuum oven under a nitrogen blanket at 120 ℃ for 16 hours each. The dried pellets of PTT and PBT were blended together in the proportions given in table 12 in a small roller by the action of hand shaking and rolling the roller. Each salt and pepper blend thus formed was melt extruded into a 34 filament yarn bundle of circular cross-section using a twin screw extruder spinner. The extruder melt zone temperature was maintained between 180 ℃ and 265 ℃. Polymer throughput, winder speed, spun denier per filament and dry heat shrinkage of the yarn bundle (tow) are provided in table 12.
Table 12 example 26: spinning conditions and dry heat shrinkage of filament bundles
Example 27
Melt spun staple fiber containing 20 wt.% PTT and 80 wt.% Co-PET salt and pepper blend
Poly (1, 3-propylene terephthalate) and co-PET (available from south Asia plastics Co.) were co-fed through a 7590 orifice spinneret using a single screw extruder at a weight ratio of 20: 80. Poly (1, 3-trimethylene terephthalate) contains 0.3% TiO2And the intrinsic viscosity was 0.96 dL/g. The round-section filaments were spun using radial quenching at an extruder throughput of 100 kg/h. The extruder melt zone temperature was maintained at 252 ℃ to 263 ℃. The polymer throughput was 0.220 g/min/hole and the feed roll speed was 650 m/m. The nominal value of the spun dpf is 3.4. The spun fibers were collected in a tank.
Sixteen (16) cans, 412,896 denier total, were fed into the draw-crimp-cut/bale module. Staple melt spun fibers are produced using a typical cotton count staple process utilizing a multi-stage draw, crimper, annealer and cutter. The tow was immersed in a 22 ℃ finish bath (0.5% strength, Duron 3176 commercially available from CHT). The tow was first drawn in a conditioning bath at 75 ℃ with a concentration of 0.5% between an 18 ℃ feed roll running at 30m/m and an 80 ℃ heated draw roll running at 84m/m, so that the first stage draw ratio was 2.8. The drawn tow was pulled through a steam cabinet at 100 ℃ by 165 ℃ downstream heated rollers running at 88.20 m/m. The tow was passed through another set of 165 ℃ rolls running at 88.20 m/m. The finish (2% strength, Duron 14+ Duron 1105PE, 30/70 actives, all available from CHT corporation) was sprayed and the tow passed over a 25 ℃ chilled drum running at 86.44 m/m. The tow enters a steam box at 100 ℃ and then enters a 40mm crimper. The crimper speed was 90.76 m/m. The crimper rolls were at a temperature and pressure of 65 c and 0.8bar, respectively. The crimped tow was annealed in a plate and strip dryer at 100 ℃ for 4 minutes and finally cut to produce staple melt spun fibers having the following characteristics (determined using the method disclosed above):
denier per filament (dpf) 1.28, Coefficient of Variation (CV) 15.47%
Toughness 5.24g/d, CV 13.05%
Elongation 53.37%, CV 39.14%
Short fiber length of 38mm
Curl number (full sine arc) 12.9/inch
Crimp stability 64.08% and CV 17.67%
The yarn finishing degree is 0.26 percent
Example 28
Melt spun staple fibers containing 50 wt.% PTT and 50 wt.% Co-PET salt and pepper blends
Poly (1, 3-trimethylene terephthalate) and co-PET (available from south Asia plastics Co.) were co-fed in a 50: 50 weight ratio through a 7590 orifice spinneret using a single screw extruder. Poly (1, 3-trimethylene terephthalate) contains 0.3% TiO2And the intrinsic viscosity was 0.96 dL/g. Round-section filaments were spun using radial quenching at an extruder throughput of 122.2 kg/h. The extruder melt zone temperature was maintained at 252 ℃ to 263 ℃. The polymer throughput was 0.268 g/min/hole and the feed roll speed was 792 m/m. The nominal value of the spun dpf is 3.4. The spun fibers were collected in a tank.
