JP2021529895A - Spun yarns containing polyester staple fibers and fabrics containing polyester staple fibers - Google Patents

Abstract

A spun yarn containing melt-spun staple fibers containing a first polymer and a second polymer, wherein the first polymer contains poly (trimethylene terephthalate) or poly (butylene terephthalate), and the second polymer is poly (ethylene). (Telephthalate) or Co-PET, where Co-PET is a poly (ethylene terephthalate) copolymer containing an isophthalic acid monomer; The weight ratio to the two polymers is in the range of about 80:20 to about 10:90; or the first polymer contains poly (butylene terephthalate) and the weight ratio of poly (butylene terephthalate) to the second polymer is about. Spun yarns in the range of 90:10 to about 10:90 are disclosed herein. The spun yarn may further include a second staple fiber such as cotton or wool. Spinned yarns are useful for preparing fabrics with advantageous properties.

Description

Mutual reference to related applications This application is filed in US Provisional Patent Application No. 62/691066 and October 19, 2018, entitled "Fabrics and Spun Yarns Comprising Polyester Staple Fiber" filed on June 28, 2018. Claims priorities and interests under US Provisional Patent Application No. 62/747999 entitled "Fabrics and Spun Yarns Comprising Polyester Staple Fiber". Both of these disclosures are incorporated herein by reference in their entirety.

The present invention relates to spun yarns containing molten spun staple fibers containing a first polymer and a second polymer, and fabrics containing spun yarns. The first polymer contains poly (trimethylene terephthalate) or poly (butylene terephthalate), the second polymer contains poly (ethylene terephthalate) or Co-PET, and Co-PET contains poly (isophthalic acid monomer). It is an ethylene terephthalate) copolymer.

Poly (trimethylene terephthalate) (PTT) is a commercially available fiber that provides desired properties such as dispersive dyeability at atmospheric pressure, relatively low flexural modulus, and relatively high elastic resilience and resilience. Is. The process of making PTT staple fibers is known, but consistent processing of PTT staples is hampered by shrinkage of partially oriented toes during storage prior to kneading, crimping, and cutting. Often. Shrinkage is affected by storage time and storage temperature, and uncontrolled shrinkage results in denier non-uniformity and stretch fracture during the kneading process. As a result, commercialization of PTT staples or blends of PTT staples with natural fibers is limited.

For end applications of certain fabrics, staple fibers are preferred over continuous filaments. For example, staple spun yarns for apparel fabrics require discontinuous rather than continuous fibers to allow the use of woven staple processing equipment. Staple fibers also allow synthetic fibers to be blended with natural fibers such as wool, cotton, and cellulose. The production of staple fibers suitable for fabrics can cause certain problems, especially in conventional split spin / drawing processes where kneading is performed in separate steps, due to the properties of unstretched fibers such as dry heat shrinkage. , May change as unstretched fibers in storage age.

There is a continuous need for economic processes to produce PTT staples with good uniformity and yarn strength, as well as such staples. There is a continuous need for spun yarns that contain PTT-based staple fibers and have good yarn strength and break point elongation, which can impart the desired properties for fabrics containing such spun yarns.

Melt-spun staple fibers, spun yarns containing melt-spun staple fibers, and fabrics containing spun yarns are disclosed herein. In one embodiment, a spun yarn is disclosed, wherein the spun yarn is a first polymer containing poly (trimethylene terephthalate) or poly (butylene terephthalate) and a second polymer containing poly (ethylene terephthalate) or Co-PET. Co-PET is a poly (ethylene terephthalate) copolymer containing an isophthalic acid monomer, and the first polymer contains poly (trimethylene terephthalate) and poly (trimethylene terephthalate). The weight ratio of poly (butylene terephthalate) to the second polymer is in the range of about 80:20 to about 10:90; or the first polymer contains poly (butylene terephthalate) and the weight ratio of poly (butylene terephthalate) to the second polymer is. , About 90:10 to about 10:90. In another embodiment of the spun yarn, the weight ratio of poly (trimethylene terephthalate) or poly (butylene terephthalate) to the second polymer is in the range of about 70:30 to 30:70. In a further embodiment, the spun yarn has a boil-off shrinkage of at least about 6% determined according to ASTM D2259.

In one embodiment of the spun yarn, the melt-spun staple fibers include poly (trimethylene terephthalate) and poly (ethylene terephthalate). In another embodiment of the spun yarn, the melt-spun staple fiber comprises poly (trimethylene terephthalate) and Co-PET. In one embodiment of the spun yarn, the first polymer comprises poly (trimethylene terephthalate), the second polymer comprises Co-PET, and co-PET is about, relative to the total copolymer composition. It contains 0.5 mol% to about 10 mol% of isophthalic acid monomer. In one additional embodiment of spun yarn, melt-spun staple fibers include poly (butylene terephthalate) and poly (ethylene terephthalate). In yet another embodiment of the spun yarn, the melt-spun staple fiber comprises poly (butylene terephthalate) and Co-PET. In one embodiment of the spun yarn, the first polymer comprises poly (butylene terephthalate), the second polymer comprises Co-PET, and Co-PET is about 0 relative to the total copolymer composition. It contains .5 mol% to about 10 mol% isophthalic acid monomer. In a further embodiment of the spun yarn, the second polymer comprises Co-PET, which is an isophthalic acid monomer of about 0.5 mole percent to about 10 mole percent relative to the total copolymer composition. Contains.

In one embodiment, the spun yarn further comprises a second staple fiber in an amount of about 5% to about 95% by weight based on the total weight of the spun yarn. In one additional embodiment, the second staple fiber comprises polylactic acid, acrylic, nylon, olefin, acetate, rayon, or polyester. In a further embodiment, the second staple fiber comprises at least one natural fiber selected from cotton, linen, wool, angora, mohair, alpaca, or cashmere. In another embodiment, the second staple fiber comprises polylactic acid, acrylic, nylon, olefin, acetate, rayon, polyester, cotton, linen, wool, angora, mohair, alpaca, cashmere, or a mixture thereof. In yet another embodiment, the second staple fiber comprises cotton or wool.

In one embodiment, the second staple fiber comprises cotton. In one embodiment, the spun yarn further comprises a second staple fiber, including cotton, and the cotton is present in an amount of about 5% to about 95% by weight based on the total weight of the spun yarn. In another embodiment, the spun yarn further containing cotton has a cotton count of about 4 Ne to about 80 Ne.

In another embodiment, the second staple fiber comprises wool. In one embodiment, the spun yarn further comprises a second staple fiber containing wool, and the wool is present in an amount of about 5% to about 95% by weight based on the total weight of the spun yarn. In another embodiment, the spun yarn further comprising wool has a worsted count in the range of 7 Nm to 120 Nm.

In another embodiment, the fabric is disclosed, which comprises the spun yarn disclosed herein. In one embodiment, the fabric has a softer feel and better drapeability than fabrics of the same fabric structure made of rayon, polyethylene terephthalate, cotton, or a combination thereof. In one embodiment, the fabric is better than a fabric of the same fabric structure consisting of polyethylene terephthalate, cotton, rayon, or a combination thereof, i) better abrasion resistance determined according to ASTM D4966 standard test method; ii) ASTM D4970. Highly pilling evaluation value determined according to standard test method; or iii) Having at least one of the large bulkiness determined according to ASTM D1777 standard test method. In another embodiment, the fabric has better dyeability than a fabric of the same structure 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 structure made of polyethylene terephthalate, cotton, rayon, or a combination thereof. In a further embodiment, the fabric produces less pills (higher pilling rating) than fabrics of the same fabric structure consisting of polyethylene terephthalate, cotton, rayon, or a combination thereof. In an additional embodiment, the fabric has a greater bulk than a fabric of the same fabric structure consisting of polyethylene terephthalate, cotton, rayon, or a combination thereof.

In one embodiment, the fabric is a woven fabric having warp and weft threads. In one embodiment, the fabric is a woven fabric having warp and weft, and both warp, weft, or both warp and weft include spun yarns disclosed herein, respectively. In one additional embodiment, the warp yarns include the spun yarns disclosed herein. In another embodiment, the weft includes the spun yarn disclosed herein. In a further embodiment, the warp yarn and the weft yarn include the spun yarn disclosed in the present specification, respectively. In another embodiment, the fabric is a knitted fabric. In one embodiment, the knitted fabric has higher resilience than a knitted fabric of the same fabric structure consisting of polyethylene terephthalate, cotton, rayon, or a combination thereof. Articles containing fabrics disclosed herein, such as clothing, are also disclosed herein.

In yet another embodiment, melt-spun staple fibers are disclosed, the fibers comprising a primary polymer comprising poly (trimethylene terephthalate) or poly (butylene terephthalate) and poly (ethylene terephthalate) or Co-PET. Co-PET is a poly (ethylene terephthalate) copolymer containing a second polymer, Co-PET is a poly (ethylene terephthalate) copolymer containing an isophthalic acid monomer, and staple fibers are weights of the first polymer relative to the second polymer in the range of about 70:30 to about 30:70. It has a ratio and has a dry heat shrinkage of less than 6% as determined by the dry heat shrinkage method. In one embodiment, the melt-spun staple fiber comprises poly (trimethylene terephthalate) and poly (ethylene terephthalate). In another embodiment, the melt-spun staple fiber comprises poly (trimethylene terephthalate) and Co-PET. In an additional embodiment, the melt-spun staple fiber comprises poly (butylene terephthalate) and poly (ethylene terephthalate). In yet another embodiment, the melt-spun staple fiber comprises poly (butylene terephthalate) and Co-PET. In a further embodiment, the second polymer comprises Co-PET, which contains from about 0.5 mole percent to about 10 mole percent isophthalic acid monomers relative to the total copolymer composition. .. In yet another embodiment of the melt-spun staple fiber, the weight ratio of the first polymer to the second polymer is in the range of about 70:30 to 50:50.

All patents, patent applications and publications cited herein are hereby incorporated by reference in their entirety.

As used herein, the terms "embodiment" or "disclosure" are not meant to be limiting, and are defined or described herein in the claims. Generally applied to any of the forms. These terms are used interchangeably herein.

A number of terms and abbreviations are used in this disclosure. Unless otherwise stated, the following definitions apply.

The articles "one (a)", "one (an)" and "the" that precede an element or component are non-limiting with respect to the number of cases (ie, appearances) of the element or component. Intended to be. "One (a)", "one (an)" and "that (the)" should be construed to include one or at least one, and the singular form of an element or component is also Includes the plural unless it clearly means that the number is singular.

The term "comprising" means the presence of a defined feature, integer, process, or component as referred to in the claims, which is one or more other features, integers, steps. , Components, or groups thereof are not excluded. The term "contains" is intended to include embodiments contained by the terms "consisting essentially of" and "consisting of". Similarly, the term "consisting essentially of" is intended to include embodiments contained by the term "consisting of".

If present, all ranges are inclusive and combineable. For example, when the range of "1 to 5" is listed, the listed ranges are "1 to 4", "1 to 3", "1 to 2", "1 to 2 and 4 to 5". , "1-3 and 5", etc. should be construed to include.

As used herein in connection with a number, the term "about" refers to the range of +/- 0.5 of a number unless the term is otherwise specifically defined in the context. For example, the phrase "pH value of about 6" refers to a pH value of 5.5 to 6.5 unless the pH value is specifically defined.

Any numerical upper limit presented throughout this specification is intended to include any smaller numerical limit as if such smaller numerical limits were expressly stated herein. Any numerical lower limit shown throughout this specification will include any larger numerical limit as if such a larger numerical limit were explicitly stated herein. Any numerical range presented throughout this specification is any narrower numerical range that falls within such a wider numerical range, as if all such narrower numerical ranges were explicitly stated herein. Will include a range.

The features and advantages of this disclosure will be more easily understood by those skilled in the art by reading the detailed description below. For clarity, it is well understood that the particular features of the present disclosure, described above and below in the context of separate embodiments, may be combined and provided in a single element. Should be. Conversely, for brevity, the various features of the present disclosure described in the context of a single embodiment may also be provided separately or in any secondary combination.

The use of numbers in the various ranges specified in this application is approximated as if both the minimum and maximum values within the specified range were preceded by the word "about", unless otherwise stated otherwise. is described. In this form, subtle fluctuations above and below the specified range can be used to achieve substantially the same results as the values within this range. Similarly, disclosure of these ranges is intended to be a continuous range that includes each and every value between the minimum and maximum values.

As used herein:
By "poly (trimethylene terephthalate)" or PTT is meant a polymer containing repeating units derived from 1,3-propanediol and terephthalic acid (or equivalent). As used herein, the term "poly (trimethylene terephthalate) homopolymer" means a polymer that is substantially free of 1,3-propanediol and terephthalic acid (or equivalent). As used herein, the term "poly (trimethylene terephthalate)" also includes PTT copolymers, thereby including repeating units derived from 1,3-propanediol and terephthalic acid (or equivalent). And further means a polymer containing at least one additional unit derived from an additional monomer. Examples of PTT copolymers include copolyesters produced using three or more reactants, each of which has two ester-forming groups. For example, copoly (trimethylene terephthalate) is a chain, cyclic, and branched aliphatic dicarboxylic acid (eg, butanedioic acid) in which the comonomer used to produce copolyester has 4 to 12 carbon atoms. , Pentandioic acid, hexanedioic acid, dodecanedioic acid, and 1,4-cyclo-hexanedicarboxylic acid); aromatic dicarboxylic acids with 8-12 carbon atoms other than terephthalic acid (eg isophthalic acid and 2,6) −Naphthalenedicarboxylic acid); 2 to 8 carbon atom chain, cyclic, and branched aliphatic diols (other than 1,3-propanediols, such as ethanediols, 1,2-propanediols, 1,4). -Butandiol, 3-methyl-1,5-pentanediol, 2,2-dimethyl-1,3-propanediol, 2-methyl-1,3-propanediol, and 1,4-cyclohexanediol); and 4 An aliphatic and aromatic ether glycol having 10 to 10 carbon atoms (for example, a poly (ethylene ether) glycol having a molecular weight of less than about 460, such as a hydroquinonebis (2-hydroxyethyl) ether or a diethylene ether glycol). Can be used when selected from the group consisting of. The comonomer is typically present in the copolyester at a concentration in the range of about 0.5 mol% to about 15 mol% and can be present in an amount up to about 30 mol%.

As used herein, the term "poly (butylene terephthalate)" or PBT means a polymer that is substantially derived solely from 1,4-butanediol and terephthalic acid, and is a poly (butylene terephthalate) homopolymer. Also called. As used herein, the term "poly (butylene terephthalate) copolymer" comprises repeating units derived from 1,4-butanediol and terephthalic acid, and also at least one addition derived from an additional monomer. Refers to a polymer that also contains the units of, eg, a comonomer in the PTT copolymer disclosed herein.

As used herein, the term "poly (ethylene terephthalate)" or PET means a polymer that is substantially derived solely from ethylene glycol and terephthalic acid (or equivalents such as dimethyl terephthalate), and poly ( Ethylene terephthalate) Also called homopolymer. As used herein, the term "poly (ethylene terephthalate) copolymer" comprises repeating units derived from ethylene glycol and terephthalic acid (or equivalent), and at least one addition derived from an additional monomer. Refers to a polymer that also contains the unit of.

As used herein, the term "Co-PET" refers to a poly (ethylene terephthalate) copolymer in which the additional monomer is isophthalic acid (or ester equivalent). As such, Co-PET is a poly (ethylene terephthalate) copolymer containing an ethylene terephthalate and an isophthalic acid monomer.

"Staple" refers to either a natural fiber or a cut length from a filament. The term staple (fiber) is used in the textile industry to distinguish natural or cut artificial fibers from filaments. The artificial fibers are cut to a specific length, for example as long as 8 inches or only 1.5 inches or less, and they can be processed by cotton, wool, or worsted yarn spinning methods or flocked.

The term "molten-spun staple fiber" is used to melt a fiber-forming material, extrude it through a spinneret, and then cool to directly solidify it; such fused-spun fibers were stored and obtained as well. Refers to staple fibers obtained by combining with other batches of molten spun fibers, stretching them together, crimping them, heat-treating them for stabilization, and cutting them to obtain staple fibers.

The term "spun yarn" refers to a yarn produced by aligning cut staple fibers in multiple steps, in which the toe of the cut staple fibers is continuously drafted to an increasingly lower denier. It becomes a continuous strand and the staple fibers are twisted and bundled together.

"Unstretched yarn" is a term commonly applied to unstretched fibers and is used herein to be stretched and processed into yarn products, such as these yarns used in knitted or woven fabrics. Not intended to contain fibers. After melt spinning, the undrawn yarn accumulates until it produces a suitable total denier for the drawing machine. Accumulation can last up to 24 hours or more, including pauses or storage times between steps. For example, it generally takes 6 hours or more to produce undrawn yarn sufficient for practical kneading on the drawing line. For production scheduling and other practical considerations, the fiber may be stored for several days. Fibers exposed to such storage time are referred to as "aged" or "aged undrawn yarns".

The "drawing ratio" or "draw down" is the amount at which the filament stretches from the stretch after melt spinning. As used herein, the "stretch ratio" is the mechanical draw ratio, which is the ratio of the surface velocity of the tension roll to the feed roll (the roll that moves the fibers). Stretching may occur as a result of tension.

"Carding" is the process by which staple fiber bundles are loosened, individualized, arranged and formed into continuous, untwisted strands called slivers. The carding machine consists of a series of rolls whose surface is covered with many protruding metal teeth or pins.

"Toe" means a large strand of continuous artificial fiber filaments collected in a loose rope-like form without a clear twist before being stapled or formed into a sliver.

A "sliver" is a continuous strand of loosely collected, untwisted staple fibers. The sliver is sent by a card machine or a kneading machine. Sliver production is the first step in the weaving process of converting staple fibers into stretchable forms and finally twisting them into spun yarns.

The term "fabric" means a flat woven structure created by interlacing threads, fibers, or filaments.

The term "woven fabric" means a fabric composed of interlaced warp threads and weft (weft) threads. In the weaving process, the warp threads along the warp or vertical lines are held stationary with tension applied to the frame or loom, while the intersecting weft threads (also referred to as weft threads) It is threaded through the warp and inserted above and below the warp.

The term "knitted fabric" means a fabric made by knitting one or more ends of a yarn.

The term "fabric structure" means the details of the fabric structure including the style, width, type of weave or knit, the number of threads per inch in warp and weft, and the weight of the product.

The term "decitex" (dtex) is a unit of linear density measurement of fibers or threads and is defined as mass in grams per 10,000 meters.

The term "sliver linear density" means the weight of a 1 meter long sliver in grams.

The term "sliver linear density" (after the carding step) is the number of 840 yard cut length slivers of one pound weight represented by imperial number Ne, or 1000 meters long represented by g / meter. Means the weight of the sliver in grams.

The term "final sliver linear density" (after the kneading step) is the number of 840 yard cut length slivers of 1 pound weight represented by the imperial number Ne, or 1 meter expressed in g / meter. Means the weight of the sliver in grams.

The term "spot%" is the weight of a 400 meter long spun yarn or a 50 meter long blister yarn or a 50 meter long sliver measured by a Uster yarn spot tester-3 (UT3) and expressed as a percentage. Means standard mean deviation. Measured by industrially established methods using UT-3 and 400 m long threads or 25 m or 50 m long sliver or blister yarns.

The term "defect" with respect to spun yarn means the numerical sum of the number of thick regions, the number of thin regions, and the number of neps in a 1000 meter long yarn determined using a Uster yarn spot tester. As used herein, the term "thick region" means a location on a spun yarn having a mass greater than or equal to + 150% of the average mass of a yarn with a cut length of 8 mm. As used herein, the term "thin region" means a location on a spun yarn having a mass of 50% or less of the average mass of a yarn with a cut length of 8 mm. As used herein, the term "nep" means a location on a spun yarn having a mass of at least 200% of the average mass of a 1 mm cut length yarn.

The term "fluff index" refers to the average overall length of the protruding fiber per 1 cm length of the yarn, measured on a 400 m long yarn, optically measured using a UT3 tester and expressed as a standardized unit. ..

The present invention relates to a spun yarn containing a melt-spun staple fiber containing a first polymer containing poly (trimethylene terephthalate) or poly (butylene terephthalate) and a second polymer containing poly (ethylene terephthalate) or Co-PET. PET is a poly (ethylene terephthalate) copolymer containing an isophthalic acid monomer; and the first polymer contains poly (trimethylene terephthalate), and the weight ratio of poly (trimethylene terephthalate) to the second polymer is about 80. : 20 to about 10:90; or the first polymer contains poly (butylene terephthalate), and the weight ratio of poly (butylene terephthalate) to the second polymer is about 90:10 to about 10:90. Is the range of. Fused-spun staple fibers do not have a clear interface between the first and second polymers. The spun yarn has a boil-off shrinkage of at least about 6% as determined according to ASTM D2259. Optionally, the spun yarn can include a second staple fiber, such as cotton or wool. Fabrics with the desired characteristics can be made from the spun yarns described above.

