KR20210024618A - Spun yarn containing polyester staple fibers and fabric containing same - Google Patents

Abstract

Disclosed herein is a spun yarn comprising a melt spun staple fiber comprising a first polymer and a second polymer, wherein the first polymer is poly(trimethylene terephthalate) or poly(butylene). Terephthalate) and the second polymer comprises poly(ethylene terephthalate) or Co-PET, and Co-PET is a poly(ethylene terephthalate) copolymer comprising an isophthalic acid monomer; The first polymer comprises poly(trimethylene terephthalate) and the weight ratio of poly(trimethylene terephthalate) to the second polymer ranges from about 80:20 to about 10:90; Or the first polymer comprises poly(butylene terephthalate) and the weight ratio of poly(butylene terephthalate) to the second polymer ranges from about 90:10 to about 10:90. The spun yarn may further include second staple fibers such as cotton or wool. Spun yarn is useful for making fabrics with advantageous properties.

Description

Spun yarn containing polyester staple fibers and fabric containing same

Cross-reference of related applications

This application is a U.S. Provisional Application No. 62/691066, filed on June 28, 2018, entitled "Fabrics and Spun Yarns Comprising Polyester Staple Fiber", and 2018 The invention claims priority and benefit to U.S. Provisional Application No. 62/747999, filed October 19, 2014, also entitled "Fabrics and Spun Yarns Including Polyester Staple Fibers", the disclosure of both of these U.S. Provisional Applications The contents are incorporated herein by reference in their entirety.

Technical field

The present invention relates to a spun yarn comprising a melt spun staple fiber comprising a first polymer and a second polymer, and to a fabric comprising such spun yarn. The first polymer comprises poly(trimethylene terephthalate) or poly(butylene terephthalate), the second polymer comprises poly(ethylene terephthalate) or Co-PET, and Co-PET comprises an isophthalic acid monomer. It is a poly(ethylene terephthalate) copolymer.

Poly(trimethylene terephthalate) (PTT) is a commercial fiber that provides desirable properties such as easy dispersion dyeing at atmospheric pressure, relatively low bending modulus, and relatively high elastic recovery and elasticity. Although the production process of PTT staple fibers is known, the consistent treatment of PTT with staples is due to the shrinkage of the partially oriented tow during storage prior to drawing, crimping, and cutting. Often disturbed. Shrinkage is affected by storage time and storage temperature, and uncontrolled shrinkage results in draw break and denier non-uniformity during the stretching process. As a result, the commercialization of PTT staples, or blends of PTT staples and natural fibers, has been limited.

In certain textile end uses, staple fibers are preferred over continuous filaments. For example, staple spun yarns for apparel fabrics require discontinuous fibers rather than continuous fibers in that textile staple processing equipment can be used. Staple fibers also make it possible to blend synthetic fibers and natural fibers such as wool, cotton, and cellulose. In the production of staple fibers suitable for fabrics, in particular, the conventional stretching is carried out in a separate step and the properties of the undrawn fibers, e.g. dry heat shrinkage, can change as the undrawn fibers age during storage. In the split spin/draw process, special problems can arise.

There is a continuing need for PTT-based staples of good uniformity and tenacity, and an economical process for producing such staples. There is a continuing need for spun yarns comprising PTT-based staple fibers and having good toughness and elongation at break, which can impart the desired quality to fabrics comprising such spun yarns.

Melt-spun staple fibers, spun yarns comprising melt-spun staple fibers, and fabrics comprising spun yarns are disclosed herein. In one embodiment, spinning yarn is disclosed, and the yarn is a first polymer comprising poly(trimethylene terephthalate) or poly(butylene terephthalate) and a second polymer comprising poly(ethylene terephthalate) or Co-PET Including a melt-spun staple fiber comprising a, Co-PET is a poly (ethylene terephthalate) copolymer containing an isophthalic acid monomer; The first polymer comprises poly(trimethylene terephthalate) and the weight ratio of poly(trimethylene terephthalate) to the second polymer ranges from about 80:20 to about 10:90; Or the first polymer comprises poly(butylene terephthalate) and the weight ratio of poly(butylene terephthalate) to the second polymer ranges from 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 ranges from about 70:30 to 30:70. In a further embodiment, the spun yarn has a boil off shrinkage of at least about 6% as 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 fibers include poly(trimethylene terephthalate) and Co-PET. In one embodiment of the spun yarn, the first polymer comprises poly(trimethylene terephthalate) and the second polymer comprises Co-PET, and the co-PET is from about 0.5 mol% to about 10 mol based on the total copolymer composition. % Of isophthalic acid monomer. In a further embodiment of the spun yarn, the melt spun staple fibers include poly(butylene terephthalate) and poly(ethylene terephthalate). In 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) and the second polymer comprises Co-PET, and the Co-PET is from about 0.5 mol% to about 10 mol based on the total copolymer composition. % Of isophthalic acid monomer. In a further embodiment of the spun yarn, the second polymer comprises Co-PET, and the Co-PET contains from about 0.5 mol% to about 10 mol% of isophthalic acid monomer based on the total copolymer composition.

In one embodiment, the spun yarn further comprises second staple fibers in an amount of about 5% to about 95% by weight based on the total weight of the spun yarn. In a further 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 mixtures 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 comprising cotton, the cotton being 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 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 comprising wool, the wool being 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 worn count in the range of 7 Nm to 120 Nm.