Sixteen (16) cans, 412,896 denier total, were fed into the draw-crimp-cut/bale module. Staple melt spun fibers are produced using a typical cotton count staple process utilizing a multi-stage draw, crimper, annealer and cutter. The tow was immersed in a 22 ℃ finish bath (0.5% strength, Duron 3176 commercially available from CHT). The tow was first drawn in a conditioning bath at 75 ℃ with a concentration of 0.5% between an 18 ℃ feed roll running at 30m/m and an 80 ℃ heated draw roll running at 87m/m, so that the first stage draw ratio was 2.9. The drawn tow was pulled through a steam cabinet at 100 ℃ by 165 ℃ downstream heated rollers running at 92.22 m/m. The tow was passed through another set of 165 ℃ rolls running at 90.38 m/m. The finish (2% strength, Duron 14+ Duron 1105PE, 30/70 actives, all available from CHT corporation) was sprayed and the tow passed over a 25 ℃ chill drum running at 90.38 m/m. The tow enters a steam box at 100 ℃ and then enters a 40mm crimper. The crimper speed was 94.89 m/m. The crimper rolls were at a temperature and pressure of 65 c and 0.8bar, respectively. The crimped tow was annealed in a plate and strip dryer at 100 ℃ for 4 minutes and finally cut to produce staple melt spun fibers having the following characteristics (determined using the method disclosed above):
denier per filament (dpf) 1.31, Coefficient of Variation (CV) 10.13%
Toughness 4.66g/d, CV 9.72%
Elongation 53.86% and CV 25.47%
Short fiber length of 38mm
Curl number (full sine arc) 13.1/inch
Crimp stability 79.51% and CV 9.45%
The yarn finishing degree is 0.20 percent
Example 29
Melt spun staple fibers containing 50 wt.% PTT and 50 wt.% Co-PET salt and pepper blends
Poly (1, 3-trimethylene terephthalate) and co-PET (available from south Asia plastics Co.) were co-fed in a 50: 50 weight ratio through a 7590 orifice spinneret using a single screw extruder. Poly (1, 3-trimethylene terephthalate) contains 0.3% TiO2And the intrinsic viscosity was 0.96 dL/g. Round-section filaments were spun using radial quenching at an extruder throughput of 122.2 kg/h. The extruder melt zone temperature was maintained at 252 ℃ to 263 ℃. The polymer throughput was 0.268 g/min/hole and the feed roll speed was 400 m/m. The nominal value of the spun dpf is 6.4. The spun fibers were collected in a tank.
Eight (8) cans, total 388,608 denier, feed the stretch-crimp-cut/bale module. Staple melt spun fibers are produced using a typical worsted count staple process utilizing a multi-stage draw, crimper, annealer and cutter. The tow was immersed in a 22 ℃ finish bath (0.5% strength, Duron 3176 commercially available from CHT). The tow was first drawn in a conditioning bath at 75 ℃ with a concentration of 0.5% between an 18 ℃ feed roll running at 30m/m and an 80 ℃ heated draw roll running at 114m/m, so that the first stage draw ratio was 3.8. The drawn tow was pulled through a steam cabinet at 100 ℃ by 165 ℃ downstream heated rolls running at 108.3 m/m. The tow was passed through another set of 165 ℃ rolls running at 106.1 m/m. The finish (2% strength, Duron 14+ Duron 1105PE, 30/70 actives, all available from CHT corporation) was sprayed and the tow passed over a 25 ℃ chilled drum running at 107.2 m/m. The tow enters a steam box at 100 ℃ and then enters a 40mm crimper. The crimper speed was 112.56 m/m. The crimper rolls were at a temperature and pressure of 65 c and 0.8bar, respectively. The crimped tow was annealed in a plate and strip dryer at 100 ℃ for 4 minutes and finally cut to produce a plurality of cut length staple melt spun fibers having the following characteristics (determined using the method disclosed above):
denier per filament (dpf) 2.08, Coefficient of Variation (CV) 7.47%
Toughness 4.31g/d, CV 15.67%
Elongation 67.77% and CV 24.33%
Short fiber length is multiple cutting length, 59.5/79.3/119mm
Curl number (full sine arc) of 12/inch
Crimp stability 72.11% and CV 12.8%
The yarn finishing degree is 0.09%
Example 30
Melt spun staple fibers containing 20 wt.% PBT and 80 wt.% Co-PET salt and pepper blend
A single screw extruder was used to co-feed a 1.15dL/g intrinsic viscosity through a 7590 hole spinneret at a weight ratio of 20: 80
6130C NC010 polybutylene terephthalate (PBT) and co-PET (available from south Asia plastics). The round-section filaments were spun using radial quenching at an extruder throughput of 100 kg/h. The extruder melt zone temperature was maintained at 252 ℃ to 263 ℃. The polymer throughput was 0.220 g/min/hole and the feed roll speed was 650 m/m. The nominal value of the spun dpf is 3.18. The spun fibers were collected in a tank.