The melt-spun staple fibers disclosed herein have improved yarn strength, crimp, and stability compared to PTT melt-spun staple fibers, and the properties of the melt-spun staple fibers make staples into spun yarns. It has been found to advantageously allow processing under conditions commonly used in PET during conversion. In addition, spun yarns comprising the melt-spun staple fibers disclosed herein, further comprising a second staple fiber, or essentially consisting entirely of melt-spun staple fibers, have cotton-like aesthetics, good strength, and. Allows the production of woven fabrics, knitted fabrics, and non-woven fabrics with other desired attributes.

In one embodiment, the melt-spun staple fiber of the spun yarn comprises a first polymer containing poly (trimethylene terephthalate). Poly (trimethylene terephthalate) suitable for use in melt-spun staple fibers is known in the art and can be prepared, for example, by polycondensation of 1,3-propanediol with terephthalic acid or a terephthalic acid equivalent. .. Optionally, 1,3-propanediol may be obtained biochemically from a renewable source (“biologically derived” 1,3-propanediol). Poly (trimethylene terephthalate) is described in E. et al. I. It is commercially available from duPont de Nemours and Company, Wilmington, DE under the trade name Solona®. Optionally, PTT or its monomers could be obtained by post-industrialization or recycling of post-consumer materials (ie, fiber or plastic waste).

"Equivalent to terephthalic acid" means a compound that acts substantially like terephthalic acid in the reaction with polymeric glycols and diols, as is generally understood by those skilled in the art. Examples of terephthalic acid equivalents include esters (such as dimethyl terephthalate) and ester-forming derivative acids such as halides (eg, acid chlorides) and anhydrides. Terephthalic acid and terephthalic acid esters, such as dimethyl esters of terephthalic acid, are suitable. Methods for preparing poly (trimethylene terephthalate) include, for example, US Pat. No. 6,277,947, US Pat. No. 6,326,456, US Pat. No. 6,657,044, US Pat. No. 6,353,062, US Pat. No. 6538076. It is disclosed in the specification and US Pat. No. 7,531617.

The 1,3-propanediol used to prepare poly (trimethylene terephthalate) as a reactant or as a component of the reactants was determined by gas chromatographic analysis in excess of about 99% by weight, eg, about 99. It preferably has a purity greater than 9% by weight. Purified 1,3-propanediol is disclosed in US Pat. No. 7038092, US Pat. No. 7098368, US Pat. No. 7084311, and US Pat. No. 7,919,658.

Suitable polys (trimethylene terephthalates) for use in melt-spun fibers are poly (trimethylene terephthalates) homopolymers (substantially derived from 1,3-propanediol and terephthalic acid and / or equivalents) and copolymers. Can be. In one embodiment, poly (trimethylene terephthalate) contains about 70 mol% or more of repeating units derived from 1,3-propanediol and terephthalic acid (and / or their equivalents such as dimethyl terephthalate). Poly (trimethylene terephthalate) is at least about 85 mol%, or at least about 90 mol%, or at least about 95 mol%, or at least about 99 mol%, or about 100 mol% of 1,3-propanediol and terephthalic acid. Can contain repeating units derived from (or equivalent).

Poly (trimethylene terephthalate) can contain small amounts of other comonomeres, and such comonomeres are usually selected so that they do not have a significant adverse effect on their properties. Such other comonomer contains sodium 5-sulfoisophthalate at a concentration in the range of, for example, about 0.2-5 mol%. Very small amounts of trifunctional comonomer, such as trimellitic acid, can be incorporated to control the viscosity.

Poly (trimethylene terephthalate) can contain up to 30 mol% of repeating units prepared from other diols or dibasic acids. Other dibasic acids 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 acids, and their derivatives such as dimethyl ester, diethyl ester, or dipropyl ester of these dicarboxylic acids. Other diols include ethylene glycol, 1,4-butanediol, 1,2-propanediol, diethylene glycol, triethylene glycol, 1,3-butanediol, 1,5-pentanediol, 1,6-hexanediol, and the like. Included are 1,2-, 1,3- and 1,4-cyclohexanedimethanol, and long-chain diols and polyols prepared from diols or reaction products of polyols and alkylene oxides.

Poly (trimethylene terephthalate) can also contain up to about 5 mol% of a functional monomer, eg, a sulfonate compound useful for imparting cationic dyeability. Specific examples of preferred sulfonate compounds include 5-lithium sulfoisophthalate, 5-sodium sulfoisophthalate, 5-potassium sulfoisophthalate, 4-sodium sulfo-2,6-naphthalenedicarboxylate, tetramethylphosphonium 3, 5-Dicarboxybenzene sulfonate, tetrabutylphosphonium 3,5-dicarboxybenzene sulfonate, tributyl-methylphosphonium 3,5-dicarboxybenzene sulfonate, tetrabutylphosphonium 2,6-dicarboxynaphthalene-4-sulfonate, tetramethylphosphonium Included are 2,6-dicarboxynaphthalene-4-sulfonate, ammonium 3,5-dicarboxybenzene sulfonate, and ester derivatives thereof, such as methyl or dimethyl ester.

Poly (trimethylene terephthalate) usually has an intrinsic viscosity of about 0.5 deciliters / gram (dl / g) or more and usually about 2 dl / g or less. In one embodiment, the poly (trimethylene terephthalate) has an intrinsic viscosity of about 0.7 dl / g or higher, for example 0.8 dl / g or higher, or for example 0.9 dl / g or higher, and the intrinsic viscosity is , Usually about 1.5 dl / g or less, for example 1.4 dl / g or less, and currently available commercial products have intrinsic viscosities of 1.2 dl / g or less.

In another embodiment, the melt-spun staple fiber of the spun yarn comprises a first polymer containing poly (butylene terephthalate). Poly (butylene terephthalate) suitable for use in melt-spun staple fibers is also known in the art and can be prepared, for example, by polycondensation of 1,4-butanediol and terephthalic acid. Poly (butylene terephthalate) is described in E. tere. I. It is commercially available from duPont de Nemours and Company, Wilmington, DE under the trade name Crustin®.

Suitable polys (butylene terephthalates) for use in melt-spun fibers can be homopolymers (substantially derived from 1,4-butanediol and terephthalic acid and / or equivalents) and copolymers. In one embodiment, poly (butylene terephthalate) contains about 80 mol% or more of repeating units derived from 1,4-butanediol and terephthalic acid. In other embodiments, poly (butylene terephthalate) is at least about 85 mol%, or at least about 90 mol%, or at least about 95 mol%, or at least about 99 mol%, or about 100 mol%, 1, It can contain repeating units derived from 4-butanediol and terephthalic acid (or equivalent). Poly (trimethylene terephthalate) can contain small amounts of other comonomer or functional monomers. Optionally, PBT or its monomers could be obtained by post-industrialization or recycling of post-consumer materials (ie, fiber or plastic waste).

Polyethylene terephthalate (PET) is a polyester that can be prepared by condensation polymerization of ethylene glycol and terephthalic acid (or dimethyl terephthalate or other terephthalate ester). The process of producing poly (ethylene terephthalate) is known and is disclosed, for example, in US Pat. No. 3,398,124 and US Pat. No. 3487049. Poly (ethylene terephthalate) suitable for preparing the melt-spun staple fibers disclosed herein is also commercially available. In one embodiment, the poly (ethylene terephthalate) is a homopolymer, substantially derived from ethylene glycol and terephthalic acid and / or equivalents. Optionally, PET or its monomers could be obtained by post-industrialization or recycling of post-consumer materials (ie, fiber or plastic waste).

In many applications, it may be desirable to modify the properties of poly (ethylene terephthalate) by adding a tertiary monomer. For example, a copolymer of polyethylene terephthalate can be prepared from a monomer of dimethyl terephthalate or terephthalic acid in combination with cyclohexanedimethanol or in combination with cyclohexanedimethanol and ethylene glycol. In other cases, isophthalic acid can be used in place of the terephthalic acid monomer moiety, which disrupts crystallinity and lowers the melting point of the copolymer referred to herein as "Co-PET".

As used herein, "Co-PET" is, as is known in the art, ethylene glycol, terephthalic acid (or dimethyl terephthalate or other terephthalate ester) and isophthalic acid (or dimethyl isophthalate or). Refers to a poly (ethylene terephthalate) copolymer that can be prepared by condensation polymerization of other terephthalate esters. Co-PET is also used in the process of producing fiber-grade post-consumer recycled Co-PETs in which recycled poly (ethylene terephthalate) bottles are shredded, melted, refined and repelletized. , Can be generated. The isophthalic acid monomer is usually present in Co-PET at a concentration in the range of about 0.5 mol% to about 15 mol% and can be present in an amount of up to about 30 mol% based on the total copolymer composition. For example, Co-PET is about 0.5, 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 19. It can contain 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, or 30 mol% isophthalic acid monomers. In one embodiment, the Co-PETs useful for melt-spun staple fibers disclosed herein are from about 1 mol% to about 5 mol%, or up to about 10 mol%, based on the total copolymer composition. Alternatively, it contains up to about 15 mol% of isophthalic acid monomer. In another embodiment, the useful Co-PET contains from about 0.5 mol% to about 3 mol% isophthalic acid monomer. The amount of isophthalic acid monomer in Co-PET can be selected to provide the Co-PET with the desired properties. It is believed that the lower the melting point of Co-PET, the better the compatibility between Co-PET and poly (trimethylene terephthalate) in melt spinning. Co-PET is commercially available.

In some embodiments, polyethylene terephthalate copolymers containing additional monomers other than isophthalic acid may be used. For example, ethylene glycol, terephthalic acid (or equivalent), and dicarboxylic acids such as succinic acid, adipic acid, azelaic acid, sebacic acid, glutaric acid, 1,10-decandicarboxylic acid, phthalic acid, dodecanedioic acid, sulfonated. Polyethylene terephthalate copolymers containing isophthalic acid, oxalic acid, fumaric acid, maleic acid, itaconic acid, 1,4-cyclohexanedicarboxylic acid, 1,3-cyclohexanedicarboxylic acid, 1,2-cyclohexanedicarboxylic acid, mixtures thereof, etc. It can be useful for preparing melt-spun staple fibers. Alternatively, ethylene glycol, terephthalic acid (or equivalent), and diols such as diethylene glycol, polyethylene glycol, butylene glycol, 1,4-cyclohexanedimethanol, 1,2-cyclohexanediol, 1,4-cyclohexanediol, Polyethylene terephthalate copolymers containing 1,3-cyclohexanediol, 1,5-pentanediol, 1,6-hexanediol, and mixtures thereof, may be useful in preparing melt-spun staple fibers.

In one embodiment, Co-PET is a poly (ethylene terephthalate) copolymer comprising an ethylene terephthalate and an isophthalic acid monomer. In another embodiment, Co-PET is a poly (ethylene terephthalate) copolymer consisting essentially of poly (ethylene terephthalate) and isophthalic acid monomers. In a further embodiment, Co-PET is a poly (ethylene terephthalate) copolymer consisting of poly (ethylene terephthalate) and isophthalic acid monomers.

The melt-spun staple fiber contains a first polymer containing poly (trimethylene terephthalate) or poly (butylene terephthalate) and a second polymer containing poly (ethylene terephthalate) or Co-PET, and the first polymer is poly (trimethylene terephthalate). The weight ratio of poly (trimethylene terephthalate) to the second polymer, including terephthalate), ranges from about 80:20 to about 10:90; or the first polymer contains poly (butylene terephthalate), poly. The weight ratio of (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 fiber comprises poly (trimethylene terephthalate) (PTT) and poly (ethylene terephthalate) (PET), and the melt-spun staple fiber is about 80 weight percent PTT and about 20 weight. Includes% PET. In one embodiment, the melt-spun staple fiber comprises about 75 weight percent PTT and about 25 weight percent PET. In one embodiment, the melt-spun staple fiber comprises about 70 weight percent PTT and about 30 weight percent PET. In another embodiment, the staple fiber comprises about 65 weight percent PTT and about 35 weight percent PET. In yet another embodiment, the staple fiber comprises about 60 weight percent PTT and about 40 weight percent PET. In an additional embodiment, the staple fiber comprises about 55 weight percent PTT and about 45 weight percent PET. In a further embodiment, the staple fiber comprises about 50 weight percent PTT and about 50 weight percent PET. In another embodiment, the staple fiber comprises about 45 weight percent PTT and about 55 weight percent PET. In a separate embodiment, the staple fiber comprises about 40 weight percent PTT and about 60 weight percent PET. In another embodiment, the staple fiber comprises about 35 weight percent PTT and about 65 weight percent PET. In yet another embodiment, the staple fiber comprises about 30 weight percent PTT and about 70 weight percent PET. In one embodiment, the melt-spun staple fiber comprises about 25 weight percent PTT and about 75 weight percent PET. In one embodiment, the melt-spun staple fiber comprises about 20 weight percent PTT and about 80 weight percent PET. In one embodiment, the melt-spun staple fiber comprises about 15 weight percent PTT and about 85 weight percent PET. In one embodiment, the melt-spun staple fiber comprises about 10 weight percent PTT and about 90 weight percent PET.

In one embodiment, the melt-spun staple fiber comprises poly (trimethylene terephthalate (PTT) and a poly (ethylene terephthalate) copolymer (Co-PET) containing an isophthalic acid monomer), 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 fiber comprises about 80 weight percent PTT and about 20 weight percent Co-PET. An additional embodiment. In embodiments, the melt-spun staple fiber comprises about 75 weight percent PTT and about 25 weight percent Co-PET. In one embodiment, the melt-spun staple fiber comprises about 70 weight percent PTT and about 30 weight percent. Includes% Co-PET. In another embodiment, the melt-spun staple fiber comprises about 65 weight percent PTT and about 35 weight percent Co-PET. In yet another embodiment, the melt-spun staple. The fiber comprises about 60 weight percent PTT and about 40 weight percent Co-PET. In an additional embodiment, the melt-spun staple fiber is about 55 weight percent PTT and about 45 weight percent Co-PET. In a further embodiment, the melt-spun staple fiber comprises about 50 weight percent PTT and about 50 weight percent Co-PET. In another embodiment, the melt-spun staple fiber contains about 45 weight percent. Includes a percent PTT and about 55 weight percent Co-PET. In a separate embodiment, the melt-spun staple fiber comprises about 40 weight percent PTT and about 60 weight percent Co-PET. Another embodiment. In yet another embodiment, the melt-spun staple fiber comprises about 35 weight percent PTT and about 65 weight percent Co-PET. In yet another embodiment, the melt-spun staple fiber contains about 30 weight percent PTT and about 70 weight percent. Includes weight percent Co-PET. In one embodiment, the melt-spun staple fiber comprises about 25 weight percent PTT and about 75 weight percent Co-PET. In another embodiment, the melt-spun staple fiber. Includes about 20 weight percent PTT and about 80 weight percent Co-PET. Yet another embodiment. In, the melt-spun staple fiber comprises about 15 weight percent PTT and about 85 weight percent Co-PET. In an additional embodiment, the melt-spun staple fiber comprises about 10 weight percent PTT and about 90 weight percent 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 has about 90 weight percent PBT and about 10 weight percent. Includes PET. In another embodiment, the melt-spun staple fiber comprises about 85 weight percent PBT and about 15 weight percent PET. In one embodiment, the melt-spun staple fiber comprises about 80 weight percent PBT and about 20 weight percent PET. In one embodiment, the melt-spun staple fiber comprises about 75 weight percent PBT and about 25 weight percent PET. In one embodiment, the melt-spun staple fiber comprises about 70 weight percent PBT and about 30 weight percent PET. In another embodiment, the staple fiber comprises about 65 weight percent PBT and about 35 weight percent PET. In yet another embodiment, the staple fiber comprises about 60 weight percent PBT and about 40 weight percent PET. In an additional embodiment, the staple fiber comprises about 55 weight percent PBT and about 45 weight percent PET. In a further embodiment, the staple fiber comprises about 50 weight percent PBT and about 50 weight percent PET. In another embodiment, the staple fiber comprises about 45 weight percent PBT and about 55 weight percent PET. In a separate embodiment, the staple fiber comprises about 40 weight percent PBT and about 60 weight percent PET. In another embodiment, the staple fiber comprises about 35 weight percent PBT and about 65 weight percent PET. In yet another embodiment, the staple fiber comprises about 30 weight percent PBT and about 70 weight percent PET. In one embodiment, the melt-spun staple fiber comprises about 25 weight percent PBT and about 75 weight percent PET. In one embodiment, the melt-spun staple fiber comprises about 20 weight percent PBT and about 80 weight percent PET. In one embodiment, the melt-spun staple fiber comprises about 15 weight percent PBT and about 85 weight percent PET. In one embodiment, the melt-spun staple fiber comprises about 10 weight percent PBT and about 90 weight percent PET.

In one embodiment, the melt-spun staple fiber comprises poly (butylene terephthalate (PBT) and a poly (ethylene terephthalate) copolymer (Co-PET) containing an isophthalic acid monomer, and the weight ratio of PBT to Co-PET is In one embodiment, the melt-spun staple fiber comprises about 85 weight percent PBT and about 15 weight percent Co-PET. In another embodiment. The melt-spun staple fiber comprises about 80 weight percent PBT and about 20 weight percent Co-PET. In an additional embodiment, the melt-spun staple fiber contains about 75 weight percent PBT and about 25 weight percent. Includes% Co-PET. In one embodiment, the melt-spun staple fiber comprises about 70 weight percent PBT and about 30 weight percent Co-PET. In another embodiment, the melt-spun staple fiber contains about 30 weight percent Co-PET. , About 65 weight percent PBT and about 35 weight percent Co-PET. In yet another embodiment, the melt-spun staple fiber comprises about 60 weight percent PBT and about 40 weight percent Co-PET. In one additional embodiment, the melt-spun staple fiber comprises about 55 weight percent PBT and about 45 weight percent Co-PET. In a further embodiment, the melt-spun staple fiber contains about 50 weight percent. Includes PBT and about 50 weight percent Co-PET. In another embodiment, the melt-spun staple fiber comprises about 45 weight percent PBT and about 55 weight percent Co-PET. In a separate embodiment. The melt-spun staple fiber comprises about 40 weight percent PBT and about 60 weight percent Co-PET. In another embodiment, the melt-spun staple fiber contains about 35 weight percent PBT and about 65 weight percent. In yet another embodiment, the melt-spun staple fiber comprises about 30 weight percent PBT and about 70 weight percent Co-PET. In one embodiment, the melt-spun staple fiber. Includes about 25 weight percent PBT and about 75 weight percent Co-PET. In another embodiment. , Molten-spun staple fibers contain about 20 weight percent PBT and about 80 weight percent Co-PET. In yet another embodiment, the melt-spun staple fiber comprises about 15 weight percent PBT and about 85 weight percent Co-PET. In an additional embodiment, the melt-spun staple fiber comprises about 10 weight percent PBT and about 90 weight percent Co-PET.

Melt-spun staple fibers can be formed in a two-step process. In the first step, the polymer is combined, melted and extruded to form a filament containing the polymer, which is cooled and recovered as tow. In the second step, the tow can be processed by at least one step of stretching, crimping, annealing, and cutting to prepare staple fibers. The process of preparing polyester staple fibers is known, for example, as disclosed in US Pat. No. 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 (a) the polymers are heated and mixed simultaneously, (b) premixed in separate devices prior to heating, or (c) mixed after heating. .. Mixing, heating, and forming can be performed by conventional instruments designed for that purpose, such as extruders. Its temperature is higher than the melting point of each polymer, but preferably lower than the lowest decomposition temperature. Suitable temperatures can range from about 140 ° C to about 240 ° C, such as at least about 200 ° C and up to about 230 ° C. In one embodiment, the melting temperature is less than 280 ° C.

In one embodiment, the polymer can be blended in the desired ratio, for example in a composite screw, to form pellets that are then fed to the spinning extruder. In another embodiment, the pellets can be made separately from each polymer, after which the pellets are blended together as a salt and pepper mixture using up to two feeders to the spinning extruder. Alternatively, pellets can be made separately from each polymer and premixed together before feeding the pellets to a spinning extruder. In yet another embodiment, the respective polymers can be melted to form a flow of molten polymer and then the flow of the molten polymer can be combined to form pellets from the molten mixture. The term "pellet" is commonly used herein and is used regardless of shape to include products sometimes referred to as "chips" or "flakes".

If desired, the additive can be added to poly (trimethylene terephthalate), poly (butylene terephthalate), poly (ethylene terephthalate), Co-PET, or a mixture of polymers. Useful additives include, for example, matting agents, nucleating agents, heat stabilizers, viscosity improvers, luminous agents, antioxidants, antibacterial agents, plasticizers, antistatic agents, lubricants, processing aids. , Flame retardants, dyes, TiO ₂ , or pigments.

The combined first and second polymers (ie, PTT and PET mixture, PTT and Co-PET mixture, PBT and PET mixture, or PBT and Co-PET mixture) are from about 250 ° C to about 275 ° C, eg at least about. It is extruded through a spun cap at a temperature of 255 ° C. and up to about 270 ° C. Spinned filaments are extruded in bundles containing at least about 34 filaments per thread line, eg, about 175 filaments to about 6800 filaments, or 6900 filaments or more. Undrawn filaments typically have a denier per filament in the range of about 3 to about 8 or more. Spinner orifices are usually circular for circular fiber cross sections, but orifices of various shapes can be used as needed, for example for trilobal or triangular cross sections. The spun filament has a denier in the range of about 3 to about 8 dpf and is collected in bundles (tows). Generally, the tow has less than 6% dry heat shrinkage as determined by the dry heat shrinkage method disclosed herein in the Examples.