Sixteen (16) cans, 386,179 denier total, feed draw-crimp-cut/bale modules. Staple melt spun fibers are produced using a typical cotton count staple process utilizing a multi-stage draw, crimper, annealer and cutter. The tow was immersed in a 22 ℃ finish bath (0.5% strength, Duron 3176 commercially available from CHT). The tow was first drawn in a conditioning bath at 75 ℃ with a concentration of 0.5% between an 18 ℃ feed roll running at 30m/m and an 80 ℃ heated draw roll running at 88.2m/m, so that the first stage draw ratio was 2.94. The drawn tow was pulled through a steam cabinet at 100 ℃ by a 165 ℃ downstream heated roller running at 92.61 m/m. The tow was passed through another set of 165 ℃ rolls running at 92.61 m/m. The finish (2% strength, Duron 14+ Duron 1105PE, 30/70 actives, all available from CHT corporation) was sprayed and the tow passed over a 25 ℃ chilled drum roller running at 90.76 m/m. The tow enters a steam box at 100 ℃ and then enters a 40mm crimper. The crimper speed was 95.30 m/m. The crimper rolls were at a temperature and pressure of 65 c and 0.8bar, respectively. The crimped tow was annealed in a plate and strip dryer at 100 ℃ for 4 minutes and finally cut to produce staple melt spun fibers having the following characteristics (determined using the method disclosed above):
denier per filament (dpf) 1.24, Coefficient of Variation (CV) 13.51%
Toughness 5.36g/d, CV 11.77%
Elongation 47.07% and CV 39.30%
Short fiber length of 40mm
Curl number (full sine arc) is 10.4/inch
Crimp stability 56.2% and CV 13.9%
The yarn finishing degree is 0.31%
Example 31
Melt spun staple fibers containing 50 wt.% PBT and 50 wt.% Co-PET salt and pepper blend
A single screw extruder was used to co-feed a 50: 50 weight ratio of 1.15dL/g inherent viscosity through a 7590 hole spinneret
6130C NC010 polybutylene terephthalate (P)BT) and co-PET (available from south asia plastics). Round-section filaments were spun using radial quenching at an extruder throughput of 122.2 kg/h. The extruder melt zone temperature was maintained at 252 ℃ to 263 ℃. The polymer throughput was 0.268 g/min/hole and the feed roll speed was 792 m/m. The nominal value of the spun dpf is 3.42. The spun fibers were collected in a tank.
Sixteen (16) cans, total 415, 324 denier, feed draw-crimp-cut/bale modules. Staple melt spun fibers are produced using a typical cotton count staple process utilizing a multi-stage draw, crimper, annealer and cutter. The tow was immersed in a 22 ℃ finish bath (0.5% strength, Duron 3176 commercially available from CHT). The tow was first drawn in a conditioning bath at 75 ℃ with a concentration of 0.5% between an 18 ℃ feed roll running at 30m/m and an 80 ℃ heated draw roll running at 87.90m/m, so that the first stage draw ratio was 2.93. The drawn tow was pulled through a steam cabinet at 100 ℃ by means of 165 ℃ downstream heated rolls running at 94.93 m/m. The tow was passed through another set of 165 ℃ rolls running at 94.93 m/m. The finish (2% strength, Duron 14+ Duron 1105PE, 30/70 actives, all available from CHT corporation) was sprayed and the tow passed over a 25 ℃ chilled drum running at 93.03 m/m. The tow enters a steam box at 100 ℃ and then enters a 40mm crimper. The crimper speed was 97.69 m/m. The crimper rolls were at a temperature and pressure of 65 c and 0.8bar, respectively. The crimped tow was annealed in a plate and strip dryer at 100 ℃ for 4 minutes and finally cut to produce staple melt spun fibers having the following characteristics (determined using the method disclosed above):
denier per filament (dpf) 1.17, Coefficient of Variation (CV) 13.6%
Toughness 5.48g/d, CV 12.38%
Elongation 39.74% and CV 27.57%
Short fiber length of 40mm
Curl number (full sine arc) is 11.8/inch
Crimp stability 60.23% and CV 8.30%
The yarn finishing degree is 0.24 percent
Example 32
40s Ne yarn with 100% melt spun fibers
A spun yarn was prepared according to the procedure of example 5 using the melt spun staple fiber from example 28, with the following exceptions:
the linear density of the final sliver was 4.75g/m and the% non-uniformity was 1.75.
The roving henry was 1.2s Ne.
In the step of drawing the roving, the twist factor/twist per inch was 3.6/22.6, the bead size was 4/0M1HO, and the spindle speed was 16500 rpm.
The spun yarn was wound onto a cone at a speed of 1500 m/min. The spinning characteristics are given in table 13. The characteristics of the spun yarns of this and the following examples were determined using the methods disclosed above.
Example 33
40s Ne yarn with 100% melt spun fibers
A spun yarn was prepared according to the procedure of example 32 using the melt spun staple fiber from example 27. The spinning characteristics are given in table 13.
Example 34
40s Ne yarn with 100% melt spun fibers
A spun yarn was prepared according to the procedure of example 32 using the melt spun staple fiber from example 31. The spinning characteristics are given in table 13.
Example 35
40s Ne yarn with 100% melt spun fibers
A spun yarn was prepared according to the procedure of example 32 using the melt spun staple fiber from example 30. The spinning characteristics are given in table 13.
Example 36
40s Ne yarn containing 40/60(wt/wt) melt spun fiber/cotton
A spun yarn was prepared using the melt spun staple fiber from example 28 and cotton (Shankar 6 variety indian cotton, commercially available from northern pont, india). The cotton staple fibers had an average length of 31mm and a linear density of 4.1 micrograms/inch (1.6 micrograms/cm). A spun yarn was prepared according to the procedure of example 32. The spinning characteristics are given in table 13.