In the second step of the process of preparing staple fibers, the tow is supplied from a series of cans or creels containing undrawn molten spun yarn. A finishing agent may be applied to promote the downstream of processing. Then, the tow is stretched while being immersed in a water bath having a finish diluted by heating. Generally, the feed roll may be kept at room temperature while the stretch roll may be heated. The stretched tow can be stabilized, optionally further stretched by passing through a chamber saturated with water vapor, and annealed on multiple heated stretched roll modules before passing over the roll module at room temperature. Will be done. Various simplifications of the drawing zone are possible by increasing or decreasing the heated drawing module or the room temperature drawing module in order to optimally draw and stabilize the yarn in preparation for crimping. The crimping module usually uses a steam chamber that reduces the Young's modulus of the yarn in preparation for crimping, and the crimping machine is usually a mechanical staff box type flapper gate that is affected by air pressure. It is a crimping machine with. A series of driven rolls pull the yarn toe into the crimper box; the back pressure of the flapper controls the flow from the crimper box so that the yarn shrinks and forms crimps. The crimp toe passes through the incinerator section before being stapled.

The final denier per filament of the melt-spun staple fiber may be in the range 1-2 for cotton-based processing and 2-3 for wool-based processing.

The melt-spun staple fibers disclosed herein provide processing advantages. For example, staple fibers can be processed with good productivity through the opening, carding, and kneading steps in the production of spun yarn. The melt-spun staple fibers disclosed herein may be carried out in a rayon spinning process using conditions typical of PET staple spinning.

The drawn fibers can be cut into staple fibers of any desired length. Carding can be difficult if the staple fibers are too short. If the staple fibers are too long, it can be difficult to spin with cotton or woolen instruments. For use in the cotton scheme, staple fibers typically have lengths in the range of about 32 mm to about 51 mm, for example in the range of about 38-40 mm. For use in the worsted yarn scheme, staple fibers typically have a plurality of cut lengths having an average cut length in the range of about 70 mm to about 100 mm, for example in the range of about 80 mm to about 90 mm. Staple fibers can be crimped and have about 10 to about 18 crimps per inch, eg, about 11 to about 15, full sinus arc. In the cotton method, the melt-spun staple fibers were obtained using the methods disclosed in the examples herein below, with denier per 1-2 filaments, yarn strength in excess of 4 g / denier, and elongation at break of 20-60%. Usually has. In the worsted yarn scheme, melt-spun staple fibers typically have a denier per 2-4 filaments, a yarn strength of more than 4 g / denier, and a breaking elongation of 30-90%.

The melt-spun staple fibers disclosed herein can be used to make spun yarns. In one embodiment, the spun yarn consists essentially of molten spun staple fibers and does not contain any other type of staple fibers. In another embodiment, the spun yarn comprises a melt-spun staple fiber disclosed herein. In a further 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 fiber can include at least one natural fiber. In a further embodiment, the second staple fiber comprises at least one natural fiber selected from cotton, linen, wool, angora, mohair, alpaca, or cashmere. In another embodiment, the second staple can include at least one synthetic fiber. In a further embodiment, the second staple fiber comprises polylactic acid, acrylic, nylon, olefin, acetate, rayon, or polyester. In yet another embodiment, the second staple fiber can include at least one regenerated cellulose fiber. As used herein, the term "regenerated cellulose fiber" means textile fiber made from regenerated cellulose, also called rayon, lyocell, viscose, Modal®, and Tencel®. Trademark) Includes fiber. As used herein, "lyocell" means the form of rayon made of cellulosic fibers made by melting bleached wood pulp using dry jet wet spinning. As used herein, "viscose" means regenerated artificial fibers made from cellulose and obtained by the viscose process. As used herein, "Modal®" means fibers made from wood pulp from beech trees. As used herein, "Tencel®" means fibers made from eucalyptus wood.

In one embodiment, the spun yarn comprises melt-spun staple fibers containing a first polymer containing PTT or PBT and a second polymer containing PET or Co-PET, and 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 containing cotton. In a further embodiment, the first polymer comprises poly (butylene terephthalate) and the weight ratio of poly (butylene terephthalate) to the second polymer is about 90:10 to about 10:90, eg, about 90: 10-10. The range is about 80:20, and the spun yarn further comprises a second staple fiber containing cotton. Cotton can be present in the spun yarn in an amount of about 5% to about 95% by weight based on the total weight of the spun yarn, and molten spun staple fibers in an amount of about 95% to about 5% by weight. Can be present in spun yarn. For example, the spun yarn is about 5% by weight cotton and about 95% by weight molten-spun staple fiber, or about 10% by weight cotton and about 90% by weight molten-spun staple fiber, based on the total weight of the spun yarn. Or about 15% by weight cotton and about 85% by weight molten-spun staple fiber, or about 20% by weight cotton and about 80% by weight molten-spun staple fiber, or about 25% by weight cotton and about 75% by weight molten. About 30% by weight cotton and about 70% by weight molten-spun staple fiber, or about 35% by weight cotton and about 65% by weight molten-spun staple fiber, or about 40% by weight cotton and about 60. About 45% by weight of molten-spun staple fiber, or about 45% by weight cotton and about 55% by weight of molten-spun staple fiber, or about 50% by weight of cotton and about 50% by weight of molten-spun staple fiber, or about 55% by weight. Cotton and about 45% by weight molten-spun staple fiber, or about 60% by weight cotton and about 40% by weight molten-spun staple fiber, or about 65% by weight cotton and about 35% by weight molten-spun staple fiber, or about 70% by weight cotton and about 30% by weight molten-spun staple fiber, or about 75% by weight cotton and about 25% by weight molten-spun staple fiber, or about 80% by weight cotton and about 20% by weight molten-spun staple Can contain fibers. In another embodiment, the spun yarn may contain more than 95% by weight of molten spun staple fibers and less than 5% by weight of second staple fibers containing cotton. The relative amounts of cotton and melt-spun staple fibers are selected to provide the desired properties for spun yarns and fabrics made from yarn. The spun yarn can have a cotton count (Ne) of about 4 to about 70, for example 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 containing cotton can have a breaking strength of at least 10 cN / tex. In some embodiments, the cotton-containing spun yarn can have a breaking strength of at least 10 cN / tex. The spun yarn containing cotton can have a breaking point elongation of at least 4%. Methods for determining yarn strength and breaking point elongation are provided in the following examples herein.

In another embodiment, the spun yarn comprises a melt-spun staple fiber containing a first polymer containing PTT or PBT and a second polymer containing PET or Co-PET, and the weight of the first polymer relative to the second polymer. The ratio 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 50:50. And the spun yarn further comprises a second staple fiber containing wool. In a further embodiment, the first polymer comprises poly (butylene terephthalate) and the weight ratio of poly (butylene terephthalate) to the second polymer is about 90:10 to about 10:90, eg, about 90: 10-10. The range is about 80:20, and the spun yarn further comprises a second staple fiber containing wool. The term "wool" refers to fibers from sheep or lamb fleece. Wool can be present in the yarn in an amount of about 5% to about 95% by weight based on the total weight of the spun yarn, and molten spun staple fiber is in an amount of about 95% to about 5% by weight. Can exist in. For example, the spun yarn is about 5% by weight wool and about 95% by weight melt-spun staple fiber, or about 10% by weight wool and about 90% by weight melt-spun staple fiber, based on the total weight of the spun yarn. Or about 15% by weight wool and about 85% by weight melt-spun staple fiber, or about 20% by weight wool and about 80% by weight melt-spun staple fiber, or about 25% by weight wool and about 75% by weight melt. Spinned staple fiber, or about 30% by weight wool and about 70% by weight molten-spun staple fiber, or about 35% by weight wool and about 65% by weight molten-spun staple fiber, or about 40% by weight wool and about 60. About 45% by weight of melt-spun staple fiber, or about 45% by weight of wool and about 55% by weight of melt-spun staple fiber, or about 50% by weight of wool and about 50% by weight of melt-spun staple fiber, or about 55% by weight. Wool and about 45% by weight melt-spun staple fiber, or about 60% by weight wool and about 40% by weight melt-spun staple fiber, or about 65% by weight wool and about 35% by weight melt-spun staple fiber, or about 70% by weight wool and about 30% by weight melt-spun staple fiber, or about 75% by weight wool and about 25% by weight melt-spun staple fiber, or about 80% by weight wool and about 20% by weight melt-spun staple fiber. Fiber, or about 85% by weight wool and about 15% by weight melt-spun staple fiber, or about 90% by weight wool and about 10% by weight molten table fiber, or about 95% by weight wool and about 5% by weight. It can contain melt-spun staple fibers. The relative amounts of wool and melt-spun staple fibers are selected to provide the desired properties for spun yarns and fabrics made from yarn. The spun yarn has a worsted count (Nm) of about 7 to about 120, for example 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. Can have.

In another embodiment, the spun yarn comprises a melt-spun staple fiber containing a first polymer containing PTT or PBT and a second polymer containing PET or Co-PET, and the weight of the first polymer relative to the second polymer. The ratio 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 50:50. And the spun yarn further comprises a second staple fiber containing rayon. In a further embodiment, the first polymer comprises poly (butylene terephthalate) and the weight ratio of poly (butylene terephthalate) to the second polymer is about 90:10 to about 10:90, eg, about 90: 10-10. The range is about 80:20, and the spun yarn further comprises a second staple fiber containing rayon. As used herein, "rayon" means woven fibers made from regenerated cellulose, including lyocell, viscose, Modal®, and Tencel® fibers. In spun yarn, rayon can be present in an amount of about 5% to about 95% by weight based on the total weight of the spun yarn, and molten spun staple fiber in an amount of about 95% to about 5% by weight. Can exist. For example, the spun yarn is about 5% by weight rayon and about 95% by weight molten-spun staple fiber, or about 10% by weight rayon and about 90% by weight molten-spun staple fiber, based on the total weight of the spun yarn. Or about 15% by weight rayon and about 85% by weight molten-spun staple fiber, or about 20% by weight rayon and about 80% by weight molten-spun staple fiber, or about 25% by weight rayon and about 75% by weight molten. Spinned staple fiber, or about 30% by weight rayon and about 70% by weight molten-spun staple fiber, or about 35% by weight rayon and about 65% by weight molten-spun staple fiber, or about 40% by weight rayon and about 60. About 45% by weight of molten-spun staple fiber, or about 45% by weight of rayon and about 55% by weight of molten-spun staple fiber, or about 50% by weight of rayon and about 50% by weight of molten-spun staple fiber, or about 55% by weight. Rayon and about 45% by weight molten-spun staple fiber, or about 60% by weight rayon and about 40% by weight molten-spun staple fiber, or about 65% by weight rayon and about 35% by weight molten-spun staple fiber, or about 70% by weight rayon and about 30% by weight molten-spun staple fiber, or about 75% by weight rayon and about 25% by weight molten-spun staple fiber, or about 80% by weight rayon and about 20% by weight molten-spun staple. Fiber, or about 85% by weight rayon and about 15% by weight molten-spun staple fiber, or about 90% by weight rayon and about 10% by weight molten staple fiber, or about 95% by weight rayon and about 5% by weight. It can contain melt-spun staple fibers. The relative amounts of rayon and melt-spun staple fibers are selected to provide the desired properties for spun yarns and fabrics made from yarn. The spun yarn can have a cotton count (Ne) of about 4 to about 80, for example about 10 to about 60, or about 12 to about 40.

In another embodiment, the spun yarn comprises a melt-spun staple fiber containing a first polymer containing PTT or PBT and a second polymer containing PET or Co-PET, and the weight of the first polymer relative to the second polymer. The ratio 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 50:50. And the spun yarn further comprises a second staple fiber containing acrylic. In a further embodiment, the first polymer comprises poly (butylene terephthalate) and the weight ratio of poly (butylene terephthalate) to the second polymer is about 90:10 to about 10:90, eg, about 90: 10-10. The range is about 80:20, and the spun yarn further comprises a second staple fiber containing acrylic. As used herein, "acrylic fiber" means a synthetic fiber made from polyacrylonitrile with an average molecular weight of about 100,000 and a monomer unit of about 1900. Acrylic fibers can be present in an amount of about 5% to about 95% by weight based on the total weight of the spun yarn, and molten spun staple fibers can be present in an amount of about 95% to about 5% by weight. For example, the spun yarn is about 5% by weight acrylic fiber and about 95% by weight molten-spun staple fiber, or about 10% by weight acrylic fiber and about 90% by weight molten-spun staple, based on the total weight of the spun yarn. Fiber, or about 15% by weight acrylic fiber and about 85% by weight molten-spun staple fiber, or about 20% by weight acrylic fiber and about 80% by weight molten-spun staple fiber, or about 25% by weight acrylic fiber and about 75% by weight melt-spun staple fiber, or about 30% by weight acrylic fiber and about 70% by weight melt-spun staple fiber, or about 35% by weight acrylic fiber and about 65% by weight melt-spun staple fiber, or about 40. About 60% by weight acrylic fiber and about 60% by weight molten-spun staple fiber, or about 45% by weight acrylic fiber and about 55% by weight molten-spun staple fiber, or about 50% by weight acrylic fiber and about 50% by weight molten. Spinned staple fiber, or about 55% by weight acrylic fiber and about 45% by weight molten-spun staple fiber, or about 60% by weight acrylic fiber and about 40% by weight molten-spun staple fiber, or about 65% by weight acrylic fiber. And about 35% by weight molten-spun staple fiber, or about 70% by weight acrylic fiber and about 30% by weight molten-spun staple fiber, or about 75% by weight acrylic fiber and about 25% by weight molten-spun staple fiber, or About 80% by weight acrylic fiber and about 20% by weight molten-spun staple fiber, or about 85% by weight acrylic fiber and about 15% by weight molten-spun staple fiber, or about 90% by weight acrylic fiber and about 10% by weight. , Or about 95% by weight acrylic fiber and about 5% by weight molten spun staple fiber. The relative amounts of acrylic fibers and melt-spun staple fibers are selected to provide the desired properties for spun yarns and fabrics made from yarn. The spun yarn can have a cotton count (Ne) of about 4 to about 80, for example about 10 to about 60, or about 12 to about 40.

In another embodiment, the spun yarn comprises a melt-spun staple fiber containing a first polymer containing PTT or PBT and a second polymer containing PET or Co-PET, and the weight of the first polymer relative to the second polymer. The ratio 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 50:50. And the spun yarn further comprises a second staple fiber containing polylactic acid (PLA). In a further embodiment, the first polymer comprises poly (butylene terephthalate) and the weight ratio of poly (butylene terephthalate) to the second polymer is about 90:10 to about 10:90, eg, about 90: 10-10. The range is about 80:20, and the spun yarn further comprises a second staple fiber containing PLA. As used herein, "polylactic acid fiber" means an artificial fiber in which the fiber-forming material is composed of lactic acid ester units derived from at least 85% by weight of natural sugar. PLA can be present in an amount of about 5% to about 95% by weight based on the total weight of the spun yarn, and molten spun staple fibers can be present in an amount of about 95% to about 5% by weight. For example, the spun yarn is about 5% by weight PLA and about 95% by weight molten-spun staple fiber, or about 10% by weight PLA and about 90% by weight molten-spun staple fiber, based on the total weight of the spun yarn. Or about 15% by weight PLA and about 85% by weight molten-spun staple fiber, or about 20% by weight PLA and about 80% by weight molten-spun staple fiber, or about 25% by weight PLA and about 75% by weight molten. Spinned staple fiber, or about 30% by weight PLA and about 70% by weight molten-spun staple fiber, or about 35% by weight PLA and about 65% by weight molten-spun staple fiber, or about 40% by weight PLA and about 60. About 45% by weight of melt-spun staple fiber, or about 45% by weight PLA and about 55% by weight of melt-spun staple fiber, or about 50% by weight of PLA and about 50% by weight of melt-spun staple fiber, or about 55% by weight. PLA and about 45% by weight molten-spun staple fiber, or about 60% by weight PLA and about 40% by weight molten-spun staple fiber, or about 65% by weight PLA and about 35% by weight molten-spun staple fiber, or about 70% by weight PLA and about 30% by weight molten-spun staple fiber, or about 75% by weight PLA and about 25% by weight molten-spun staple fiber, or about 80% by weight PLA and about 20% by weight molten-spun staple. Fiber, or about 85% by weight PLA and about 15% by weight molten-spun staple fiber, or about 90% by weight PLA and about 10% by weight molten staple fiber, or about 95% by weight PLA and about 5% by weight. It can contain melt-spun staple fibers. The relative amounts of PLA and melt-spun staple fibers are selected to provide the desired properties for spun yarns and fabrics made from yarn.

In another embodiment, the spun yarn comprises a melt-spun staple fiber containing a first polymer containing PTT or PBT and a second polymer containing PET or Co-PET, and the weight of the first polymer relative to the second polymer. The ratio 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 50:50. And the spun yarn further comprises a second staple fiber containing nylon. In a further embodiment, the first polymer comprises poly (butylene terephthalate) and the weight ratio of poly (butylene terephthalate) to the second polymer is about 90:10 to about 10:90, eg, about 90: 10-10. The range is about 80:20, and the spun yarn further comprises a second staple fiber containing nylon. As used herein, "nylon fiber" means an artificial fiber in which the fiber-forming material is a long-chain synthetic polyamide in which less than 85% of amide bonds are directly attached to two aliphatic groups. .. Nylon can be present in an amount of about 5% to about 95% by weight based on the total weight of the spun yarn, and molten spun staple fibers can be present in an amount of about 95% to about 5% by weight. For example, the spun yarn is about 5% by weight nylon and about 95% by weight molten-spun staple fiber, or about 10% by weight nylon and about 90% by weight molten-spun staple fiber, based on the total weight of the spun yarn. Or about 15% by weight nylon and about 85% by weight molten-spun staple fiber, or about 20% by weight nylon and about 80% by weight molten-spun staple fiber, or about 25% by weight nylon and about 75% by weight molten. About 30% by weight nylon and about 70% by weight molten-spun staple fiber, or about 35% by weight nylon and about 65% by weight molten-spun staple fiber, or about 40% by weight nylon and about 60. About 45% by weight of fused-spun staple fiber, or about 45% by weight nylon and about 55% by weight of molten-spun staple fiber, or about 50% by weight of nylon and about 50% by weight of molten-spun staple fiber, or about 55% by weight. Nylon and about 45% by weight molten-spun staple fiber, or about 60% by weight nylon and about 40% by weight molten-spun staple fiber, or about 65% by weight nylon and about 35% by weight molten-spun staple fiber, or about 70% by weight nylon and about 30% by weight molten-spun staple fiber, or about 75% by weight nylon and about 25% by weight molten-spun staple fiber, or about 80% by weight nylon and about 20% by weight molten-spun staple. Fiber, or about 85% by weight nylon and about 15% by weight molten-spun staple fiber, or about 90% by weight nylon and about 10% by weight molten staple fiber, or about 95% by weight nylon and about 5% by weight. It can contain melt-spun staple fibers. The relative amounts of nylon and melt-spun staple fibers are selected to provide the desired properties for spun yarns and fabrics made from yarn.

In another embodiment, the spun yarn comprises a melt-spun staple fiber containing a first polymer containing PTT or PBT and a second polymer containing PET or Co-PET, and the weight of the first polymer relative to the second polymer. The ratio 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 50:50. And the spun yarn further comprises a second staple fiber containing an olefin. In a further embodiment, the first polymer comprises poly (butylene terephthalate) and the weight ratio of poly (butylene terephthalate) to the second polymer is about 90:10 to about 10:90, eg, about 90: 10-10. The range is about 80:20, and the spun yarn further comprises a second staple fiber containing an olefin. As used herein, "olefin fiber" is another olefin unit excluding amorphous (amorphous) polyolefin in which the fiber-forming material corresponds to at least 85% by weight of ethylene, propylene, or rubber fiber. It means an artificial fiber which is an arbitrary long-chain synthetic polymer composed of. Olefin fibers can be present in an amount of about 5% to about 95% by weight based on the total weight of the spun yarn, and molten spun staple fibers can be present in an amount of about 95% to about 5% by weight. For example, the spun yarn is about 5% by weight of olefin fibers and about 95% by weight of melt-spun staple fibers, or about 10% by weight of olefin fibers and about 90% by weight of melt-spun staples, based on the total weight of the spun yarns. Fiber, or about 15% by weight olefin fiber and about 85% by weight melt-spun staple fiber, or about 20% by weight olefin fiber and about 80% by weight melt-spun staple fiber, or about 25% by weight olefin fiber and about 75% by weight melt-spun staple fiber, or about 30% by weight olefin fiber and about 70% by weight melt-spun staple fiber, or about 35% by weight olefin fiber and about 65% by weight melt-spun staple fiber, or about 40. About 60% by weight of olefin fibers and about 60% by weight of melt-spun staple fibers, or about 45% by weight of olefin fibers and about 55% by weight of melt-spun staple fibers, or about 50% by weight of olefin fibers and about 50% by weight of melt. Spinned staple fiber, or about 55% by weight olefin fiber and about 45% by weight molten-spun staple fiber, or about 60% by weight olefin fiber and about 40% by weight molten-spun staple fiber, or about 65% by weight olefin fiber. And about 35% by weight of melt-spun staple fibers, or about 70% by weight of olefin fibers and about 30% by weight of melt-spun staple fibers, or about 75% by weight of olefin fibers and about 25% by weight of melt-spun staple fibers, or About 80% by weight of olefin fibers and about 20% by weight of melt-spun staple fibers, or about 85% by weight of olefin fibers and about 15% by weight of melt-spun staple fibers, or about 90% by weight of olefin fibers and about 10% by weight. Can contain about 95% by weight of olefin fibers and about 5% by weight of melt-spun staple fibers. The relative amounts of olefin fibers and melt-spun staple fibers are selected to provide the desired properties for spun yarns and fabrics made from yarn.

In another embodiment, the spun yarn comprises a melt-spun staple fiber containing a first polymer containing PTT or PBT and a second polymer containing PET or Co-PET, and the weight of the first polymer relative to the second polymer. The ratio 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 50:50. And the spun yarn further comprises a second staple fiber containing acetate. In a further embodiment, the first polymer comprises poly (butylene terephthalate) and the weight ratio of poly (butylene terephthalate) to the second polymer is about 90:10 to about 10:90, eg, about 90: 10-10. The range is about 80:20, and the spun yarn further comprises a second staple fiber containing acetate. As used herein, "acetate fiber" means an artificial fiber in which the fiber-forming material is cellulose acetate and contains diacetate and triacetate. Diacetate is defined as a cellulose acetate fiber in which more than 74% and less than 92% hydroxyl groups are acetylated (esterification degree greater than 2.22 and less than 2.76). Triacetate is defined as a cellulose acetate fiber in which more than 92% of hydroxyl groups are acetylated (esterification degree is greater than 2.76 and less than 3.00). Acetate fibers can be present in an amount of about 5% to about 95% by weight based on the total weight of the spun yarn, and molten spun staple fibers can be present in an amount of about 95% to about 5% by weight. For example, the spun yarn is about 5% by weight acetate fiber and about 95% by weight molten-spun staple fiber, or about 10% by weight acetate fiber and about 90% by weight molten-spun staple, based on the total weight of the spun yarn. Fiber, or about 15% by weight acetate fiber and about 85% by weight molten-spun staple fiber, or about 20% by weight acetate fiber and about 80% by weight molten-spun staple fiber, or about 25% by weight acetate fiber and about 75% by weight melt-spun staple fiber, or about 30% by weight acetate fiber and about 70% by weight melt-spun staple fiber, or about 35% by weight acetate fiber and about 65% by weight melt-spun staple fiber, or about 40. About 60% by weight of acetate fiber and about 60% by weight of melt-spun staple fiber, or about 45% by weight of acetate fiber and about 55% by weight of melt-spun staple fiber, or about 50% by weight of acetate fiber and about 50% by weight of melt. Spinned staple fiber, or about 55% by weight acetate fiber and about 45% by weight molten-spun staple fiber, or about 60% by weight acetate fiber and about 40% by weight molten-spun staple fiber, or about 65% by weight acetate fiber. And about 35% by weight of melt-spun staple fibers, or about 70% by weight of acetate fibers and about 30% by weight of melt-spun staple fibers, or about 75% by weight of acetate fibers and about 25% by weight of melt-spun staple fibers, or About 80% by weight acetate fiber and about 20% by weight molten-spun staple fiber, or about 85% by weight acetate fiber and about 15% by weight molten-spun staple fiber, or about 90% by weight acetate fiber and about 10% by weight. Can contain about 95% by weight of acetate fibers and about 5% by weight of molten spun staple fibers. The relative amounts of acetate fibers and melt-spun staple fibers are selected to provide the desired properties for spun yarns and fabrics made from yarn.

In another embodiment, the spun yarn comprises a melt-spun staple fiber containing a first polymer containing PTT or PBT and a second polymer containing PET or Co-PET, and the weight of the first polymer relative to the second polymer. The ratio 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 50:50. And the spun yarn further comprises a second staple fiber containing a polyester such as poly (ethylene terephthalate), poly (trimethylene terephthalate), or poly (butylene terephthalate). In a further embodiment, the first polymer comprises poly (butylene terephthalate) and the weight ratio of poly (butylene terephthalate) to the second polymer is about 90:10 to about 10:90, eg, about 90: 10-10. The range is about 80:20, and the spun yarn further comprises a second staple fiber containing polyester. Polyester can be present in an amount of about 5% to about 95% by weight based on the total weight of the spun yarn, and molten spun staple fibers can be present in an amount of about 95% to about 5% by weight. For example, the spun yarn is about 5% by weight polyester fiber and about 95% by weight melt-spun staple fiber, or about 10% by weight polyester fiber and about 90% by weight melt-spun staple, based on the total weight of the spun yarn. Fiber, or about 15% by weight polyester fiber and about 85% by weight melt-spun staple fiber, or about 20% by weight polyester fiber and about 80% by weight melt-spun staple fiber, or about 25% by weight polyester fiber and about 75% by weight melt-spun staple fiber, or about 30% by weight polyester fiber and about 70% by weight melt-spun staple fiber, or about 35% by weight polyester fiber and about 65% by weight melt-spun staple fiber, or about 40. About 60% by weight polyester fiber and about 60% by weight melt-spun staple fiber, or about 45% by weight polyester fiber and about 55% by weight melt-spun staple fiber, or about 50% by weight polyester fiber and about 50% by weight melt. Spinned staple fiber, or about 55% by weight polyester fiber and about 45% by weight molten-spun staple fiber, or about 60% by weight polyester fiber and about 40% by weight molten-spun staple fiber, or about 65% by weight polyester fiber. And about 35% by weight of melt-spun staple fibers, or about 70% by weight of polyester fibers and about 30% by weight of melt-spun staple fibers, or about 75% by weight of polyester fibers and about 25% by weight of melt-spun staple fibers, or About 80% by weight polyester fiber and about 20% by weight melt-spun staple fiber, or about 85% by weight polyester fiber and about 15% by weight melt-spun staple fiber, or about 90% by weight polyester fiber and about 10% by weight. Can contain about 95% by weight polyester fiber and about 5% by weight molten spun staple fiber. Relative amounts of polyester fibers and melt-spun polyester staple fibers are selected to provide the desired properties for spun yarns and fabrics made from yarn. The spun yarn can have a cotton count (Ne) of about 4 to about 80, for example about 10 to about 60, or about 12 to about 40.

The melt-spun staple fibers are blended with a second fiber and then cut to the desired length for processing in a cotton or woolen fashion. For example, melt-spun staple fibers and spun yarns containing cotton, linen, polylactic acid, acrylic, nylon, olefin, acetate, polyester, or rayon fibers can usually be processed by the cotton method. Fused-spun staple fibers and spun yarns containing wool, angora, mohair, or cashmere fibers can usually be processed by a woolen method.

To form a spun yarn, a melt-spun staple fiber and optionally at least one second staple fiber is a process in which, for example, a fiber veil is opened, mixed, and laminated. It is first blended by stack mixing. The fiber bundle can be opened to a smaller size fiber tuft in a blow room using, for example, a series of coarse-spreading machines and then a fine-spreading machine. The smaller fiber bundles are then carded to form continuous fiber strands called slivers, in which almost all fibers are oriented along the sliver axis. Since slivers from carding machines can have very large mass / length variability, a large number of carding slivers (ie 6) are usually combined and, for example, kneading machines or known in the art. In other ways, the same amount is drafted at the same time (ie 6 times) to further orient the fibers in the resulting sliver. The sliver delivered from the finisher kneader has minimal mass / length variation, but has a higher linear density compared to the linear density desired for the final spun yarn, so the sliver linear density is kneaded. Reduced in the article process. Generally, the kneading process is carried out in two steps, in which partial drafting and twisting are performed to prepare the blister. The blister is further converted to spun yarn by drafting the blister in the final spinning frame using known processes such as rings, open ends, air jets, and vortex spinning. The spun yarn can be wrapped in a small package called a cup in ring spinning; several cups can be wrapped together in a large final package called a cone.

Woven and knitted fabrics can be made from the spun yarns disclosed herein. Examples of stretch fabrics include circular weaves, plain weaves, and warp weaves, as well as plain weaves, twill weaves, and satin weaves. Articles such as clothing can be made from fabrics containing spun yarns disclosed herein. Nonwovens can be made from staple fibers disclosed herein and can be useful for articles such as wipes, diapers, napkins, and personal care products. Nonwovens can also be used as a substrate for coated fabrics and for a variety of other uses such as clothing and household items.

The spun yarns disclosed herein are useful for making fabrics such as woven or knitted fabrics. In one embodiment, the fabric containing the spun yarn disclosed herein is a woven fabric having warp and weft yarns. In one embodiment, the warp yarn includes the spun yarn disclosed herein. In another embodiment, the weft includes the spun yarn disclosed herein. In one additional embodiment, the warp and weft yarns each include a spun yarn disclosed herein. The woven fabric can further include, for example, additional threads or continuous filaments in the warp, in the weft, or in both the warp and the weft. In another embodiment, the spun yarns disclosed herein are used for warp yarns, and spun yarns containing natural fibers are used for weft yarns. In another embodiment, the spun yarns disclosed herein are used for warp yarns, and spun yarns containing synthetic fibers are used for weft yarns. In yet another embodiment, spun yarns containing natural fibers are used for warp yarns, and the spun yarns disclosed herein are used for weft yarns. In a further embodiment, spun yarns containing synthetic fibers are used for warp yarns, and the spun yarns disclosed herein are used for weft yarns. In yet another embodiment, the spun yarns disclosed herein are used for both warp and weft yarns. Knitted fabrics can be made using only the spun yarns disclosed herein or with spun yarns containing natural or synthetic fibers. The woven fabric containing the spun yarn disclosed in the present specification can have a fabric weight in the range of ^{, for example, about 80 g / m 2} to about 600 g / m ^2.

The fabric containing the spun yarn disclosed herein comprises a spun yarn of PET, cotton, rayon, PTT, or a combination thereof, and lacking the melt-spun staple fibers disclosed herein. Can provide benefits that go beyond. For example, fabrics containing spun yarns including melt-spun staple fibers disclosed herein have greater bulk as suggested by greater fabric thickness than PET, cotton, rayon, or a combination thereof. Not only can it have a soft feel (ie, a soft feel). Fabrics containing spun yarns disclosed herein can have better dyeability than fabrics of the same construction consisting of PET, cotton, rayon, or a combination thereof. Compared to PET fabrics of similar structure, the fabrics disclosed herein can be dyed deeply at lower temperatures. The fabrics disclosed herein can have a better dye pickup than PET fabrics when dyed at low temperatures, thereby resulting in cost savings due to energy savings. For example, fabrics containing spun yarns disclosed herein can be dyed darker than PET fabrics when dyed simultaneously (ie, ^{have a lower L *} value when measured under a D65 light source), and 130. Compared to PET fabrics dyed at ° C, even when dyed at 100 ° C, they can be dyed darker than PET fabrics. The property of impregnating more dye, the property of impregnating at a lower temperature, and the property of dyeing more intensely can be referred to as "better dyeability" of the fabric. The woven fabrics disclosed herein can also have improved drapeability, as demonstrated by, for example, the highly drapeable region and, for example, the drape coefficient value determined by method BS5058. A combination of soft feel and improved drape is particularly desirable for fabrics. Furthermore, the fabrics disclosed herein are less likely to generate pills (higher pilling properties, as determined by, for example, the ASTM D4970 method, than fabrics of the same structure consisting of PET, cotton, rayon, or a combination thereof. Evaluation value) and good abrasion resistance were demonstrated. The fabrics disclosed herein can also have better tear strength in the warp and / or weft directions than fabrics of the same construction made of PET, cotton, rayon, or a combination thereof. The knitted fabric containing the spun yarn disclosed herein can have higher resilience than the knitted fabric of the same structure made of polyethylene terephthalate, cotton, rayon, or a combination.

Non-limiting examples of embodiments disclosed herein include:
1. 1. A melt-spun staple fiber containing a first polymer containing poly (trimethylene terephthalate) (PTT) or poly (butylene terephthalate) (PBT) and a second polymer containing poly (ethylene terephthalate) (PET) or Co-PET. In the spun yarn containing, Co-PET is a poly (ethylene terephthalate) copolymer containing an isophthalic acid monomer; and the first polymer contains poly (trimethylene terephthalate), and the poly (trimethylene terephthalate) first. The weight ratio to the two polymers ranges from about 80:20 to about 10:90; or the first polymer contains poly (butylene terephthalate) and the weight ratio of poly (butylene terephthalate) to the second polymer is about. A spun yarn in the range of 90:10 to about 10:90.
2. The spun yarn according to the first embodiment, wherein the first polymer contains poly (trimethylene terephthalate) and the second polymer contains poly (ethylene terephthalate).
3. 3. The spun yarn according to embodiment 1 or 2, wherein the first polymer contains poly (trimethylene terephthalate) and the second polymer contains Co-PET.
4. The spun yarn according to the first embodiment, wherein the first polymer contains poly (butylene terephthalate) and the second polymer contains poly (ethylene terephthalate).
5. The spun yarn according to embodiment 1 or 4, wherein the first polymer contains poly (butylene terephthalate) and the second polymer contains Co-PET.
6. Embodiments 1, 3 or 5 in which the second polymer contains Co-PET and the Co-PET contains from about 0.5 mol% to about 10 mol% isophthalic acid monomer relative to all copolymer compositions. The spun yarn described in.
7. The spun yarn according to 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 according to 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. The spun yarn according to 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. Embodiments 1, 2, 3, 4, 5, 6, or 7 in which the weight ratio of poly (trimethylene terephthalate) or poly (butylene terephthalate) to the second polymer is in the range of about 70:30 to about 30:70. The spun yarn of the spun yarn described in.
11. The spun yarn according to embodiment 1, 2, 3, 4, 5, 6, 7, 8, 9, or 10, wherein the spun yarn has a boil-off shrinkage of at least about 6% as determined according to ASTM D2259.
12. In the first, second, third, fourth, fifth, sixth, seventh, eighth, ninth, tenth, or eleventh embodiments, which further include about 5% by weight to about 95% by weight of the second staple fiber based on the total weight of the spun yarn. The described spun yarn.
13. 12. The spun yarn according to embodiment 12, wherein the second staple fiber comprises polylactic acid, acrylic, nylon, olefin, acetate, rayon, polyester, cotton, linen, wool, angora, mohair, alpaca, cashmere, or a mixture thereof.
14. The spun yarn according to embodiment 12, wherein the second staple fiber comprises cotton or wool.
15. The spun yarn according to embodiment 12, 13, or 14, wherein the second staple fiber comprises cotton.
16. The spinning according to embodiment 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, or 15 in which the spun yarn has a cotton count of about 4 Ne to about 80 Ne. thread.
17. The spun yarn according to embodiment 12, 13, or 14, wherein the second staple fiber contains wool.
18. The spinning according to embodiment 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 7 Nm to 120 Nm. thread.
19. A fabric comprising the spun yarn according to embodiment 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, or 18.
20. 19. The fabric according to embodiment 19, wherein the fabric has a softer feel and better drapeability than a fabric of the same fabric structure made of rayon, polyethylene terephthalate, cotton, or a combination thereof.
21. The fabric according to embodiment 19 or 20, wherein the fabric has better dyeability than a fabric having the same fabric structure consisting of polyethylene terephthalate, cotton, rayon, or a combination thereof.
22. 19. 20. Cloth.
23. Embodiments 19, 20, the fabric has fewer pills (higher pilling rating) determined according to the ASTM D4970 standard test method than fabrics of the same fabric structure consisting of polyethylene terephthalate, cotton, rayon, or a combination thereof. 21 or 22.
24. In embodiments 19, 20, 21, 22, or 23, wherein the fabric is larger than a fabric of the same fabric structure consisting of polyethylene terephthalate, cotton, rayon, or a combination thereof, and has bulkiness determined according to the ASTM D1777 standard test method. The fabric described.
25. The fabric is better than fabrics of the same fabric structure consisting of polyethylene terephthalate, cotton, rayon, or a combination thereof i) Good abrasion resistance determined according to the ASTM D4966 standard test method;
ii) High pilling property assessment value determined according to ASTM D4970 standard test method; or iii) Large bulkiness determined according to ASTM D1777 standard test method;
The fabric according to embodiment 19, 20, or 21 having at least one of.
26. The fabric according to embodiment 19, 20, 21, 22, 23, 24, or 25, wherein the fabric is a woven fabric having warp threads and weft threads.
27. Embodiment 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, or 18 the warp yarn comprises the spun yarn according to embodiment 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13. 26.
28. Embodiment 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, or 18 the weft yarn comprises the spun yarn according to embodiment 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13. 26, or 27.
29. Each of the warp and weft yarns is the spun yarn according to the first, second, third, fourth, fifth, sixth, seventh, eighth, ninth, tenth, eleventh, twelve, thirteenth, fourteenth, fifteenth, 16, 17th, or eighteenth embodiments. 28. The fabric according to embodiment 26, 27, or 28.
30. The cloth according to embodiment 19, 20, 21, 22, 23, 24, or 25, wherein the cloth is a knitted cloth.
31. The fabric according to embodiment 30, wherein the knitted fabric has higher resilience as determined according to Method BS4294 than a knitted fabric having the same fabric structure consisting of polyethylene terephthalate, cotton, rayon, or a combination thereof.
32. An article comprising the fabric according to embodiment 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, or 31.
33. The article according to embodiment 32, wherein the article is clothing.
34. A melt-spun staple fiber containing a first polymer containing poly (trimethylene terephthalate) or poly (butylene terephthalate) and a second polymer containing poly (ethylene terephthalate) or Co-PET, wherein Co-PET is isophthalate. It is a poly (ethylene terephthalate) polymer containing an acid monomer, and the staple fiber is:
a) Weight ratio of poly (trimethylene terephthalate) to secondary polymer in the range of about 80:20 to about 10:90; or poly (butylene terephthalate) in the range of about 90:10 to about 10:90. (2) Weight ratio to polymer; and b) Molten-spun staple fiber having a dry heat shrinkage of less than 6% as determined by the dry heat shrink method.
35. The melt-spun staple fiber according to embodiment 34, wherein the weight ratio of poly (trimethylene terephthalate) or poly (butylene terephthalate) to the second polymer is in the range of about 70:30 to about 30:70.
36. The melt-spun staple fiber according to embodiment 34, wherein the weight ratio of poly (trimethylene terephthalate) or 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 according to embodiment 34, 35, or 36, wherein the first polymer contains poly (trimethylene terephthalate) and the second polymer contains poly (ethylene terephthalate).
38. The melt-spun staple fiber according to embodiment 34, 35, or 36, wherein the first polymer contains poly (trimethylene terephthalate) and the second polymer contains Co-PET.
39. The melt-spun staple fiber according to embodiment 34, 35, or 36, wherein the first polymer contains poly (butylene terephthalate) and the second polymer contains poly (ethylene terephthalate).
40. The melt-spun staple fiber according to embodiment 34, 35, or 36, wherein the first polymer contains poly (butylene terephthalate) and the second polymer contains Co-PET.
41. 80. 36, 38, or 40 melt-spun staple fiber.

As used herein, "Comp. Ex." Means comparative examples, "Ex." Means examples, "rpm" means rotations / minute, and "wt%". Means weight percent, "dL / g" is deciliters / gram, "g" is grams, "mg" is milligrams, "° C" means degrees Celsius, "Min" is minutes, "h" is hours, "s" is seconds, "lb" is pounds, "kg" is kilograms, and "mm" is millimeters. , "M" is a meter, "gpl" is a gram / liter, "m / min" is a meter / minute, "mol" is a mol, and "kg" is It is kilograms, "ppm" is part / million, "Hz" is hertz, "cN" is sentinuton, "rpm" is rotation / minute, "wt" is By weight, "dpf" is denier / filament, "g / d" is gram / denier, "Ne" means cotton count (UK), and 1 pound (0.45 kg). A measure of linear density defined as the number of skeins (850 yards or 770 meters) of one skein material of weight, "Nm" means metric count, and 1000 gram units in 1 gram thread. "Dtex" means decitex, "AATCC" means American Association of Textile Chemists and Colorists, and "ASTM" means American test material. It means Association (American Society for Testing and Materials), and "BS" means British Standards Institute.

Materials Unless otherwise stated, all materials were used as received.

E. polytrimethylene terephthalate (PTT) containing 0.3% TiO ₂ and having an intrinsic viscosity of 0.96 dL / g. I. Obtained as merge K2266 from duPont de Nemours and Company (Wilmington, DE).