Example 37
40s Ne yarn containing 40/60(wt/wt) melt spun fiber/cotton
A spun yarn was prepared using the melt spun staple fiber from example 27 and cotton (Shankar 6 variety indian cotton, commercially available from northern pont, india). The cotton staple fibers had an average length of 31mm and a linear density of 4.1 micrograms/inch (1.6 micrograms/cm). A spun yarn was prepared according to the procedure of example 8. The spinning characteristics are given in table 13.
Example 38
40s Ne yarn containing 40/60(wt/wt) melt spun fiber/cotton
A spun yarn was prepared using the melt spun staple fiber from example 31 and cotton (Shankar 6 variety indian cotton, commercially available from northern pont, india). The cotton staple fibers had an average length of 31mm and a linear density of 4.1 micrograms/inch (1.6 micrograms/cm). A spun yarn was prepared according to the procedure of example 8. The spinning characteristics are given in table 13.
Example 39
40s Ne yarn containing 40/60(wt/wt) melt spun fiber/cotton
A spun yarn was prepared using the melt spun staple fiber from example 30 and cotton (Shankar 6 variety indian cotton, commercially available from northern pont, india). The cotton staple fibers had an average length of 31mm and a linear density of 4.1 micrograms/inch (1.6 micrograms/cm). A spun yarn was prepared according to the procedure of example 8. The spinning characteristics are given in table 13.
Example 40
40s Ne yarn comprising 40/60 melt spun fiber/Tencel
Using the melt-spun staple fiber from example 28 and a commercially available one
Spun yarns were prepared from staple fibers (lanjing corporation).
The average length of the staple was 40mm and the denier was 1.2D. A spun yarn was prepared according to the procedure of example 10. The spinning characteristics are given in table 13.
Example 41
40s Ne yarn comprising 40/60 melt spun fiber/Tencel
Is used forMelt spun staple fiber from example 27 and commercially available
Spun yarns were prepared from staple fibers (lanjing corporation).
The average length of the staple was 40mm and the denier was 1.2D. A spun yarn was prepared according to the procedure of example 10. The spinning characteristics are given in table 13.
Example 42
40s Ne yarn comprising 40/60 melt spun fiber/Tencel
Using the melt spun staple fiber from example 31 and commercially available
Spun yarns were prepared from staple fibers (lanjing corporation).
The average length of the staple was 40mm and the denier was 1.2D. A spun yarn was prepared according to the procedure of example 10. The spinning characteristics are given in table 13.
Example 43
40s Ne yarn comprising 40/60 melt spun fiber/Tencel
Using the melt spun staple fiber from example 30 and commercially available
Spun yarns were prepared from staple fibers (lanjing corporation).
The average length of the staple was 40mm and the denier was 1.2D. A spun yarn was prepared according to the procedure of example 10. The spinning characteristics are given in table 13.
Example 44
2/68s Nm spun yarn containing 45/55 wool/melt spun staple fibers
A spun yarn was prepared using a worsted system according to the following procedure.
The spun yarn of example 44 was prepared using the meltspun staple fiber from example 29. Melt-spun staple fibers of 2.5 denier and an average length of 84mm were taken and converted to sliver in a cotton-card spinning system according to a conventional carding process commonly used in spinning mills. The sliver was blended with wool top (australian merino wool, 20.5 microns, average length 68mm) and spun in a worsted system at 45/55(wt/wt) wool/melt spun staple fiber blend ratio. The nominal spun count of the spun yarn was 2/68s Nm.
In table 13, the reported boiling water shrinkage values were obtained according to method ASTM D2259 and using a 1kg weight.
In comparison with the results in tables 4 and 5, the results in Table 13 show that the tenacity of the spun yarn incorporating the salt and pepper blended PET/PTT 50: 50 melt spun staple is similar to the tenacity of the spun yarn incorporating the composite PET/PTT 50: 50 melt spun staple. The boiling water shrinkage percentage of the spun yarn incorporating salt and pepper PET/PTT 50: 50 melt spun staple was higher compared to the boiling water shrinkage percentage of the spun yarn incorporating composite PET/PTT 50: 50 melt spun staple. All other characteristics were found to be similar.
Examples of woven fabrics
The spun yarns of examples 32 to 44 were used to prepare woven fabrics as shown in table 14. Plain woven (1/1) shirt fabric was prepared using the spun yarns disclosed herein as warp and fill yarns (stuffer yarns). For each woven fabric, the same yarns are used in the warp and weft. The fabric evaluation results are presented in tables 15 and 16. Unless otherwise stated, results for the finished fabric are reported. The fabric properties of this example and the following examples were determined using the methods disclosed above.
Example 45
The spun yarn from example 32 was used as warp and weft to make a plain woven (1/1) shirt fabric. The warp yarns were sized using an Elvanol-T25 PVA sizing agent and then warped using a CCI single head sizing machine. Using a 350m/min warper, a beam was prepared ending at 1680, 18 inches wide and 3.5 meters long. The following reeding scheme was used:
stretching: 4-shaft
Drawing type (straight drawing (1, 2, 3 and 4))
Reeding: 2 warp density/reed
Reed number: 84 reed/2 inch
A1/1 plain weave fabric was woven on a CCI sample loom at a loom speed of 40 picks per minute. The pick count value was set to 49 pick counts/inch.