Nan Ya Plastics Corporation contains Co-PET containing 1.7 mol% isophthalic acid (IPA) monomer, 48.4 mol% terephthalic acid (TPA) monomer, and 49.9 mol% ethylene glycol (EG) monomer. , America, P. et al. O. Box 939, Lake City, S.A. Obtained from C29560, USA. The Co-PET composition is measured by NMR analysis and is shown relative to all copolymer compositions. Co-PET had an intrinsic viscosity of 0.80 dL / g.

William Barnet & Son, LLC, P. et al., Fiber-grade post-consumer recycled Co-PET containing 1.1 mol% IPA monomer, 49.1 mol% TPA monomer, and 49.9 mol% EG monomer. O. Box 171898, Spartanburg, S.A. C. Obtained from 29301, USA. The Co-PET composition is measured by NMR analysis and is shown relative to all copolymer compositions. Co-PET had an intrinsic viscosity of 0.76 dL / g.

Method The "Co-PET" composition was measured by NMR analysis using the following procedure. After co-PET pellets are pulverized at low temperature to form a powder, about 18 mg is weighed in an NMR tube, and 5: 1 CDCl ₃ : TFA-D (chloroform / deuterated trifluoro diluted to 5: 1). A solution of chloroform) was added up to a total volume of 0.6 mL. The sample was vortexed to dissolve Co-PET. Proton NMR spectra were obtained within 30 minutes of dissolution.

Proton NMR spectra were obtained by 500 MHz Bruker Avance III HD NMR at 30 ° C. with a 5 mm CPQCI (indirect) cryoprobe. The following parameters were used for acquisition: 30 seconds latency, 4 seconds acquisition time, 8.0 seconds 90 degree pulse, 10000 Hz spectral window, 79998 points, 64 scans / collected in total. Averaged transients. The spectrum was treated at 0.10 Hz in pounds relative to the chloroform-d residual proton signal at 7.24 ppm and zeroed down to 512 k.

The composition of Co-PET was calculated from the integrals for the signals at about 8.7 ppm, 8.1 ppm, and 4.8 ppm corresponding to ethylene glycol between isophthalic acid, terephthalic acid, and terephthalic acid groups, respectively. Since the isophthalic acid signal used represents 1 mole of protons, its integral value was already relative. The integral value of terephthalic acid represents 4 moles of protons of terephthalate and contains 2 moles of protons of isophthalate; the value obtained by subtracting the relative integral value of 2 × isophthalic acid is divided by 4 to obtain the relative integral value of terephthalic acid. I asked. The integral value associated with ethylene glycol corresponded to 4 moles of ethylene glycol proton, and the measured integral value was divided by 4 to obtain the relative integral value. The three relative integral values were summed, each divided by the total value and multiplied by 100%, and the relative molar% value was calculated as the corresponding relative integral value.

The dry heat shrinkage of the undrawn molten spun fiber was determined using the following procedure called the dry heat shrinkage method in the present specification. A 10-loop skein with a diameter of 50 cm was prepared and its length was measured under 20 g weight. These two loops were exposed to 40 ° C. for 20 hours under zero tension and contracted. The loops were cooled to 21 ° C. at 65% relative humidity before re-measuring the length of the loops under 20 g weight. The dry heat shrinkage at the percentage was calculated as follows:

For melt-spun staple fibers, fiber properties were determined using the following method using the Automatic Single-Fiber Test System FAVIMAT +. The denier was determined according to the ASTM D1577 standard test method for the linear density of the woven fibers. ASTM D3822 Thread strength and break point elongation were determined according to the tensile properties of a single woven fiber (Tensile Properties of Single Textile Fibers).

The crimpability of staple fibers is characterized by crimp contraction, crimp stability, and crimp recovery. The crimp shrinkage rate is the difference in length between the crimped fibers and the non-crimped fibers. By measuring the crimp length L0 under a low load of 0.001 cN / dtex and the non-crimp length L1 under a heavy load of 0.1 cN / dtex, [(L1-L0) / L1] ^* The crimp shrinkage rate can be calculated as shown by 100.

Crunch stability is a measure of crimp stability under a particular load. The crimp stability can be measured by determining the recovery rate of the staple length when the load is removed. The staple fiber length 60 seconds after applying a high load of 0.1 cN / dtex for 10 seconds (defined as L1) is L2 (measured under 0.001 cN / dtex), and the crimp stability is [(L1). -L2 / (L1-L0)] ^* Can be calculated as 100.

The crimp recovery rate is the difference between the length L1 of the non-crimped fiber and the length L2 of the fiber after releasing the crimp removing force, and is expressed as a percentage of the non-crimped fiber: [(L1-L1-). L2) / L1] ^* 100.

Molten Spinned Fiber Example Comparative Example A
Melt-spun PTT fiber _{Polytrimethylene terephthalate (PTT) containing 0.3% TiO 2} and having an intrinsic viscosity of 0.96 dL / g is dried in a vacuum oven at 120 ° C. for 16 hours in a nitrogen atmosphere. A shaft-extruded spinning frame was used to melt-extrude into a 34-filament yarn bundle with a circular cross section. The temperature of the melt region of the extruder was maintained at 180-255 ° C. The polymer treatment was 14.06 g / min at a winder rate of 1250 m / m, which imparted spinning denier per 2.9 filaments.

The dry heat shrinkage of the yarn bundle was determined to be 47%.

Example 1
Unstretched molten-spun fiber containing PTT and Co-PET Polyethylene terephthalate containing 0.3% TiO ₂ and having an intrinsic viscosity of 0.96 dL / g, and polyethylene having an intrinsic viscosity of 0.80 dL / g. A compound pellet was formed by melt-blending with terephthalate co-ethylene isophthalate (Co-PET) (manufactured by Nan Ya Plastics) at a weight ratio of 50/50 in a twin-screw extruder. The processing amount of the extruder was 150 lb / h (68.04 kg / h, 0.0189 kg / s), and the melting temperature at the outlet of the extruder was less than 285 ° C. measured by a handheld thermocouple.

PTT: Co-PET blended pellets were dried in a vacuum oven at 120 ° C. for 16 hours in a nitrogen atmosphere and melt-extruded into a 34-filament yarn bundle having a circular cross section using a twin-screw extrusion spinning frame. The temperature of the melt region of the extruder was maintained at 180-255 ° C. The polymer treatment amount was either 14.06 g / min or 21.52 g / min. For each treated amount, the winder rate is either 750 m / m or 1250 m / m, imparting spinning denier per filament in the range 3.3-7.7. The dry heat shrinkage rate of the thread bundle (tow) was measured and was in the range of 1.2% to 3.1%. This amount of dry heat shrinkage in unstretched fibers is very low, suggesting the stability of the material during storage. The results are shown in the table below.

Example 2
Unstretched melt-spun fiber containing PTT and Co-PET _{Polytrimethylene terephthalate containing 0.3% TiO 2} and having an intrinsic viscosity of 0.96 dL / g was added to 1.1 mol% of IPA monomer, 49. Fiber grade post-consumer recycled Co-PET containing 1 mol% TPA monomer and 49.9 mol% EG monomer are melt-blended and blended in a twin-screw extruder at a weight ratio of 50/50. Pellets were formed. Co-PET had an intrinsic viscosity of 0.76 dL / g. The processing amount of the extruder was 150 lb / h (0.0189 kg / s), and the melting temperature at the outlet of the extruder was less than 285 ° C. measured by a handheld thermocouple.

PTT: Co-PET blended pellets were dried in a vacuum oven at 120 ° C. for 16 hours in a nitrogen atmosphere and melt-extruded into a 34-filament yarn bundle having a circular cross section using a twin-screw extrusion spinning frame. The temperature of the melt region of the extruder was maintained at 180-255 ° C. The polymer treatment amount was either 14.06 g / min or 21.52 g / min. For each treated amount, the winder rate is either 750 m / m or 1250 m / m, imparting spinning denier per filament of 3.3-7.7. The dry heat shrinkage rate of the thread bundle (toe) was measured and was in the range of 1.2% to 2.5%. This amount of dry heat shrinkage in unstretched fibers is very low, suggesting the stability of the material during storage. The results are shown in the table below.

Example 3
Molten-spun staple fiber containing PTT and Co-PET _{Polytrimethylene terephthalate containing 0.3% TiO 2} and having an intrinsic viscosity of 0.96 dL / g was used with Co-PET (manufactured by Nan Ya Plastics). Blended pellets were formed by melt blending in a shaft extruder at a weight ratio of 50/50. The processing amount of the extruder was 150 lb / h (0.0189 kg / s), and the melting temperature at the outlet of the extruder was less than 285 ° C. measured by a handheld thermocouple. The material was blended at 145 ° C. for 20 hours.

A single extrusion spinning frame with radiant quenching was used to spin 6800 circular cross-section filaments. The temperature of the melt region of the extruder was maintained at 252 to 274 ° C. The polymer treatment was 0.379 g / min / pore and the feed roll speed was 1100 m / m. The spinning dpf was 3.0. The spun fibers were collected in a can. Twenty-two cans, a total of 448,800 denier, were fed into the stretch-crimp-cut / bale module. Staple melt-spun fibers were produced using a typical cotton count staple process utilizing a multi-step stretcher, crimping machine, incinerator, and cutter. The tow was immersed in a finishing bath (0.5% concentration, commercially available from Schill + Seilacher as Seilacher) at 22 ° C. The tow is first stretched in a 0.5% concentration finishing bath at 80 ° C. between a 22 ° C. feed roll operating at 36 m / m and a heat stretched roll at 75 ° C. operating at 110.88 m / m. , The first stage draw ratio of 3.08 was obtained. The stretched tow was pulled through the steam chamber at 100 ° C. by a heating roll on the downstream side at 165 ° C. operating at 110.88 m / m. The tow was passed over another series of rolls heated to 165 ° C. operating at 99.8 m / m. A finishing agent (6% concentration) was sprayed and the tow was passed over a 25 ° C. cooling drum roll operating at 99.8 m / m. The tow entered the steam chamber at 100 ° C. before entering the 50 mm crimping machine. The crimping machine speed was 100 m / m. The temperature and pressure of the rollers of the crimping machine were 65 ° C. and 0.8 bar, respectively. The crimped tow was annealed in a plate belt dryer at 100 ° C. for 8 minutes and finally the crimped tow was cut to produce staple melt spun fibers with the following properties:
Denier / filament (dpf) = 1.2, coefficient of variation (CV) = 8.79%
Thread strength = 4.89 g / d, CV = 8.79%
Elongation = 45.97%, CV = 19.59%
Staple length = 37-38 mm
Number of crimps (perfect sine arc) = 12 / inch Crunch stability = 67.09%, CV = 22.1%
Thread finishing agent = 0.26%

Example 4
Molten-spun fiber containing PTT and Co-PET _{Polytrimethylene terephthalate containing 0.3% TiO 2} and having an intrinsic viscosity of 0.96 dL / g is biaxial with Co-PET (manufactured by Nan Ya Plastics). Blended pellets were formed by melt blending in an extruder at a weight ratio of 50/50. The processing amount of the extruder was 150 lb / h (0.0189 kg / s), and the melting temperature at the outlet of the extruder was less than 285 ° C. measured by a handheld thermocouple. The material was blended at 145 ° C. for 20 hours.

A single extrusion spinning frame with radiant quenching was used to spin 6800 circular cross-section filaments. The temperature of the melt region of the extruder was maintained at 252 to 274 ° C. The polymer treatment was 0.493 g / min / pore and the feed roll speed was 600 m / m. The spinning dpf was 7.2. The spun fiber was collected in a can. Ten cans, totaling 489,600 denier, were supplied with stretching-crimping-cutting / bale modules. Melt-spun staple fibers were produced using a typical wool-count staple process utilizing multi-stage stretching, crimping machines, incinerators, and cutters. The tow was immersed in a finishing bath (0.5% concentration, commercially available from Schill + Seilacher as Seilacher) at 22 ° C. The tow was first stretched in a 0.5% concentration finishing bath at 80 ° C. between a 22 ° C. feed roll operating at 30 m / m and a 75 ° C. heat stretching roll operating at 109.3 m / m. The first stage draw ratio of 3.64 was obtained. The tow was pulled by a heating roll on the downstream side at 165 ° C. operating at 103.9 m / m. A finishing agent (6% concentration) was sprayed and the tow was passed over a 25 ° C. cooling drum roll operating at 101.9 m / m. The tow entered the steam chamber at 100 ° C. before entering the 50 mm crimping machine. The crimping machine speed was 110.6 m / m. The temperature and pressure of the rollers of the crimping machine were 65 ° C. and 1.3 bar, respectively. The crimped tow was annealed in a plate belt dryer at 100 ° C. for 8 minutes and finally the crimped tow was cut to produce staples with the following properties:
dpf = 2.5, CV = 6.98%
Thread strength = 3.83 g / d, CV = 8.74%
Elongation = 69.72%, CV = 25.26%
Staple length = 82-125 mm Multiple cut lengths with an average of 84 mm Number of crimps (perfect sinusoidal arc) = 14 / inch Crunch stability = 91.19%, CV = 8.31%
Thread finishing agent = 0.21%

Commercially available spun yarns Table 3 lists commercially available spun yarns and the abbreviations used for those spun yarns in the table below. Some of these threads were used to prepare comparative fabrics.

Examples of spun yarns produced by the cotton method The spun yarns of Examples 5 to 10 were prepared using the melt-spun staple fibers from Example 3. The following methods were used to evaluate the spun yarn and intermediate materials such as sliver obtained during the preparation of the spun yarn:

Using a CRE type tensile test instrument (such as Uster Tensorapid-3), the jaw speed (jaw speed) was 5 m / min and the length of the test piece was 50 cm, and the yarn strength was measured at 5 m / min.

Using a CRE type tensile test instrument (such as Uster Tensorapid-3), the elongation at break was measured at a jaw speed of 5 m / min and a length of the test piece of 50 cm.

Example 5
20sNe spun yarn containing 100% molten spun fiber A spun yarn was produced using a cotton spinning method according to the following procedure.

The melt-spun staple fibers from Example 3 were pulled out of the veil and manually mixed. The average length of the staple fibers was 40 mm and the denier was 1.2D. In the stack mixing process, the fibers were mixed and laminated and then conditioned at 65% relative humidity and 25 ° C. for 24 hours. By pulling the material vertically, the fiber mass was pulled out of the stack and sent to the blowroom line, which is usually used to spin synthetic fibers. In this process, the size of the fiber tuft is broken to about 150 mg to about 30 mg. I used the following parameters:
・ Feed roller and beater blade set value = 1.7 mm
・ Wrap linear density approx. 400 g / meter ・ The set value for waste collection was set to “0” ・ Coarse opening fiber beater speed = 400 rpm
・ Smelting fiber beater speed = 450 rpm

A 30 mg fiber bundle was then carded into a single fiber and arranged within a continuous fiber strand (sliver) in which the fibers were oriented along the length of the sliver. I used the parameters below:
・ Model, model: Card frame, LRC 1/3
・ M / c production speed = 70 meters / minute ・ Feed plate and licker (gauge) = 32 mils (1/1000 inch)
・ Flat gauge = 14, 14, 14, 12, 12 mil ・ Trumpet size = 4.0 mm or more ・ Sliver linear density = 4.5 g / meter ・ Ricca (speed) = 650 rpm
・ Cylinder speed = 350 rpm
・ Flat speed = 6 inches / minute ・ Final sliver linear density = 5.0 g / meter

In the kneading machine, 6 carding slivers were doubled together and at the same time drafted the same amount (6 times) to further orient the fibers in the resulting sliver. The first step is called the breaker paver and the second step is called the finisher paver. I used the following parameters:
-Model and model: kneading machine, LR RSB 851
・ Bottom roller gauge (front / back) = 44 / 48mm
・ Trumpet diameter = 3.8mm
・ Sliver linear density = 4.5g / meter ・ Top cot hardness = 83 ° degree ・ Break draft = 1.4 for breaker, machine 1.4 for finisher kneading
・ Draft of web tension = 1
・ Creel tension draft = 1.02
・ Delivery speed = 250MPM for kneading machine I, 350MPM for kneading machine II
・ Dubbing = 6 times for both I and II kneading machines ・ Linear density of final sliver = 5.00 g / meter ・ Spot% = 1.88 in final sliver

Next, in a scouring machine, blister yarn was prepared from a sliver sent from a finisher kneading machine. Further partial twisting is applied in the scouring machine to give strength to the blister. I used the following parameters:
-Model and model: Rough spinning machine, LF4200
・ Spacer size = 5.5 mm
・ Spindle speed = 1000 rpm
・ Twist coefficient = 0.70
・ Coarse thread skein = 0.75sNe
・ Roller gauge = 48/55/62 mm
・ Cradle = 36mm

The blister yarn was found to have a Worcester value (spot) of 3.16% and a Worcester (Uster)% (spot%) of 3.26.

The blister yarn was further drafted on a ring spinning machine to produce a spun yarn with a yarn count of 20 sNe. I used the following parameters:
・ Model and model = ring spinning machine, LR G5 / 1
・ Roller gauge = 42.5 / 65mm
・ Saddle gauge = 51 / 66mm
-Cott hardness (front / back F / B) = 68/83 °
・ Break draft = 1.22
-Torsion coefficient / Twist per inch = 3.6 / 16.09
・ Traveler size: 1/0 M1HO
・ Spindle speed: 15500 rpm

The spun yarn was wound by a ring spinning machine on a small package called a cup each weighing about 50 g. Many cups were put together to remove any imperfections in the yarn and finally wrapped around the cone on a winding machine with the following parameters:
・ Velocity = 1000m / min ・ Thread tension = 5-6% of thread breaking load
・ Package hardness-minimum ・ Cone weight = 1.0 kg or more

The final spun yarn was evaluated in terms of tensile properties and percentage of spots on a Uster tensile tester (Uster tensorapid-3) and a Uster spot tester-3. The results are shown in Table 4.

The yarn wound in the final machine was vibrant and could become entangled as a result of the twisting applied during the spinning process. Tangles can cause yarn breakage during fabric production, so the cones were conditioned in an autoclave at a maximum temperature of 70 ° C. for 50 minutes to stabilize the yarns.

Example 6
40sNe spun yarn containing 100% melt spun fiber A spun yarn was prepared using the melt spun staple fiber from Example 3 according to the method of Example 5 except for the following differences:

The linear density of the final sliver was 4.75 g / meter, and the percentage of spots was 1.75.

Crude yarns were prepared as in Example 5, except that the blister skein was 1.2 sNe.

In the step of drafting the blister, the twist factor / twist per inch was 3.6 / 22.6, the traveler size was 4 / 0M1HO, and the spindle speed was 16500 rpm.

The spun yarn was wound around the cone at 1500 m / min.

The characteristics of the spun yarn are shown in Table 4.

Example 7
20sNe spun yarn containing 40/60 melt-spun fiber / cotton (weight / weight) Melt-spun staple fibers from Example 3 and cotton (Shankar 6, various Indian cottons obtained in Northern India such as Punjab and Hayana). Used to prepare spun yarn. The cotton staples had an average length of 31 mm and a fineness (fiber linear density) of 4.1 micrograms / inch measured using the airflow method. A spun yarn was produced according to the procedure of Example 5 except for the following differences.

In the manual mixing step, a two-layer cotton sliver fragmented into a small tuft of 25-30 mg size, taken from a 100% cotton yarn spinning process after the combing machine, was overlaid on a single layer of melt-spun staple fiber.

The linear density of the final sliver from the carding step was 4.7 g / meter.

Crude yarns were prepared as in Example 5, except that the twist coefficient was 0.85 and the skein was 0.7 sNe.

The blister was further drafted as in Example 5, with the exception of 16.99 twists / inch.

The characteristics of the spun yarn are shown in Table 4.

Example 8
40sNe spun yarn containing 40/60 melt-spun fiber / cotton (weight / weight) Spinned using the melt-spun staple fiber from Example 3 and cotton (Shankar 6, various commercially available Indian cotton from northern India). Threads were prepared. The cotton staples had an average length of 31 mm and a linear density of 4.1 micrograms / inch. A spun yarn was produced according to the procedure of Example 5 except for the following differences.

In the manual mixing step, a two-layer cotton sliver, taken from a 100% cotton-strand spinning process after a combing machine and fragmented into small tufts of 25-30 mg size, is placed over a single layer of melt-spun staple fibers. rice field.

The linear density of the final sliver from the carding step was 4.7 g / meter.

After kneading, the final sliver linear density was 4.75 g / meter.

Crude yarns were prepared as in Example 5, except that the twist coefficient was 0.85 and the skein was 1.2 sNe.

The blister was further drafted as in Example 5, except that it had a twist / inch of 24.02, a traveler size of 4 / 0M1HO, and a spindle speed of 16500 rpm.

The spun yarn was wound around the cone at 1500 m / min.

The characteristics of the spun yarn are shown in Table 4.

Example 9
20sNe spun yarn containing 40/60 molten spun fiber / Tencel A spun yarn was prepared using the melt spun staple fiber from Example 3 and a commercially available Tencel® staple fiber (Lensing). Tencel® staple fibers had an average length of 40 mm and a denier of 1.2D. A spun yarn was produced according to the procedure of Example 5 except for the following differences.

In the manual mixing step, two layers of Tencel® fibers (fragmented into small tufts 25-30 mg in size) were placed over one layer of melt-spun staples.

The linear density of the final sliver from the carding step was 4.7 g / meter.

Crude yarns were prepared as in Example 5, except that the twist coefficient was 0.85.

The blister was further drafted as in Example 5, except that it had 16.99 twists / inch.

The characteristics of the spun yarn are shown in Table 4.

Example 10
40sNe spun yarn containing 40/60 molten spun fiber / Tencel A spun yarn was prepared using the melt spun staple fiber from Example 3 and a commercially available Tencel® staple fiber (Lensing). Tencel® staples had an average length of 40 mm and a denier of 1.2D. A spun yarn was produced according to the procedure of Example 5 except for the following differences.

In the manual mixing step, two layers of Tencel® fibers (fragmented into small tufts 25-30 mg in size) were placed over one layer of melt-spun staples.

The linear density of the final sliver from the carding step was 4.7 g / meter.

After kneading, the final sliver linear density was 4.75 g / meter.

Crude yarns were prepared as in Example 5, except that the twist coefficient was 0.85 and the skein was 1.2 sNe. The blister was further drafted as in Example 5, except that it had a twist / inch of 24.02, a traveler size of 4 / 0M1HO, and a spindle speed of 16500 rpm.

The spun yarn was wound around the cone at 1500 m / min. The characteristics of the spun yarn are shown in Table 4.

The results in Table 4 show that spun yarns containing only 100% melt-spun staple fibers, or spun yarns containing melt-spun staple fibers in combination with cotton or Tencel®, have sufficient yarn strength for the weaving or knitting process. Indicates that it has breaking elongation.

Spinned yarns (Examples 5 and 6) containing only melt-spun staple fibers of Example 3, poly (ethylene terephthalate) staples, or poly (trimethylene terephthalate) staples were subjected to a boiling water shrinkage test method according to ASTM D2259. The length of the skein with its own weight as indicated in the attachment is before soaking in boiling water (100 ° C, 30 minutes in an autoclave, MLR 1:40, "MLR" means the ratio of the material to the liquid) and Measured after immersion, the value obtained by dividing the difference in skein length by the skein length before boiling is reported in Table 5 as the shrinkage rate (%). PET spun yarn and PTT spun yarn were obtained from commercially available products.

The highest% boiling water shrinkage was observed with the spun yarn of Example 6 containing only molten spun staple fibers, the lowest% boiling water shrinkage was observed with the spun yarn containing PET, and the intermediate% shrinkage value was PTT. Was observed on spun yarns containing. This imparts a large bulk to the fabric after finishing it into a melt-spun staple fiber fabric, which is desirable.

Examples of woven fabrics Fabrics were evaluated using the following methods:
Cloth weight (raw machine and finished product) -ASTM D3776 Standard test method for mass (weight) per unit area of cloth (Standard Test Methods for Mass Per Unit Area (Weight) of Fabric)
Dimensional stability (for both warp and weft directions after 3 washes) -AATCC135 Dimensional Changes of Fabrics After Home landing after washing at home
Wicking-Vertical Wicking of Textiles of AATCC197 woven fabric
Tear Strength (for both warp and weft directions) -Standard Test Method Method for Tearing Strength ) Apparatus)
Thickness-ASTM D1777 Standard Test Method for Tickness of Textile Materials (Standard Test Method for Textile Materials)
Pilling Grade (1000 times) -Standard Test Method for Pilling Resistance and Other Related Surface Changes of ASTM D4970 Textiles (Standard Test Method for Pilling Resistance and Resisted Surface Change Chains of Textile
Abrasion (5000 times) -ASTM D4966 Standard Test Method for Abrasion Resistance of Textile Fabric (Martindale Abrasion Test Method) (Standard Test Method for Abrasion Resistance of Textile Fabrics (Martindale)
Drapeability-Method for evaluating the drapeability of BS5058 fabric (Method for the Assessment of Drape of Fabrics)
Friction Fastness-AATCC8 Color Fastness to Locking
Washing fastness-AATCC61-2A (49 ° C, 45 minutes, 1.5 gpl)
Burst Strength (Circular Knitting) -Standard Test Method for Bursting Strength of Textile Fabrics of ASTM D3786 Woven Fabric
Stretching and Recovery (Circular Knitting) -BS4294 (5kg) Test Method for Stretching and Recovery Properties of Fabrics and Recovery Properties of Fabrics

The% shrinkage (relative to the finished product of the raw machine in the fabric) was determined as follows. The fabric of the raw machine was marked with an oil-based marker so as to show a line of 30 cm in the length of the fabric (direction of the warp) and a line of 30 cm in the width of the fabric (direction of the weft). Next, the fabric was dyed and finished, and the line length of the oil-based marker was re-measured. For each of the length (warp) direction and the width (weft) direction, the difference in line length before and after dyeing and finishing was divided by 30, and multiplied by 100 to calculate the shrinkage rate (percentage). In the present specification, this method is referred to as a shrinkage rate method.

Evaluation of softness (also referred to as subjective value of touch) -The feel of the fabric was evaluated by 12 persons skilled in the art to perform a subjective evaluation of the feel, and tested in South India Textile Research Association (SITRA), Coimbatore, and India. This is a widely used method in the textile industry to assess the softness of fabrics. The fabric was coded with A and B, and the grade of the fabric was independently verified based on how the softness of the fabric was felt. Each expert graded the softer fabric as "1" and the less soft fabric as "2". This was done for 100% PET fabrics and the fabrics of Examples 11 and 14. A final rating was made by averaging 12 readings. The fabric with the lower average grade was given the final grade 1 (softer), and the fabric with the higher average grade was given 2.

The woven fabrics shown in Table 6 were prepared using the spun yarns of Examples 5 to 10. The spun yarn disclosed in the present specification is used as a warp yarn and a weft yarn (weft yarn fill) to prepare a twill weave (3/1) bottom weight fabric and a plain weave (1/1) shirt fabric (shirting fabrics). Commercially available spun yarn was used for warp and weft to make comparative fabrics. For each woven fabric, the same threads were used for both the warp and weft threads. The evaluation results of the fabric are shown in Tables 7 and 8. Unless otherwise stated, results are reported for the finished fabric.

Example 11
The spun yarn from Example 5 was used as a warp yarn and a weft yarn to prepare a thick twill fabric. The warp was sized prior to the warp unwinding using a CCI single gluing machine using an Elvanol-T25PVA sizing agent. A warp was used at 350 m / min to prepare a final beam with 2150 warp threads, a width of 18 inches, and a warp thread length of 3.5 meters. The following denting plans:
Kneading: 4-shaft kneading type (straight kneading (1, 2, 3, and 4)
Reed threading: 2 warp threads / number of reed feather leads: 75 reed feathers / 2 inches 3/1 LHT twill fabric was woven on a CCI sample loom at a loom speed of 40 picks / minute. The pick value was set to 63 picks / inch. A raw fabric having a length of 2 m and a width of 49.5 cm was obtained.

The raw fabric was deglued as follows with an RBE lab jigger machine. The fabric sample was loaded onto a jigger filled with water (2 L), NaOH (2 gpl), and a wetting agent; Levocol CESR (wetting agent) was added (5 gpl) to raise the bath temperature to 90 ° C. After the fabric was allowed to flow in the bath for 60 minutes, the bath was drained and refilled with fresh water to raise the temperature of the bath to 85 ° C. The fabric was washed with warm water for 15 minutes and drained from the bath. The bath was filled with water again and the fabric was flushed with water for 15 minutes (cold water wash). The bath was drained, filled with water and neutralized by adding acetic acid (1 gpl); the fabric was run in this bath for 15 minutes. The bath was then drained, refilled with fresh water and the fabric run in a cold water bath for 15 minutes. The fabric was then removed from the jigger, dried under atmospheric conditions and then heat set at 160 ° C. for 45 seconds in an RBE stenter.

The fabric was then dyed with a mixture of disperse dyes using the following time and temperature profiles. Heat to 70 ° C. and hold for 10 minutes, then raise the temperature to 130 ° C. at 1.5 ° C./min, hold for 30 minutes, then lower the temperature to 70 ° C. at 1.5 ° C./min. Drained. After dyeing, the fabric was reduced and washed with Hydros and NaOH (2 gpl each) at 90 ° C. for 20 minutes. Then, the cloth was washed with cold water for 10 minutes, contacted with acetic acid (2 gpl) for 15 minutes, and then washed with cold water for 10 minutes. After impregnating the dyed fabric with a finishing agent (softener), the dyed fabric was heat-set at 160 ° C. for 45 seconds in an RBE lab stenter.

The dough structure is shown in Table 6. The result of the wicking test was 100%. In comparison with the fabric of Comparative Example B, the fabric of Example 11 was found to have a soft touch (that is, good softness). Other features of the fabric are shown in Tables 7 and 8.

Comparative Example B
A commercially available 20sNe 100% PET staple spun yarn (“P1”) according to the procedure of Example 11 except that the reed threading plan used 4 warp yarns / reed feathers and the number of leads was 50 reed feathers / 2 inches. ”) Was used as the warp and weft to produce a comparatively thick 3/1 LHT twill fabric. In the same manner as in Example 11, the raw fabric was dyed, finished, and heat-set.

The dough structure is shown in Table 6. The result of the wicking test was 100%. Other features of the fabric are shown in Tables 7 and 8.

Example 12
Thick twill fabrics were prepared using the spun yarns from Example 7 as warp and weft according to the procedure of Example 11 with the following exceptions. The raw fabric was desizing and bleached with a jigger, heat set in a stenter, then dyed with a mixture of disperse dyes and then further dyed with a reactive dye under cotton dyeing conditions.

The dough structure is shown in Table 6. The result of the wicking test was 100%. Other features of the fabric are shown in Tables 7 and 8.

Comparative Example C
A comparative thick 3/1 LHT twill fabric was made in the same manner as in Example 12, except that a commercially available 20sNe40 / 60PET / cotton staple spun yarn (“PC1”) was used as the warp and weft.

The dough structure is shown in Table 6. The result of the wicking test was 100%. Other features of the fabric are shown in Tables 7 and 8.

Example 13
Thick twill fabrics were prepared using the spun yarns from Example 9 as warp and weft according to the procedure of Example 12, except that no peroxide killer was used at the end of the bleaching step.

The dough structure is shown in Table 6. The result of the wicking test was 100%. Other features of the fabric are shown in Tables 7 and 8.

Comparative Example D
A comparative thick 3/1 LHT twill fabric was made according to the procedure of Example 12, except that a commercially available 20sNe40 / 60PET / Tencel® staple spun yarn (“PT1”) was used as the warp and weft. .. The raw fabric was dyed, finished and heat-set in the same manner as in Example 12, except that the second dyeing step with the reactive dye was performed under Tencel® dyeing conditions.

The dough structure is shown in Table 6. The result of the wicking test was 100%. Other features of the fabric are shown in Tables 7 and 8.

Example 14
The spun yarn from Example 6 was used as a warp yarn and a weft yarn to prepare a plain weave shirt fabric. The procedure was as described in Example 11, except for the following differences: after warping, the beam contained 1680 warp threads, and the number of leads was 84 reeds / 2 inches. there were.

The dough structure is shown in Table 6. The result of the wicking test was 100%. In comparison with the fabric of Comparative Example E, the fabric of Example 14 was found to have a good (soft) feel. Other features of the fabric are shown in Tables 7 and 8.

Comparative Example E
Comparative plain weave shirt fabrics were made according to the procedure of Example 11, except that a commercially available 40sNe 100% PET staple spun yarn (“P2”) was used as the warp and weft yarns. After warping, the beam contained 1680 warp threads and the number of leads was 84 reeds / 2 inches. A raw fabric having a length of 2 m and a length of 47.7 cm was obtained.

The dough structure is shown in Table 6. The result of the wicking test was 100%. Other features of the fabric are shown in Tables 7 and 8.

Example 15
The spun yarn from Example 8 was used as a warp yarn and a weft yarn to prepare a plain weave shirt fabric. The procedure was as described in Example 12, except that no peroxide killer was used at the end of the bleaching step.

The dough structure is shown in Table 6. The result of the wicking test was 100%. Other features of the fabric are shown in Tables 7 and 8.

Comparative Example F
The use of commercially available 40sNe 40/60 PET / cotton staple spun yarn (“PC2”) for warp and weft, and further differences in the following procedure: after warping, the beam contains 1748 warp yarns and leads. Comparative plain weave shirt fabrics were made according to the procedure of Example 11, except that the number was 92 reeds / 2 inches. Raw fabrics 2 m long and 48.7 cm wide were obtained and dyed as described in Example 12.

The dough structure is shown in Table 6. The result of the wicking test was 100%. Other features of the fabric are shown in Tables 7 and 8.

Example 16
The spun yarn from Example 10 was used as a warp yarn and a weft yarn to prepare a plain weave shirt fabric. After warping, the procedure is Example Wfab-1 except that the beam contains 1748 warp threads, the number of leads is 92 reeds / 2 inches, and the pick value is set to 62 picks / inch. It was as described in. Raw fabrics 2 m long and 48.7 cm wide were obtained and dyed as described in Example 12.

The dough structure is shown in Table 6. The result of the wicking test was 100%. Other features of the fabric are shown in Tables 7 and 8.

Comparative Example G
Follow the procedure of Example 11 except that the commercially available 40sNe40 / 60 PET / Tencel® staple spun yarn (“PT2”) is used as the warp and weft and has the following additional differences in the procedure: After warping, the beam contained 1748 warp yarns, the number of leads was 92 reeds / 2 inches, and the pick value was set to 62 picks / inch. A raw fabric having a length of 2 m and a width of 48.7 cm was obtained and dyed as described in Example 12.

The dough structure is shown in Table 6. The result of the wicking test was 100%. Other features of the fabric are shown in Tables 7 and 8.

The results in the table above demonstrate that the fabrics containing spun yarns disclosed herein offer a number of advantages over the fabrics of the Comparative Examples. Woven fabrics containing spun yarns disclosed herein have greater bulk, as suggested by the larger thickness of the fabrics of the Examples when compared to the fabrics of Comparative Examples of similar construction. be able to. The woven fabric of the example also has less pilling (high pilling evaluation value), good abrasion resistance (small weight% loss), and good drapeability (small weight% loss) as compared with the fabric of the comparative example. Demonstrate that the drape property coefficient value is high). In addition, the fabrics of the examples can also be dyed more intensely ( ^{low L *} values at D65 light source). A combination of improved feel (soft feel) and good drapeability is especially desired for fabrics.

Examples of circular knitted fabrics The spun yarns of Examples 5 to 10 were used as knitting yarns to prepare the circular knitted fabrics shown in Table 9. Commercially available spun yarns were used to prepare comparative fabrics. The knitting machine gauge was 20 "for all circular knitted fabrics using a 20sNe count. The knitting machine gauge was 24" for all circular knitted fabrics using a 40sNe count. The evaluation results of the fabric are shown in Tables 9 and 10. Unless otherwise stated, results are reported for the finished fabric.

Example 17
Using the spun yarn from Example 5, a circular knitted fabric was prepared with a Mesdan lab knitting machine. The raw fabric was heat-set at 160 ° C. for 45 seconds with an RBE stainer and then refined with an HTHP Beaker dyeing machine using the following procedure. NaOH (2 gpl) and the wetting agent Levocol CESR (5 gpl) were added and the fabric was smelted at 90 ° C. for 60 minutes. The fabric was washed at 85 ° C. for 15 minutes, then in cold water for 15 minutes, then in a neutralizing solution containing acetic acid (1 gpl) for 15 minutes, and then in another cold water for 15 minutes.

The scouring fabric was then dyed in the same machine with a mixture of disperse dyes using the following time and temperature profiles: heat to 70 ° C., hold for 10 minutes and then temperature to 1.5 ° C./min. The temperature was raised to 130 ° C. and kept for 30 minutes, then the temperature was lowered to 70 ° C. at 1.5 ° C./min and drained. After dyeing, the fabric was reduced and washed with Hydros and NaOH (2 gpl each) at 90 ° C. for 20 minutes. Then, the cloth was washed with cold water for 10 minutes, neutralized with acetic acid (2 gpl) for 15 minutes, and then washed with cold water for 10 minutes. After impregnating the dyed fabric with a finishing agent (softener), the dyed fabric was heat-set at 160 ° C. for 45 seconds in a lab stenter.

The fabric structure is shown in Table 9. The result of the wicking test was 100%. Compared with the fabric of Comparative Example H, the fabric of Example 17 was found to have a soft touch (that is, good softness). Other features of the fabric are shown in Tables 9 and 10.

Comparative Example H
Comparative knitted fabrics were made using the procedure of Example 17 below, except that a commercially available 20sNe 100% PET staple spun yarn (“P1”) was used.

The fabric structure is shown in Table 9. The result of the wicking test was 100%. Other features of the fabric are shown in Tables 9 and 10.

Example 18
Performed according to the procedure of Example 17, except that the fabric was dyed with a reactive dye mixture to which a salt (60 gpl) was added in the same machine after dyeing with a disperse dye using the following time and temperature profiles. Using the spun yarn from Example 7, a circular knitted fabric was prepared on a Mesdan lab knitting machine: heated to 60 ° C. and kept for 30 minutes, then soda ash (15 gpl) was added and 30 before draining. I kept it for a minute. Next, the fabric was washed with cold water for 10 minutes, washed with acetic acid (1 gpl) for 15 minutes, and then soaped at high temperature with Albatex AD (2 gpl) while raising the temperature to 90 ° C. and keeping it for 15 minutes. .. Next, the fabric was washed with warm water (85 ° C.) for 15 minutes and then with cold water for 10 minutes. The dye was fixed with Levocol HCF (0.5 gpl) while raising the temperature to 50 ° C. and keeping it for 20 minutes. After impregnating the dyed fabric with the finishing agent, it was heat-set in a lab stenter at 160 ° C. for 45 seconds.

The fabric structure is shown in Table 9. The result of the wicking test was 100%. Other features of the fabric are shown in Tables 9 and 10.

Comparative Example I
Comparative knitted fabrics were made using the procedure of Example 18 below, except that a commercially available 20sNe 40/60 PET / cotton staple spun yarn (“PC1”) was used.

The fabric structure is shown in Table 9. The result of the wicking test was 100%. Other features of the fabric are shown in Tables 9 and 10.

Example 19
Using the spun yarn from Example 9, a circular knitted fabric was prepared on a Mesdan lab knitting machine according to the procedure of Example 18.

The fabric structure is shown in Table 9. The result of the wicking test was 100%. Other features of the fabric are shown in Tables 9 and 10.

Comparative example J
Comparative knitted fabrics were made using the procedure of Example 18 below, except that a commercially available 20sNe 40/60 PET / Tencel® staple spun yarn (“PT1”) was used.

The fabric structure is shown in Table 9. The result of the wicking test was 100%. Other features of the fabric are shown in Tables 9 and 10.

Example 20
Round knitted fabrics were prepared on a Mesdan lab knitting machine using the spun yarns from Example 6 according to the procedure of Example 1, except that different disperse dye mixtures were used.

The fabric structure is shown in Table 9. The result of the wicking test was 100%. Compared with the fabric of Comparative Example K, the fabric of Example 20 was found to have a good feel (that is, good softness). Other features of the fabric are shown in Tables 9 and 10.

Comparative example K
Comparative knitted fabrics were made using the procedure of Example 17 below, except that a commercially available 40sNe 100% PET staple spun yarn (“P2”) and a different disperse dye mixture were used.

The fabric structure is shown in Table 9. The result of the wicking test was 100%. Other features of the fabric are shown in Tables 9 and 10.

Example 21
Round knitted fabrics were prepared on a Mesdan lab knitting machine using the spun yarn from Example 8 according to the procedure of Example 18, except that different disperse dye mixtures were used.

The fabric structure is shown in Table 9. The result of the wicking test was 100%. Other features of the fabric are shown in Tables 9 and 10.

Comparative Example L
A comparison was made using the procedure of Example 18 below, except that a commercially available 40sNe 40/60 PET / cotton staple spun yarn (“PC2”), a different disperse dye mixture, and a different reactive dye mixture were used. A knitted cloth was produced.

The fabric structure is shown in Table 9. The result of the wicking test was 100%. Other features of the fabric are shown in Tables 9 and 10.

Example 22
Round knitted fabrics were prepared on a Mesdan lab knitting machine using the spun yarn from Example 10 according to the procedure of Example 18, except that different disperse dye mixtures and different reactive dye mixtures were used.

The fabric structure is shown in Table 9. The result of the wicking test was 100%. Other features of the fabric are shown in Tables 9 and 10.

Comparative Example M
Using the procedure of Example 18 below, except that a commercially available 40sNe 40/60 PET / Tencel® staple spun yarn (“PT2”), a different disperse dye mixture, and a different reactive dye mixture were used. A comparative knitting cloth was prepared.

The fabric structure is shown in Table 9. The result of the wicking test was 100%. Other features of the fabric are shown in Tables 9 and 10.