The greige cloth was desized on an RBE lab jig dyeing machine as follows. The fabric samples were loaded into a jig dyeing machine filled with water (2L), NaOH (2gpl) and wetting agent; levocol CESR (wetting agent) (5gpl) was added and the bath temperature was raised to 90 ℃. The fabric was run in the bath for 60min, then the bath was drained, refilled with fresh water, and the bath temperature was raised to 85 ℃. The fabric was washed with hot water for 15min and the bath drained. The bath was again filled with water and the fabric was passed through it for 15min (cold water wash). The bath was drained, filled with water and neutralized by the addition of acetic acid (1 gpl); the fabric was run in the bath for 15 min. The bath was then drained, refilled with fresh water, and the fabric was run in a cold water bath for 15 min. The fabric was then discharged from the jig and dried under atmospheric conditions and then heat-set in an RBE tenter at 160 ℃ for 45 seconds.
The fabric was then dyed with a mixture of disperse dyes using the following time and temperature profiles: heating to 70 deg.C and holding for 10min, then raising the temperature to 130 deg.C at 1.5 deg.C/min and holding for 30min, then lowering the temperature to 70 deg.C at 1.5 deg.C/min and draining. After dyeing, the fabric was reductively cleaned with hydro and NaOH (2gpl each) at 90 ℃ for 20 min. The fabric was then washed with cold water for 10min, contacted with acetic acid (2gpl) for 15min, and then washed with cold water for 10 min. The dyed fabric was filled with a finish (softener) and then heat set in an RBE lab tenter at 160 ℃ for 45 seconds.
The fabric construction is shown in table 14. The wicking test results were 100%. Other fabric properties are presented in tables 15 and 16.
Example 46
The spun yarn from example 33 was used as warp and weft to prepare a plain woven shirt fabric following the procedure given in example 45. The fabric construction is shown in table 14. The wicking test results were 100%. Other fabric properties are presented in tables 15 and 16.
Example 47
The spun yarn from example 34 was used as warp and weft to prepare a plain woven shirt fabric following the procedure given in example 45. The fabric construction is shown in table 14. The wicking test results were 100%. Other fabric properties are presented in tables 15 and 16.
Example 48
The spun yarn from example 35 was used as warp and weft to prepare a plain woven shirt fabric following the procedure given in example 45. The fabric construction is shown in table 14. The wicking test results were 100%. Other fabric properties are presented in tables 15 and 16.
Example 49
A plain woven shirt fabric was prepared using the spun yarn from example 36 as warp and weft according to the procedure of example 45, but in a different manner. The weft density value was set to 58 weft densities/inch on the loom. The greige goods fabric is desized and bleached in a jig dyeing machine, heat-set in a tenter, dyed with a mixture of disperse dyes, and then dyed with reactive dyes under cotton dyeing conditions. The fabric construction is shown in table 14. The wicking test results were 100%. Other fabric properties are presented in tables 15 and 16.
Example 50
A plain woven shirt fabric was prepared using the spun yarn from example 37 as warp and weft according to the procedure of example 49, but in a different manner. The greige goods fabric is desized and bleached in a jig dyeing machine, heat-set in a tenter, dyed with a mixture of disperse dyes, and then dyed with reactive dyes under cotton dyeing conditions. The fabric construction is shown in table 14. The wicking test results were 100%. Other fabric properties are presented in tables 15 and 16.
Example 51
A plain woven shirt fabric was prepared using the spun yarn from example 38 as warp and weft according to the procedure of example 49, but with the following exceptions. The greige goods fabric is desized and bleached in a jig dyeing machine, heat-set in a tenter, dyed with a mixture of disperse dyes, and then dyed with reactive dyes under cotton dyeing conditions. The fabric construction is shown in table 14. The wicking test results were 100%. Other fabric properties are presented in tables 15 and 16.
Example 52
A plain woven shirt fabric was prepared using the spun yarn from example 39 as warp and weft according to the procedure of example 49, but in a different manner. The greige goods fabric is desized and bleached in a jig dyeing machine, heat-set in a tenter, dyed with a mixture of disperse dyes, and then dyed with reactive dyes under cotton dyeing conditions.
The fabric construction is shown in table 14. The wicking test results were 100%. Other fabric properties are presented in tables 15 and 16.
Example 53
A plain woven shirt fabric was prepared according to the procedure of example 49 using the spun yarn from example 40 as warp and weft, except that no hydrogen peroxide neutralizer was used at the end of the bleaching step. The weft density value was set to 65 weft densities/inch on the loom.
The fabric construction is shown in table 14. The wicking test results were 100%. Other fabric properties are presented in tables 15 and 16.
Example 54
A plain woven shirt fabric was prepared according to the procedure of example 53 using the spun yarn from example 41 as warp and weft. The fabric construction is shown in table 14. The wicking test results were 100%. Other fabric properties are presented in tables 15 and 16.
Example 55
A plain woven shirt fabric was prepared according to the procedure of example 53 using the spun yarn from example 42 as warp and weft. The fabric construction is shown in table 14. The wicking test results were 100%. Other fabric properties are presented in tables 15 and 16.
Example 56
A plain woven shirt fabric was prepared according to the procedure of example 53 using the spun yarn from example 42 as warp and weft. The fabric construction is shown in table 14. The wicking test results were 100%. Other fabric properties are presented in tables 15 and 16.
Example 57
The spun yarn from example 34 was used as warp and weft to make 2/1 twill construction of a suit fabric. The warp yarns were sized using an Elvanol-T25 PVA sizing agent and softener and then beamed using a CCI single head sizing machine. Using a 350m/min warper, a beam was prepared ending at 1518, 18 inches wide and 3.5 meters long. The following reeding scheme was used:
stretching: 3 shaft
Drawing type (straight drawing (1, 2 and 3))
Reeding: 3 warp density/reed
Reed number: 51.5 reed/2 inch
2/1RHT twill was woven on a CCI sample loom at a loom speed of 40 picks per minute. The pick count value was set to 53 picks/inch. A greige cloth fabric 2m long and 48.3cm wide was obtained.
Greige goods fabric was sized in a jig dyeing machine using a procedure similar to that of example 49, except Albatex AD was used in conjunction with the Levocol CESR. The fabric was then subjected to a hot water wash (85 ℃, 15min), a cold water wash (15min), a neutralization step with acetic acid (15min) and another cold water wash (15 min). The fabric was allowed to flat dry at atmospheric conditions and then heat set at 170 ℃ for 45 seconds.
The fabric was then dyed with a mixture of disperse dyes using the following time and temperature profiles: heating to 70 deg.C and holding for 10min, then raising the temperature to 130 deg.C at 1.5 deg.C/min and holding for 30min, then lowering the temperature to 70 deg.C at 1.5 deg.C/min and draining. The fabric was rinsed with 90 ℃ Hydros and NaOH (1gpl each) for 20 min. The fabric was then washed with cold water for 10min, contacted with acetic acid (2gpl) for 15min, and then washed with cold water for 10 min.
The fabric was then dyed with a mixture of acid dyes using the following time and temperature profiles: heating to 70 deg.C and holding for 10min, then raising the temperature to 98 deg.C at 1.5 deg.C/min and holding for 45min, then lowering the temperature to 70 deg.C at 1.5 deg.C/min and draining. The fabric was washed in cold water (10min), treated with acetic acid (1gpl, 15min), then hot soaped with Albatex AD (90 ℃, 15min), washed with hot water (85 ℃, 15min), washed with cold water (10min), then contacted with levacol HCF (0.5gpl) at 50 ℃ for 20min to fix the dye.
The fabric was steamed in an autoclave (130 ℃, 3min), then filled with a finish (Levofin HYP-5gpl Levocol PNLI-10gpl), then heat-set in a laboratory tenter at 160 ℃ for 45 seconds, then steamed again in an autoclave (130 ℃, 3 min).
The greige goods and finished fabric were evaluated. The fabric constructions and test results are given in tables 14, 15 and 16. The wicking test results were 100%.
Examples of tubular knitted fabrics
The spun yarns of examples 32 to 44 were used as knitting yarns to prepare circular knitted fabrics as shown in table 17. The machine gauge was 24 inches for all circular knit fabrics made using 40s Ne yarns. The fabric evaluation results are presented in table 18. Unless otherwise stated, results for the finished fabric are reported.
Examples 58, 59, 60 and 61
Tubular knit fabrics were prepared on a Mesdan laboratory knitting machine using the spun yarns from examples 32, 33, 34 and 35, respectively. The greige cloth fabric was heat-set in an RBE tenter frame at 160 ℃ for 45 seconds and then scoured in an HTHP baker dyeing machine using the following procedure. The fabric was scoured with NaOH (2gpl) at 90 ℃ for 60 minutes and the wetting agent Levocol CESR (5gpl) was added. The fabric was washed at 85 ℃ for 15 minutes, then with cold water for 15 minutes, then with a neutralizing solution containing acetic acid (1gpl) for 15 minutes, and then again with cold water for 15 minutes.
The scoured fabric was then dyed with a mixture of disperse dyes in the same machine using the following time and temperature profiles: heating to 70 deg.C and holding for 10min, then raising the temperature to 130 deg.C at 1.5 deg.C/min and holding for 30min, then lowering the temperature to 70 deg.C at 1.5 deg.C/min and draining. After dyeing, the fabric was reductively cleaned with hydro and NaOH (2gpl each) at 90 ℃ for 20 min. The fabric was then washed with cold water for 10min, neutralized with acetic acid (2gpl) for 15min, and then washed again with cold water for 10 min. The dyed fabric was filled with a finish (softener) and then heat-set in a laboratory tenter at 160 ℃ for 45 seconds. The fabric constructions and test results are presented in tables 17 and 18. Wicking test results for all fabrics were 100%.