The results in Tables 9 and 10 demonstrate that the circular knitted fabrics of the Examples offer advantages over the fabrics of the Comparative Examples. For example, a circular knitted fabric containing a spun yarn containing a molten spun staple fiber disclosed herein has a large bulk as shown by the large thickness of the fabric as compared to the fabric of the comparative example. The circular knitted fabric of the example also demonstrates low pilling (high pilling rating) and good abrasion resistance (small weight% loss). In addition, the fabrics of the examples have better stretch recovery than the fabrics of the comparative examples, both in short recovery times and long recovery times.

Example 23
2 / 64sNm spun yarn containing 70/30 wool / melt-spun staple fibers A spun yarn was produced using the worsted yarn spinning method according to the following procedure.

The spun yarn of Example 23 was prepared using the melt-spun staple fibers from Example 4. Molten-spun staple fibers of 2.5 denier and an average length of 84 mm were removed and converted to sliver in a cotton carding spinning process by the usual carding process commonly used in spinning mills. This sliver is blended with a wool top (20.5 micron, 68 mm average length Australian Merino) and a 70/30 (weight / weight) wool / melt-spun staple fiber blending ratio, worsted yarn spinning method. Spinned in. The nominal count for the spun yarn was 2 / 64sNm.

Example 24
The spun yarn from Example 23 was used as a warp yarn and a weft yarn to prepare a thick twill fabric. The warp was sized prior to the warp unwinding using a CCI single gluing machine using an Elvanol-T25PVA sizing agent and a fabric softener. A warp was used at 350 m / min to prepare a final beam with 1770 warp threads, a width of 18 inches, and a warp thread length of 3.5 meters. The following denting plans:
Kneading: 3-shaft kneading type (straight kneading (1, 2, and 3))
Reed threading: 3 warp threads / number of reed feather leads: 60 reed feathers / 2 inches 2/1 RHT twill fabric was woven on a CCI sample loom at a loom speed of 40 picks / minute. The pick value was set to 63 picks / inch. A raw fabric having a length of 2 m and a width of 50 cm was obtained.

The raw fabric was gelatinized with a jigger using the same procedure as in Example 11, except that Albatex AD was used with Levocol CESR. The fabric was then subjected to a hot water wash (15 minutes at 85 ° C.), a cold water wash (15 minutes), a neutralization step with acetic acid (15 minutes), and another cold water wash (15 minutes). The fabric was flat-dried under atmospheric conditions and then heat-set at 170 ° C. for 45 seconds.

The fabric was then dyed with a mixture of disperse dyes using the following time and temperature profiles. Heat to 70 ° C. and hold for 10 minutes, then raise the temperature to 130 ° C. at 1.5 ° C./min, hold for 30 minutes, then lower the temperature to 70 ° C. at 1.5 ° C./min. Drained. The fabric was reduced and washed with Hydros and NaOH (1 gpl each) at 90 ° C. for 20 minutes. Then, the cloth was washed with cold water for 10 minutes, contacted with acetic acid (2 gpl) for 15 minutes, and then washed with cold water for 10 minutes.

The fabric was then dyed with an acid dye mixture using the following time and temperature profiles: heated to 70 ° C., kept for 10 minutes and then raised to 98 ° C. at 1.5 ° C./min. After keeping for 45 minutes, the temperature was lowered to 70 ° C. at 1.5 ° C./min and drained. The fabric is washed in cold water (10 minutes), treated with acetic acid (1 gpl, 15 minutes), soaped at high temperature with Albatex AD (90 ° C, 15 minutes) and washed with warm water (85 ° C, 15 minutes). After washing with cold water (10 minutes), the dye was fixed by contacting with Levocol HCF (0.5 gpl) at 50 ° C. for 20 minutes.

The fabric is steamed in an autoclave (130 ° C. for 3 minutes), then impregnated with a finishing agent before heat-setting at 160 ° C. for 45 seconds in a lab stenter, and then steamed again in an autoclave (130 ° C.). 3 minutes).

The raw fabric and the finished fabric were evaluated. The results are as follows:
Fabric structure of raw machine: 96 ^* 54 (warp / inch ^* pick / inch)
Finished fabric structure: 114 ^* 63 (warp / inch ^* pick / inch)
Raw fabric weight: 198 g / m ²
Finished fabric weight: 249g / m ²
Dimensional stability (%):
Length-2.8%;
Width-1.7%
Wicking test: 100%
Tear strength: Warp yarn 1984g, Weft yarn 896g
Elongation%: 42.7
Recovery rate in 1 minute,%: 83.1
Recovery rate in 30 minutes,%: 90.9
Recovery rate in 60 minutes,%: 93.51

Example 25
Unstretched melt-spun fiber containing PTT and Co-PET _{Pellets of polytrimethylene terephthalate (PTT) containing 0.3% TiO 2} and having an intrinsic viscosity of 0.96 dL / g, and 0.80 dL / g. Pellets of polyethylene terephthalate co-ethylene isophthalate (Co-PET) (manufactured by Nan Ya Plastics) having an intrinsic viscosity were separately dried at 120 ° C. in a nitrogen atmosphere for 16 hours in a vacuum oven. Dried PTT pellets and dried Co-PET pellets were blended together in small drums at the ratios shown in Table 11 by manually shaking and rolling the drums. Each of the salt and pepper-like blends thus produced was melt-extruded into 34 filament yarn bundles having a circular cross section by a twin-screw extrusion spinning frame. The temperature of the melt region of the extruder was maintained at 180-265 ° C. Table 11 shows the amount of polymer processed, the winder rate, the spinning denier / filament, and the dry heat shrinkage of the yarn bundle (toe).

Example 26
Unstretched molten-spun fiber containing Co-PET and PBT Polyethylene terephthalate co-ethylene isophthalate (Co-PET) pellets (manufactured by Nan Ya Plastics) having an intrinsic viscosity of 0.80 dL / g and 1.15 dL / g. Pellets of CRASTIN® 6130C NC010 polybutylene terephthalate (PBT) with intrinsic viscosity were separately dried at 120 ° C. under a nitrogen atmosphere in a vacuum oven for 16 hours. The dried PTT pellets and PBT pellets were blended together in small drums at the ratios shown in Table 12 by manually shaking and rolling the drums. Each of the salt-and-pepper blends thus produced was melt-extruded into 34 filament yarn bundles with a circular cross section by a twin-screw extruder. The temperature of the melt region of the extruder was maintained at 180-265 ° C. Table 12 shows the amount of polymer processed, the winder rate, the spinning denier / filament, and the dry heat shrinkage of the yarn bundle (toe).

Example 27
Polytrimethylene terephthalate and co-PET (manufactured by Nan Ya Plastics) in 7590-pores using a melt-spun staple fiber single-screw extruder containing a sesame salt-like blend of 20% by weight PTT and 80% by weight Co-PET. It was co-supplied to the spinneret at a weight ratio of 20:80. Polytrimethylene terephthalate contained 0.3% TiO ₂ and had an intrinsic viscosity of 0.96 dL / g. A filament with a circular cross section was spun at a throughput of a 100 kg / h extruder using radiant quenching. The temperature of the melt region of the extruder was maintained at 252 to 263 ° C. The polymer treatment was 0.220 g / min / pore and the feed roll rate was 650 m / m. The spinning dpf was nominally 3.4. The spun fibers were collected in a can.

A total of 421,896 denier of 16 (16) cans was supplied to the stretch-crimp-cut / bale module. Staple melt-spun fibers were produced using a typical cotton count staple process utilizing a multi-step stretcher, crimping machine, incinerator, and cutter. The tow was immersed in a finishing bath (0.5% concentration, commercially available from CHT as Duron 3176) at 22 ° C. The tow is first stretched in a 0.5% concentration finishing bath at 75 ° C. between an 18 ° C. feed roll operating at 30 m / m and a heat stretched roll at 80 ° C. operating at 84 m / m. A draw ratio of 2.8 was obtained at the stage of. The stretched tow was pulled through a steam chamber at 100 ° C. by a heating roll on the downstream side at 165 ° C. operating at 88.20 m / m. The tow was passed over another series of rolls heated to 165 ° C. operating at 88.20 m / m. A finishing agent (2% concentration, Duron14 + Duron1105PE, 30/70 active substance, both from comp. CHT) was sprayed and the tow was passed over a 25 ° C. cooling drum roll operating at 86.44 m / m. The tow entered the steam chamber at 100 ° C. before entering the 40 mm crimping machine. The crimping machine speed was 90.76 m / m. The temperature and pressure of the rollers of the crimping machine were 65 ° C. and 0.8 bar, respectively. The crimped tow is annealed in a plate belt dryer at 100 ° C. for 4 minutes, and finally the crimped tow is cut to have the following properties (determined using the method already disclosed herein). Produced staple melt-spun fibers:
Denier / filament (dpf) = 1.28, coefficient of variation (CV) = 15.47%
Thread strength = 5.24 g / d, CV = 13.05%
Elongation = 53.37%, CV = 39.14%
Staple length = 38mm
Number of crimps (perfect sine arc) = 12.9 / inch Crunch stability = 64.08%, CV = 17.67%
Thread finishing agent = 0.26%

Example 28
A melt-spun staple fiber uniaxial extruder containing a sesame-salt blend of 50% by weight PTT and 50% by weight Co-PET was used to spin polytrimethylene terephthalate and co-PET (manufactured by Nan Ya Plastics) into a 7590-hole spinneret. Co-supplied at a weight ratio of 50:50. Polytrimethylene terephthalate contained 0.3% TiO ₂ and had an intrinsic viscosity of 0.96 dL / g. A filament with a circular cross section was spun at a processing rate of 122.2 kg / h using radiant quenching. The temperature of the melt region of the extruder was maintained at 252 to 263 ° C. The polymer treatment was 0.268 g / min / pore and the feed roll rate was 792 m / m. The spinning dpf was nominally 3.4. The spun fibers were collected in a can.

A total of 421,896 denier of 16 (16) cans was supplied to the stretch-crimp-cut / bale module. Staple melt-spun fibers were produced using a typical cotton count staple process utilizing a multi-step stretcher, crimping machine, incinerator, and cutter. The tow was immersed in a finishing bath (0.5% concentration, commercially available from CHT as Duron 3176) at 22 ° C. The tow is first stretched in a 0.5% concentration finishing bath at 75 ° C. between an 18 ° C. feed roll operating at 30 m / m and a heat stretched roll at 80 ° C. operating at 87 m / m. A draw ratio of 2.9 was obtained at the stage of. The stretched tow was pulled through a steam chamber at 100 ° C. by a heating roll on the downstream side at 165 ° C. operating at 92.22 m / m. The tow was passed over another series of rolls heated to 165 ° C. operating at 90.38 m / m. A finishing agent (2% concentration, Duron14 + Duron1105PE, 30/70 active substance, both from comp. CHT) was sprayed and the tow was passed over a 25 ° C. cooling drum roll operating at 90.38 m / m. The tow entered the steam chamber at 100 ° C. before entering the 40 mm crimping machine. The crimping machine speed was 94.89 m / m. The temperature and pressure of the rollers of the crimping machine were 65 ° C. and 0.8 bar, respectively. The crimped tow is annealed in a plate belt dryer at 100 ° C. for 4 minutes, and finally the crimped tow is cut to have the following properties (determined using the method already disclosed herein). Produced staple melt-spun fibers:
Denier / filament (dpf) = 1.31, coefficient of variation (CV) = 10.13%
Thread strength = 4.66 g / d, CV = 9.72%
Elongation = 53.86%, CV = 25.47%
Staple length = 38mm
Number of crimps (perfect sine arc) = 13.1 / inch crimp stability = 79.51%, CV = 9.45%
Thread finishing agent = 0.20%

Example 29
A melt-spun staple fiber uniaxial extruder containing a sesame-salt blend of 50% by weight PTT and 50% by weight Co-PET was used to spin polytrimethylene terephthalate and co-PET (manufactured by Nan Ya Plastics) into a 7590-hole spinneret. Co-supplied at a weight ratio of 50:50. Polytrimethylene terephthalate contained 0.3% TiO ₂ and had an intrinsic viscosity of 0.96 dL / g. A filament with a circular cross section was spun at a processing rate of 122.2 kg / h using radiant quenching. The temperature of the melt region of the extruder was maintained at 252 to 263 ° C. The polymer treatment was 0.268 g / min / pore and the feed roll speed was 400 m / m. The spinning dpf was nominally 6.4. The spun fibers were collected in a can.

8 (8) cans, a total of 388,608 denier, were fed into the stretch-crimp-cut / bale module. Staple melt-spun fibers were produced using a typical worsted staple process utilizing multi-step drawing, crimping machines, incinerators, and cutters. The tow was immersed in a finishing bath (0.5% concentration, commercially available from CHT as Duron 3176) at 22 ° C. The tow is first stretched in a 0.5% concentration finishing bath at 75 ° C. between an 18 ° C. feed roll operating at 30 m / m and a heat stretched roll at 80 ° C. operating at 114 m / m. A draw ratio of 3.8 was obtained at the stage of. The stretched tow was pulled through a steam chamber at 100 ° C. by a heating roll on the downstream side at 165 ° C. operating at 108.3 m / m. The tow was passed over another series of rolls heated to 165 ° C. operating at 106.1 m / m. A finishing agent (2% concentration, Duron14 + Duron1105PE, 30/70 active substance, both from comp. CHT) was sprayed and the tow was passed over a 25 ° C. cooling drum roll operating at 107.2 m / m. The tow entered the steam chamber at 100 ° C. before entering the 40 mm crimping machine. The crimping machine speed was 112.56 m / m. The temperature and pressure of the rollers of the crimping machine were 65 ° C. and 0.8 bar, respectively. The crimped tow is annealed in a plate belt dryer at 100 ° C. for 4 minutes, and finally the crimped tow is cut to have the following properties (determined using the method already disclosed herein). Produced staple melt spun fibers with multiple cut lengths:
Denier / filament (dpf) = 2.08, coefficient of variation (CV) = 7.47%
Thread strength = 4.31 g / d, CV = 15.67%
Elongation = 67.77%, CV = 24.33%
Staple length = multiple cut lengths, 59.5 / 79.3 / 119 mm
Number of crimps (perfect sine arc) = 12 / inch Crunch stability = 72.11%, CV = 12.8%
Thread finishing agent = 0.09%

Example 30
CRASTIN® 6130C NC010 polybutylene terephthalate with an intrinsic viscosity of 1.15 dL / g using a melt-spun staple fiber single-screw extruder containing a sesame salt-like blend of 20 wt% PBT and 80 wt% Co-PET (registered trademark) PBT) and co-PET (manufactured by Nan Ya Plastics) were co-supplied at a weight ratio of 20:80 via a 7590-well spun spout. A filament with a circular cross section was spun at a throughput of a 100 kg / h extruder using radiant quenching. The temperature of the melt region of the extruder was maintained at 252 to 263 ° C. The polymer treatment was 0.220 g / min / pore and the feed roll rate was 650 m / m. The spinning dpf was nominally 3.18. The spun fibers were collected in a can.

A total of 386,179 denier of 16 (16) cans was fed to the stretch-crimp-cut / bale module. Staple melt-spun fibers were produced using a typical cotton count staple process utilizing a multi-step stretcher, crimping machine, incinerator, and cutter. The tow was immersed in a finishing bath (0.5% concentration, commercially available from CHT as Duron 3176) at 22 ° C. The tow is first stretched in a 0.5% concentration finishing bath at 75 ° C. between an 18 ° C. feed roll operating at 30 m / m and a heat stretched roll at 80 ° C. operating at 88.2 m / m. , The first stage draw ratio of 2.94 was obtained. The stretched tow was pulled through a steam chamber at 100 ° C. by a heating roll on the downstream side at 165 ° C. operating at 92.61 m / m. The tow was passed over another series of rolls heated to 165 ° C. operating at 92.61 m / m. A finishing agent (2% concentration, Duron14 + Duron1105PE, 30/70 active substance, both from comp. CHT) was sprayed and the tow was passed over a 25 ° C. cooling drum roll operating at 90.76 m / m. The tow entered the steam chamber at 100 ° C. before entering the 40 mm crimping machine. The crimping machine speed was 95.30 m / m. The temperature and pressure of the rollers of the crimping machine were 65 ° C. and 0.8 bar, respectively. The crimped tow is annealed in a plate belt dryer at 100 ° C. for 4 minutes, and finally the crimped tow is cut to have the following properties (determined using the method already disclosed herein). Produced staple melt-spun fibers:
Denier / filament (dpf) = 1.24, coefficient of variation (CV) = 13.51%
Thread strength = 5.36 g / d, CV = 11.77%
Elongation = 47.07%, CV = 39.30%
Staple length = 40 mm
Number of crimps (perfect sine arc) = 10.4 / inch Crunch stability = 56.2%, CV = 13.9%
Thread finishing agent = 0.31%

Example 31
CRASTIN® 6130C NC010 polybutylene terephthalate with an intrinsic viscosity of 1.15 dL / g using a melt-spun staple fiber single-screw extruder containing a sesame salt-like blend of 50% by weight PBT and 50% by weight Co-PET. PBT) and co-PET (manufactured by Nan Ya Plastics) were co-supplied at a weight ratio of 50:50 via a 7590-well spun spout. A filament with a circular cross section was spun at a processing rate of 122.2 kg / h using radiant quenching. The temperature of the melt region of the extruder was maintained at 252 to 263 ° C. The polymer treatment was 0.268 g / min / pore and the feed roll rate was 792 m / m. The spinning dpf was nominally 3.42. The spun fibers were collected in a can.

A total of 415,324 denier of 16 (16) cans was supplied to the stretch-crimp-cut / bale module. Staple melt-spun fibers were produced using a typical cotton count staple process utilizing a multi-step stretcher, crimping machine, incinerator, and cutter. The tow was immersed in a finishing bath (0.5% concentration, commercially available from CHT as Duron 3176) at 22 ° C. The tow is first stretched in a 0.5% concentration finishing bath at 75 ° C. between an 18 ° C. feed roll operating at 30 m / m and a heat stretched roll at 80 ° C. operating at 87.90 m / m. , The first stage draw ratio of 2.93 was obtained. The stretched tow was pulled through a steam chamber at 100 ° C. by a heating roll on the downstream side at 165 ° C. operating at 94.93 m / m. The tow was passed over another series of rolls heated to 165 ° C. operating at 94.93 m / m. A finishing agent (2% concentration, Duron14 + Duron1105PE, 30/70 active substance, both from comp. CHT) was sprayed and the tow was passed over a 25 ° C. cooling drum roll operating at 93.03 m / m. The tow entered the steam chamber at 100 ° C. before entering the 40 mm crimping machine. The crimping machine speed was 97.69 m / m. The temperature and pressure of the rollers of the crimping machine were 65 ° C. and 0.8 bar, respectively. The crimped tow is annealed in a plate belt dryer at 100 ° C. for 4 minutes, and finally the crimped tow is cut to have the following properties (determined using the method already disclosed herein). Produced staple melt-spun fibers:
Denier / filament (dpf) = 1.17, coefficient of variation (CV) = 13.6%
Thread strength = 5.48 g / d, CV = 12.38%
Elongation = 39.74%, CV = 27.57%
Staple length = 40 mm
Number of crimps (perfect sine arc) = 11.8 / inch Crunch stability = 60.23%, CV = 8.30%
Thread finishing agent = 0.24%

Example 32
40sNe spun yarn containing 100% melt spun fiber A spun yarn was prepared using the melt spun staple fiber from Example 28 according to the method of Example 5 except for the following differences:

The linear density of the final sliver was 4.75 g / meter, and the percentage of spots was 1.75.

The coarse thread skein was 1.2 sNe.

In the step of drafting the blister, the twist factor / twist per inch was 3.6 / 22.6, the traveler size was 4 / 0M1HO, and the spindle speed was 16500 rpm.

The spun yarn was wound around the cone at 1500 m / min. The characteristics of the spun yarn are shown in Table 13. The properties of the spun yarns of this example and the following examples were determined using the methods already disclosed herein.

Example 33
40sNe spun yarn containing 100% melt spun fiber A spun yarn was prepared according to the procedure of Example 32 using the melt spun staple fiber from Example 27. The characteristics of the spun yarn are shown in Table 13.

Example 34
40sNe spun yarn containing 100% melt spun fiber A spun yarn was prepared according to the procedure of Example 32 using the melt spun staple fiber from Example 31. The characteristics of the spun yarn are shown in Table 13.

Example 35
40sNe spun yarn containing 100% melt spun fiber A spun yarn was prepared according to the procedure of Example 32 using the melt spun staple fiber from Example 30. The characteristics of the spun yarn are shown in Table 13.

Example 36
40sNe spun yarn containing 40/60 (weight / weight) melt-spun fiber / cotton The melt-spun staple fiber from Example 28 and cotton (Shankar 6, various commercially available Indian cotton from northern India) were used. Spinned yarn was prepared. The cotton staples had an average length of 31 mm and a linear density of 4.1 micrograms / inch (1.6 micrograms / cm). A spun yarn was produced according to the procedure of Example 32. The characteristics of the spun yarn are shown in Table 13.

Example 37
40sNe spun yarn containing 40/60 (weight / weight) melt-spun fiber / cotton The melt-spun staple fiber from Example 27 and cotton (Shankar 6, various commercially available Indian cotton from northern India) were used. Spinned yarn was prepared. The cotton staples had an average length of 31 mm and a linear density of 4.1 micrograms / inch (1.6 micrograms / cm). A spun yarn was produced according to the procedure of Example 8. The characteristics of the spun yarn are shown in Table 13.

Example 38
40sNe spun yarn containing 40/60 (weight / weight) melt-spun fiber / cotton The melt-spun staple fiber from Example 31 and cotton (Shankar 6, various commercially available Indian cotton from northern India) were used. Spinned yarn was prepared. The cotton staples had an average length of 31 mm and a linear density of 4.1 micrograms / inch (1.6 micrograms / cm). A spun yarn was produced according to the procedure of Example 8. The characteristics of the spun yarn are shown in Table 13.

Example 39
40sNe spun yarn containing 40/60 (weight / weight) melt-spun fiber / cotton The melt-spun staple fiber from Example 30 and cotton (Shankar 6, various commercially available Indian cotton from northern India) are used. Spinned yarn was prepared. The cotton staples had an average length of 31 mm and a linear density of 4.1 micrograms / inch (1.6 micrograms / cm). A spun yarn was produced according to the procedure of Example 8. The characteristics of the spun yarn are shown in Table 13.

Example 40
40sNe spun yarn containing 40/60 molten spun fiber / Tencel A spun yarn was prepared using the melt spun staple fiber from Example 28 and a commercially available Tencel® staple fiber (Lensing). Tencel® staples had an average length of 40 mm and a denier of 1.2D. A spun yarn was produced according to the procedure of Example 10. The characteristics of the spun yarn are shown in Table 13.

Example 41
40sNe spun yarn containing 40/60 molten spun fiber / Tencel A spun yarn was prepared using the melt spun staple fiber from Example 27 and a commercially available Tencel® staple fiber (Lensing). Tencel® staples had an average length of 40 mm and a denier of 1.2D. A spun yarn was produced according to the procedure of Example 10. The characteristics of the spun yarn are shown in Table 13.

Example 42
40sNe spun yarn containing 40/60 molten spun fiber / Tencel A spun yarn was prepared using the melt spun staple fiber from Example 31 and a commercially available Tencel® staple fiber (Lensing). Tencel® staples had an average length of 40 mm and a denier of 1.2D. A spun yarn was produced according to the procedure of Example 10. The characteristics of the spun yarn are shown in Table 13.

Example 43
40sNe spun yarn containing 40/60 molten spun fiber / Tencel A spun yarn was prepared using the melt spun staple fiber from Example 30 and a commercially available Tencel® staple fiber (Lensing). Tencel® staples had an average length of 40 mm and a denier of 1.2D. A spun yarn was produced according to the procedure of Example 10. The characteristics of the spun yarn are shown in Table 13.

Example 44
2 / 68sNm spun yarn containing 45/55 wool / melt-spun staple fibers A spun yarn was produced using the worsted yarn spinning method according to the following procedure.

The spun yarn of Example 44 was prepared using the melt-spun staple fibers from Example 29. Molten-spun staple fibers of 2.5 denier and an average length of 84 mm were removed and converted to sliver in a cotton carding spinning process by the usual carding process commonly used in spinning mills. This sliver is blended with a wool top (20.5 micron, 68 mm average length Australian Merino) and a worsted yarn spinning method with a blending ratio of 45/55 (weight / weight) wool / melt-spun staple fibers. Spinned in. The nominal number for the spun yarn was 2 / 68sNm.

In Table 13, the reported boiling shrinkage values were obtained using 1 kg weight according to Method ASTM D2259.

The results in Table 13 are compared with the results in Tables 4 and 5, and the yarn strength of the spun yarn incorporating the melt-spun staple with a sesame salt-like blend of PET / PTT at 50:50 is a blend of PET / PTT at 50:50. It is shown that the yarn strength of the spun yarn incorporating the melt-spun staple is about the same. The percentage of boiling water shrinkage is compared to the percentage of boiling water shrinkage of spun yarns incorporating melt-spun staples containing PET / PTT at 50:50, and spinning incorporating melt-spun staples blended with PET / PTT at 50:50. The thread is higher. All other properties have been found to be similar.

Examples of woven fabrics The woven fabrics shown in Table 14 were prepared using the spun yarns of Examples 32 to 44. A plain weave (1/1) shirt fabric was prepared using the spun yarn disclosed in the present specification as a warp yarn and a weft yarn (weft yarn (fil)). For each woven fabric, the same threads were used for both the warp and weft threads. The evaluation results of the fabric are shown in Tables 15 and 16. Unless otherwise stated, results are reported for the finished fabric. The properties of the fabrics of this example and the following examples were determined using the methods already disclosed herein.

Example 45
A plain weave (1/1) shirt fabric was prepared using the spun yarn from Example 32 as a warp yarn and a weft yarn. The warp was sized prior to the warp unwinding using a CCI single gluing machine using an Elvanol-T25PVA sizing agent. A warp was used at 350 m / min to prepare a final beam with 1680 warp threads, a width of 18 inches, and a warp thread length of 3.5 meters. The following denting plans:
Kneading: 4-shaft kneading type (straight kneading (1, 2, 3, and 4)
Reed threading: 2 warp threads / number of reed feather leads: 84 reed feathers / 2 inch 1/1 plain weave fabric was woven on a CCI sample loom at a loom speed of 40 picks / minute. The pick value was set to 49 picks / inch.

The raw fabric was deglued as follows with an RBE lab jigger machine. The fabric sample was loaded onto a jigger filled with water (2 L), NaOH (2 gpl), and a wetting agent; Levocol CESR (wetting agent) was added (5 gpl) to raise the bath temperature to 90 ° C. After the fabric was allowed to flow in the bath for 60 minutes, the bath was drained and refilled with fresh water to raise the temperature of the bath to 85 ° C. The fabric was washed with warm water for 15 minutes and drained from the bath. The bath was filled with water again and the fabric was flushed with water for 15 minutes (cold water wash). The bath was drained, filled with water and neutralized by adding acetic acid (1 gpl); the fabric was run in this bath for 15 minutes. The bath was then drained, refilled with fresh water and the fabric run in a cold water bath for 15 minutes. The fabric was then removed from the jigger, dried under atmospheric conditions and then heat set at 160 ° C. for 45 seconds in an RBE stenter.

The fabric was then dyed with a disperse dye mixture using the following time and temperature profiles. Heat to 70 ° C. and hold for 10 minutes, then raise the temperature to 130 ° C. at 1.5 ° C./min, hold for 30 minutes, then lower the temperature to 70 ° C. at 1.5 ° C./min. Drained. After dyeing, the fabric was reduced and washed with Hydros and NaOH (2 gpl each) at 90 ° C. for 20 minutes. Then, the cloth was washed with cold water for 10 minutes, contacted with acetic acid (2 gpl) for 15 minutes, and then washed with cold water for 10 minutes. After impregnating the dyed fabric with a finishing agent (softener), the dyed fabric was heat-set at 160 ° C. for 45 seconds in an RBE lab stenter.

The dough structure is shown in Table 14. The result of the wicking test was 100%. Other features of the fabric are shown in Tables 15 and 16.

Example 46
Using the spun yarn from Example 33 as the warp and weft, a plain weave shirt fabric was prepared by the procedure shown in Example 45. The dough structure is shown in Table 14. The result of the wicking test was 100%. Other features of the fabric are shown in Tables 15 and 16.

Example 47
Using the spun yarn from Example 34 as the warp and weft, a plain weave shirt fabric was prepared by the procedure shown in Example 45. The dough structure is shown in Table 14. The result of the wicking test was 100%. Other features of the fabric are shown in Tables 15 and 16.

Example 48
Using the spun yarn from Example 35 as the warp and weft, a plain weave shirt fabric was prepared by the procedure shown in Example 45. The dough structure is shown in Table 14. The result of the wicking test was 100%. Other features of the fabric are shown in Tables 15 and 16.

Example 49
A plain weave shirt fabric was prepared using the spun yarn from Example 36 as the warp and weft according to the procedure of Example 45 with the following exceptions. The pick value was set to 58 picks / inch on the loom. The raw fabric was desizing and bleached with a jigger, heat set in a stenter, then dyed with a mixture of disperse dyes and then further dyed with a reactive dye under cotton dyeing conditions. The dough structure is shown in Table 14. The result of the wicking test was 100%. Other features of the fabric are shown in Tables 15 and 16.

Example 50
A plain weave shirt fabric was prepared using the spun yarn from Example 37 as the warp and weft according to the procedure of Example 49 with the following exceptions. The raw fabric was desizing and bleached with a jigger, heat set in a stenter, then dyed with a mixture of disperse dyes and then further dyed with a reactive dye under cotton dyeing conditions. The dough structure is shown in Table 14. The result of the wicking test was 100%. Other features of the fabric are shown in Tables 15 and 16.

Example 51
A plain weave shirt fabric was prepared using the spun yarn from Example 38 as warp and weft according to the procedure of Example 49 with the following exceptions. The raw fabric was desizing and bleached with a jigger, heat set in a stenter, then dyed with a mixture of disperse dyes and then further dyed with a reactive dye under cotton dyeing conditions. The dough structure is shown in Table 14. The result of the wicking test was 100%. Other features of the fabric are shown in Tables 15 and 16.

Example 52
A plain weave shirt fabric was prepared using the spun yarns from Example 39 as warp and weft yarns according to the procedure of Example 49 with the following exceptions. The raw fabric was desizing and bleached with a jigger, heat set in a stenter, then dyed with a mixture of disperse dyes and then further dyed with a reactive dye under cotton dyeing conditions.
The dough structure is shown in Table 14. The result of the wicking test was 100%. Other features of the fabric are shown in Tables 15 and 16.

Example 53
Plain weave shirt fabrics were prepared using the spun yarns from Example 40 as warp and weft yarns according to the procedure of Example 49, except that no peroxide killer was used at the end of the bleaching step. The pick value was set to 65 picks / inch on the loom.
The dough structure is shown in Table 14. The result of the wicking test was 100%. Other features of the fabric are shown in Tables 15 and 16.

Example 54
A plain weave shirt fabric was prepared using the spun yarn from Example 41 as the warp and weft according to the procedure of Example 53. The dough structure is shown in Table 14. The result of the wicking test was 100%. Other features of the fabric are shown in Tables 15 and 16.

Example 55
A plain weave shirt fabric was prepared using the spun yarn from Example 42 as the warp and weft according to the procedure of Example 53. The dough structure is shown in Table 14. The result of the wicking test was 100%. Other features of the fabric are shown in Tables 15 and 16.

Example 56
A plain weave shirt fabric was prepared using the spun yarn from Example 42 as the warp and weft according to the procedure of Example 53.

The dough structure is shown in Table 14. The result of the wicking test was 100%. Other features of the fabric are shown in Tables 15 and 16.

Example 57
The spun yarn from Example 34 was used as a warp yarn and a weft yarn to prepare a suit fabric having a 2/1 twill weave structure. The warp was sized prior to the warp unwinding using a CCI single gluing machine using an Elvanol-T25PVA sizing agent and a fabric softener. A warp was used at 350 m / min to prepare a final beam with 1518 warp threads, a width of 18 inches, and a warp thread length of 3.5 meters. The following denting plans:
Kneading: 3-shaft kneading type (straight kneading (1, 2, and 3)
Reed thread: 3 warp threads / number of reed feather leads: 51.5 reed feathers / 2 inches 2/1 RHT twill fabric was woven on a CCI sample loom at a loom speed of 40 picks / minute. The pick value was set to 53 picks / inch. A raw fabric having a length of 2 m and a width of 48.3 cm was obtained.

The raw fabric was gelatinized with a jigger using a procedure similar to that of Example 49, except that Albatex AD was used with Levocol CESR. The fabric was then subjected to a hot water wash (15 minutes at 85 ° C.), a cold water wash (15 minutes), a neutralization step with acetic acid (15 minutes), and another cold water wash (15 minutes). The fabric was flat-dried under atmospheric conditions and then heat-set at 170 ° C. for 45 seconds.

The fabric was then dyed with a disperse dye mixture using the following time and temperature profiles. Heat to 70 ° C. and hold for 10 minutes, then raise the temperature to 130 ° C. at 1.5 ° C./min, hold for 30 minutes, then lower the temperature to 70 ° C. at 1.5 ° C./min. Drained. The fabric was reduced and washed with Hydros and NaOH (1 gpl each) at 90 ° C. for 20 minutes. Then, the cloth was washed with cold water for 10 minutes, contacted with acetic acid (2 gpl) for 15 minutes, and then washed with cold water for 10 minutes.

The fabric was then dyed with an acid dye mixture using the following time and temperature profiles: heated to 70 ° C., kept for 10 minutes and then raised to 98 ° C. at 1.5 ° C./min. After keeping for 45 minutes, the temperature was lowered to 70 ° C. at 1.5 ° C./min and drained. The fabric is washed in cold water (10 minutes), treated with acetic acid (1 gpl, 15 minutes), soaped at high temperature with Albatex AD (90 ° C, 15 minutes) and washed with warm water (85 ° C, 15 minutes). After washing with cold water (10 minutes), the dye was fixed by contacting with Levocol HCF (0.5 gpl) at 50 ° C. for 20 minutes.

After the fabric is autoclaved in an autoclave (130 ° C. for 3 minutes) and then impregnated with the finishing agent, Levofin HYP-5gpl Levocol PNLI-10gpl, before heat setting at 160 ° C. in a lab stenter for 45 seconds, the autoclave It was autoclaved again (130 ° C., 3 minutes).

The raw fabric and the finished fabric were evaluated. The fabric structure and test results are shown in Tables 14, 15, and 16. The result of the wicking test was 100%.

The results are shown in Tables 14, 15, and 16, and also Tables 6, 7, and 8 above show that the spun yarns disclosed herein can be used to make woven fabrics with the desired properties. Demonstrate.

Example of circular knitted fabric The circular knitted fabric shown in Table 17 was prepared using the spun yarns of Examples 32 to 44 as the knitting yarn. For all round knitted fabrics with a 40sNe count, the knitting machine gauge was 24 ". The results of the fabric evaluation are shown in Table 18. Unless otherwise stated, the results are reported for the finished fabric.

Examples 58, 59, 60, and 61
Round knitted fabrics were prepared on a Mesdan lab knitting machine using the spun yarns from Examples 32, 33, 34, and 35, respectively. The raw fabric was heat-set at 160 ° C. for 45 seconds with an RBE stainer and then refined with an HTHP Beaker dyeing machine using the following procedure. NaOH (2 gpl) and the wetting agent Levocol CESR (5 gpl) were added and the fabric was smelted at 90 ° C. for 60 minutes. The fabric was washed at 85 ° C. for 15 minutes, then in cold water for 15 minutes, then in a neutralizing solution containing acetic acid (1 gpl) for 15 minutes, and then in another cold water for 15 minutes.

The scouring fabric was then dyed in the same machine with a mixture of disperse dyes using the following time and temperature profiles: heat to 70 ° C., hold for 10 minutes and then temperature to 1.5 ° C./min. The temperature was raised to 130 ° C. and kept for 30 minutes, then the temperature was lowered to 70 ° C. at 1.5 ° C./min and drained. After dyeing, the fabric was reduced and washed with Hydros and NaOH (2 gpl each) at 90 ° C. for 20 minutes. Then, the cloth was washed with cold water for 10 minutes, neutralized with acetic acid (2 gpl) for 15 minutes, and then washed with cold water for 10 minutes. After impregnating the dyed fabric with a finishing agent (softener), the dyed fabric was heat-set at 160 ° C. for 45 seconds in a lab stenter. The fabric structure and test results are shown in Tables 17 and 18. The result of the wicking test was 100% for all fabrics.

Examples 62, 63, 64, and 65
Performed according to the procedure of Example 58, except that the fabric was dyed with a reactive dye mixture to which a salt (60 gpl) was added in the same machine after dyeing with a disperse dye using the following time and temperature profiles. Round knitted fabrics were prepared on a Mesdan lab knitting machine using the spun yarns from Examples 36, 37, 38 and 39, respectively: heated to 60 ° C. and kept for 30 minutes before adding soda ash (15 gpl). And kept for 30 minutes before draining. Next, the fabric was washed with cold water for 10 minutes, washed with acetic acid (1 gpl) for 15 minutes, and then soaped at high temperature with Albatex AD (2 gpl) while raising the temperature to 90 ° C. and keeping it for 15 minutes. .. Next, the fabric was washed with warm water (85 ° C.) for 15 minutes and then with cold water for 10 minutes. The dye was fixed with Levocol HCF (0.5 gpl) while raising the temperature to 50 ° C. and keeping it for 20 minutes. After impregnating the dyed fabric with the finishing agent, it was heat-set in a lab stenter at 160 ° C. for 45 seconds. The fabric structure and test results are shown in Tables 17 and 18. The result of the wicking test was 100% for all fabrics.

Examples 66, 67, 68, and 69
Examples 40, 41, 42 according to the procedure of Example 18, except that different disperse dye mixtures and different reactive dye mixtures were used, and no peroxide killer was used at the end of the bleaching step. , And 43 spun yarns were used to prepare circular knitted fabrics on a Mesdan lab knitting machine. The fabric structure and test results are shown in Tables 17 and 18. The result of the wicking test was 100% for all fabrics.

Example 70
Using the spun yarn from Example 44, a circular knitted fabric was prepared on a Mesdan lab knitting machine according to the procedure of Example 14. The fabric was dyed and finished according to Example 57. The fabric structure and test results are shown in Tables 17 and 18. The result of the wicking test was 100% for all fabrics.

The results from Tables 17 and 18 and Tables 9 and 10 above demonstrate that the spun yarns disclosed herein can be used to make circular knitted fabrics with the desired properties.

Claims (20)

It is a spun yarn:
It contains melt-spun staple fibers containing a first polymer containing poly (trimethylene terephthalate) or poly (butylene terephthalate) and a second polymer containing poly (ethylene terephthalate) or Co-PET, where Co-PET is isophthalic acid. It is a poly (ethylene terephthalate) copolymer containing a monomer; and the first polymer contains poly (trimethylene terephthalate), and the weight ratio of the poly (trimethylene terephthalate) to the second polymer is about 80:20. In the range of ~ about 10:90;
A spun yarn in which the first polymer contains 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 according to claim 1, wherein the first polymer contains poly (trimethylene terephthalate), and the second polymer contains poly (ethylene terephthalate). The first polymer contains poly (trimethylene terephthalate), the second polymer contains Co-PET, and the Co-PET is from about 0.5 mol% based on the total copolymer composition. The spun yarn according to claim 1, which contains about 10 mol% of an isophthalic acid monomer. The spun yarn according to claim 1, wherein the first polymer contains poly (butylene terephthalate), and the second polymer contains poly (ethylene terephthalate). The first polymer contains poly (butylene terephthalate), the second polymer contains Co-PET, and the Co-PET is from about 0.5 mol% to about, relative to the total copolymer composition. The spun yarn according to claim 1, which contains 10 mol% of an isophthalic acid monomer. The spun yarn according to any one of claims 3 to 5, wherein the spun yarn has a boil-off shrinkage of at least about 6% determined according to ASTM D2259. The spun yarn according to claim 1, wherein the weight ratio of the poly (trimethylene terephthalate) or the poly (butylene terephthalate) to the second polymer is in the range of 70:30 to 30:70. The spun yarn according to claim 1, further comprising a second staple fiber in an amount of about 5% by weight to about 95% by weight based on the total weight of the spun yarn. The spinning according to claim 9, wherein the second staple fiber comprises polylactic acid, acrylic, nylon, olefin, acetate, rayon, polyester, cotton, linen, wool, angora, mohair, alpaca, cashmere, or a mixture thereof. thread. The spun yarn according to claim 10, wherein the second staple fiber contains cotton or wool. A fabric containing the spun yarn according to claim 1. The fabric according to claim 12, wherein the first polymer contains poly (trimethylene terephthalate), and the second polymer contains poly (ethylene terephthalate). The fabric according to claim 12, wherein the first polymer contains poly (trimethylene terephthalate), and the second polymer contains Co-PET. The fabric according to claim 12, wherein the first polymer contains poly (butylene terephthalate), and the second polymer contains poly (ethylene terephthalate). The fabric according to claim 12, wherein the first polymer contains poly (butylene terephthalate), and the second polymer contains Co-PET. The fabric is: better than fabric of the same fabric structure consisting of polyethylene terephthalate, cotton, rayon, or a combination thereof i) Good abrasion resistance determined according to ASTM D4966 standard test method;
ii) High pilling property assessment value determined according to ASTM D4970 standard test method; or iii) Large bulkiness determined according to ASTM D1777 standard test method;
The fabric according to claim 12, which has at least one of. The fabric according to claim 12, wherein the fabric is a woven fabric having a warp yarn and a weft yarn, and the warp yarn, the weft yarn, or both the warp yarn and the weft yarn each include the spun yarn according to claim 1. .. The cloth according to claim 12, wherein the cloth is a knitted cloth. The fabric according to claim 19, wherein the fabric has higher resilience as determined according to method BS4294 than a knitted fabric having the same fabric structure consisting of polyethylene terephthalate, cotton, rayon, or a combination thereof. An article containing the fabric according to claim 12.