Examples 62, 63, 64 and 65
Tubular knitted fabrics were prepared according to the procedure of example 58 on a Mesdan laboratory knitting machine using the spun yarns from examples 36, 37, 38 and 39, respectively, except that after dyeing with disperse dye, the fabrics were dyed in the same machine with a reactive dye mixture with added salt (60gpl) using the following time and temperature profile: heat to 60 ℃ and hold for 30min, then add soda ash (15gpl) and hold for 30min, then drain. The fabric was then washed with cold water for 10min, acetic acid (1gpl) for 15min, and then heat soaped with Albatex AD (2gpl), during which the temperature was raised to 90 ℃ and held for 15 min. The fabric was then washed with hot water (85 ℃) for 15min and then with cold water for 10 min. The dye was fixed with Levocol HCF (0.5gpl), during which the temperature was raised to 50 ℃ and held for 20 min. The dyed fabric was filled with finish and then heat set in a laboratory tenter at 160 ℃ for 45 seconds. The fabric constructions and test results are presented in tables 17 and 18. Wicking test results for all fabrics were 100%.
Examples 66, 67, 68 and 69
Tubular knit fabrics were prepared on a Mesdan laboratory knitting machine following the procedure of example 18 using the spun yarns from examples 40, 41, 42 and 43, respectively, except that different mixtures of disperse and reactive dyes were used and no hydrogen peroxide neutralizer was used at the end of the bleaching step. The fabric constructions and test results are presented in tables 17 and 18. Wicking test results for all fabrics were 100%.
Example 70
A circular knit fabric was prepared on a Mesdan laboratory knitting machine using the spun yarn from example 44 following the procedure of example 14. The fabric was dyed and finished as per the example of 57. The fabric constructions and test results are presented in tables 17 and 18. Wicking test results for all fabrics were 100%.
Claims (20)
1. A spun yarn, comprising:
melt-spun staple fiber comprising a first polymer comprising poly (1, 3-trimethylene terephthalate) or poly (tetramethylene terephthalate) and a second polymer comprising poly (ethylene terephthalate) or Co-PET, wherein Co-PET is a poly (ethylene terephthalate) copolymer comprising isophthalic acid monomers; and is
Wherein
The first polymer comprises poly (1, 3-trimethylene terephthalate), and the weight ratio of the poly (1, 3-trimethylene terephthalate) to the second polymer is in the range of about 80: 20 to about 10: 90; or
The first polymer comprises poly (butylene terephthalate), and the weight ratio of the poly (butylene terephthalate) to the second polymer is in the range of about 90: 10 to about 10: 90.
2. The spun yarn of claim 1, wherein the first polymer comprises poly (1, 3-trimethylene terephthalate) and the second polymer comprises poly (ethylene terephthalate).
3. The spun yarn of claim 1, wherein the first polymer comprises poly (1, 3-trimethylene terephthalate) and the second polymer comprises Co-PET, and the Co-PET contains about 0.5 to about 10 mole percent of isophthalic acid monomer based on total copolymer composition.
4. The spun yarn of claim 1, wherein the first polymer comprises poly (butylene terephthalate) and the second polymer comprises poly (ethylene terephthalate).
5. The spun yarn of claim 1, wherein the first polymer comprises poly (butylene terephthalate) and the second polymer comprises Co-PET, and the Co-PET contains about 0.5 to about 10 mole percent of isophthalic acid monomer based on total copolymer composition.
6. The spun yarn of claim 3 or claim 5, wherein the spun yarn has a scouring shrinkage of at least about 6% as determined by ASTM D2259.
7. The spun yarn of claim 1, wherein the weight ratio of the poly (1, 3-trimethylene terephthalate) or the poly (butylene terephthalate) to the second polymer is in the range of 70: 30 to 30: 70.
8. The spun yarn of claim 1, further comprising a second staple fiber in an amount of from about 5 wt% to about 95 wt% based on the total weight of the spun yarn.
9. The spun yarn of claim 9, wherein the second staple fiber comprises polylactic acid, acrylic, nylon, olefin, acetate, rayon, polyester, cotton, flax, wool, angora, mohair, alpaca, cashmere, or mixtures thereof.
10. The spun yarn of claim 10, wherein the second staple fiber comprises cotton or wool.
11. A fabric comprising the spun yarn of claim 1.
12. The fabric of claim 12, wherein the first polymer comprises poly (1, 3-trimethylene terephthalate) and the second polymer comprises poly (ethylene terephthalate).
13. The fabric of claim 12, wherein the first polymer comprises poly (1, 3-trimethylene terephthalate) and the second polymer comprises Co-PET.
14. The fabric of claim 12, wherein the first polymer comprises poly (butylene terephthalate) and the second polymer comprises poly (ethylene terephthalate).
15. The fabric of claim 12, wherein the first polymer comprises poly (butylene terephthalate) and the second polymer comprises Co-PET.
16. The fabric of claim 12, wherein the fabric has at least one of the following compared to a fabric of the same fabric construction consisting of polyethylene terephthalate, cotton, rayon, or a combination thereof:
i) better wear resistance as determined according to ASTM D4966 standard test method;
ii) a higher pilling note value as determined according to ASTM D4970 standard test method; or
iii) greater bulk as determined according to ASTM D1777 standard test method.
17. The fabric of claim 12, wherein the fabric is a woven fabric having warp yarns and weft yarns, and the warp yarns, the weft yarns, or both the warp yarns and the weft yarns each comprise the spun yarns of claim 1.
18. The fabric of claim 12, wherein the fabric is a knit fabric.
19. The fabric of claim 19, wherein the fabric has a higher degree of recovery as determined according to method BS 4294 as compared to a knit fabric of the same fabric construction consisting of polyethylene terephthalate, cotton, rayon, or a combination thereof.
20. An article comprising the fabric of claim 12.
Applications Claiming Priority (5)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US201862691066P | 2018-06-28 | 2018-06-28 | |
| US62/691066 | 2018-06-28 | ||
| US201862747999P | 2018-10-19 | 2018-10-19 | |
| US62/747999 | 2018-10-19 | ||
| PCT/US2019/039183 WO2020006043A1 (en) | 2018-06-28 | 2019-06-26 | Spun yarn comprising polyester staple fibre and fabric comprising the same |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CN112639183A true CN112639183A (en) | 2021-04-09 |
Family
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Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CN201980056390.5A Pending CN112639183A (en) | 2018-06-28 | 2019-06-26 | Spun yarn comprising polyester staple fibers and fabric comprising said spun yarn |
Country Status (8)
| Country | Link |
|---|---|
| US (1) | US20210164131A1 (en) |
| EP (1) | EP3814562A1 (en) |
| JP (1) | JP2021529895A (en) |
| KR (1) | KR20210024618A (en) |
| CN (1) | CN112639183A (en) |
| BR (1) | BR112020026622A2 (en) |
| TW (1) | TWI828715B (en) |
| WO (1) | WO2020006043A1 (en) |
Families Citing this family (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| GB2590767B (en) * | 2019-10-14 | 2023-10-18 | Indo Count Industries Ltd | Fibers, woven fabric including the fibers, and methods of manufacturing the same |
| CN114717684A (en) * | 2021-01-06 | 2022-07-08 | 杜邦中国集团有限公司 | Chemical fiber material prepared from mixed polyester |
| WO2022184789A1 (en) * | 2021-03-02 | 2022-09-09 | Sanko Tekstil Isletmeleri San. Ve Tic. A.S. | Protective woven fabric |
| CN118461168B (en) * | 2024-07-09 | 2024-09-03 | 桐昆集团浙江恒通化纤有限公司 | Production method of super-black polyester fiber |
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- 2019-06-26 WO PCT/US2019/039183 patent/WO2020006043A1/en active Application Filing
- 2019-06-26 BR BR112020026622-1A patent/BR112020026622A2/en not_active Application Discontinuation
- 2019-06-26 EP EP19746554.5A patent/EP3814562A1/en active Pending
- 2019-06-26 CN CN201980056390.5A patent/CN112639183A/en active Pending
- 2019-06-26 US US17/251,917 patent/US20210164131A1/en active Pending
- 2019-06-26 JP JP2020573031A patent/JP2021529895A/en active Pending
- 2019-06-26 KR KR1020217002577A patent/KR20210024618A/en not_active Application Discontinuation
- 2019-06-27 TW TW108122695A patent/TWI828715B/en active
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| JP2004084119A (en) * | 2002-08-27 | 2004-03-18 | Toray Ind Inc | Polyester short fiber and pile fabric using the same |
| CN1946885A (en) * | 2004-04-23 | 2007-04-11 | 因维斯塔技术有限公司 | Bicomponent fiber and yarn comprising such fiber |
| CN101273159A (en) * | 2005-09-29 | 2008-09-24 | 因维斯塔技术有限公司 | Scalloped oval bicomponent fibers with good wicking, and high uniformity spun yarns comprising such fibers |
| CN101191255A (en) * | 2006-11-28 | 2008-06-04 | 富图拉聚酯有限公司 | Polyester staple fiber (PSF)/filament yarn (POY and PFY) for textile applications |
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Also Published As
| Publication number | Publication date |
|---|---|
| BR112020026622A2 (en) | 2021-03-30 |
| US20210164131A1 (en) | 2021-06-03 |
| WO2020006043A1 (en) | 2020-01-02 |
| EP3814562A1 (en) | 2021-05-05 |
| KR20210024618A (en) | 2021-03-05 |
| JP2021529895A (en) | 2021-11-04 |
| TWI828715B (en) | 2024-01-11 |
| TW202001018A (en) | 2020-01-01 |
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