In another embodiment, a fabric is disclosed, the fabric comprising the spun yarn disclosed herein. In one embodiment, the fabric has a softer feel and better drape than fabrics of the same fabric structure made of rayon, polyethylene terephthalate, cotton, or combinations thereof. In one embodiment, the fabric has i) better abrasion resistance as determined according to ASTM D4966 standard test methods than fabrics of the same fabric structure consisting of polyethylene terephthalate, cotton, rayon, or combinations thereof;

ii) a higher pill rating value as determined according to ASTM D4970 standard test method; or

iii) larger bulk as determined according to ASTM D1777 standard test method

Has one or more of In another embodiment, the fabric has better dyeability than fabrics of the same structure made of polyethylene terephthalate, cotton, rayon, or combinations thereof. In yet another embodiment, the fabric has better abrasion resistance than a fabric of the same fabric structure consisting of polyethylene terephthalate, cotton, rayon, or combinations thereof. In a further embodiment, the fabric has less fluff (higher fluff rating values) than fabrics of the same fabric structure made of polyethylene terephthalate, cotton, rayon, or combinations thereof. In a further embodiment, the fabric has a larger bulk than a fabric of the same fabric structure consisting of polyethylene terephthalate, cotton, rayon, or combinations thereof.

In one embodiment, the fabric is a woven fabric having warp and weft yarns. In one embodiment, the present fabric is a woven fabric having warp and weft yarns, and the warp, weft, or both warp and weft yarns each comprise a spun yarn as disclosed herein. In a further embodiment, the warp yarn comprises spun yarn as disclosed herein. In another embodiment, the weft yarn comprises spun yarn as disclosed herein. In yet a further embodiment, the warp and weft yarns each comprise spun yarns as disclosed herein. In another embodiment, the fabric is a knitted fabric. In one embodiment, the knitted fabric has a higher recovery rate than a knitted fabric of the same fabric structure consisting of polyethylene terephthalate, cotton, rayon, or combinations thereof. Also disclosed herein are articles, such as garments, comprising a fabric as disclosed herein.

In another embodiment, melt-spun staple fibers are disclosed, the fibers comprising a first polymer comprising poly(trimethylene terephthalate) or poly(butylene terephthalate) and poly(ethylene terephthalate) or Co-PET A second polymer, wherein Co-PET is a poly(ethylene terephthalate) copolymer comprising an isophthalic acid monomer, and the staple fiber has a weight ratio of the first polymer to the second polymer of about 70:30 to about 30:70 And the dry heat shrinkage is 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 a further embodiment, the melt spun staple fibers include poly(butylene terephthalate) and poly(ethylene terephthalate). In another embodiment, the melt spun staple fiber comprises poly(butylene terephthalate) and Co-PET. In a further embodiment, the second polymer comprises Co-PET and the Co-PET contains from about 0.5 mol% to about 10 mol% isophthalic acid monomer based on the total copolymer composition. In another embodiment of the melt spun staple fiber, the weight ratio of the first polymer to the second polymer ranges from about 70:30 to 50:50.

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

As used herein, the terms “embodiment” or “invention” are not intended to be limiting but apply generally to any embodiment defined in the claims or described herein. These terms are used interchangeably herein.

In this disclosure, several terms and abbreviations are used. Unless specifically stated otherwise, the following definitions apply.

Articles preceding an element or component are non-limiting with respect to the number of instances (ie, occurrences) of the element or component. Accordingly, the singular form should be understood to include one or at least one, and the singular form of an element or component also includes the plural form unless the number is clearly meant to be singular.

The term “comprising” refers to the presence of a feature, integer, step, or component recited as referred to in the claims, but does not exclude the presence or addition of one or more other features, integers, steps, components or groups thereof. Does not. The term “comprising” is intended to include embodiments encompassed by the terms “consisting essentially of” and “consisting of”. Similarly, the term “consisting essentially of” is intended to encompass embodiments encompassed by the term “consisting of”.

If present, all ranges are inclusive and combinable. For example, when a range of "1 to 5" is mentioned, the stated range is "1 to 4", "1 to 3", "1 to 2", "1 to 2 and 4 to 5", "1 It is to be construed as inclusive of the ranges such as ~3 and 5".

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

All maximum numerical limits given throughout this specification are intended to include all such lower numerical limits, as if all lower numerical limits were expressly stated herein. All minimum numerical limits given throughout this specification will include all such larger numerical limits, as if all larger numerical limits were expressly written herein. All numerical ranges given throughout this specification will include all narrower numerical ranges within such broader numerical ranges, as if all of the narrower numerical ranges were expressly written herein.

Features and advantages of the present invention will be more readily understood by those skilled in the art by reading the following detailed description. For clarity, it is to be understood that certain features of the invention described above and below in the context of individual embodiments may be provided in combination as a single element. Conversely, the various features of the invention described in the context of a single embodiment for brevity may also be provided individually or in any subcombination.

The use of the various ranges of numerical values specified in this application, unless otherwise specified, is referred to as an approximation as if the word "about" was preceded by both the minimum and maximum values within the stated range. In this way, slight deviations above and below the stated range can be used to achieve results that are substantially the same as values within the range. Further, the disclosure of this range is intended to be a continuous range inclusive of each and every value between the minimum and maximum values.

As used herein,

"Poly(trimethylene terephthalate)" or PTT means a polymer comprising repeating units derived from 1,3-propanediol and terephthalic acid (or equivalent). As used herein, the term “poly(trimethylene terephthalate) homopolymer” refers to a polymer of substantially only 1,3-propanediol and terephthalic acid (or equivalent). As used herein, the term “poly(trimethylene terephthalate)” also includes PTT copolymers, which include repeat units derived from 1,3-propanediol and terephthalic acid (or equivalent) and from additional monomers. It means a polymer which also contains at least one additional unit derived. Examples of PTT copolymers include copolyesters prepared using three or more reactants, each having an ester forming group. For example, copoly(trimethylene terephthalate) can be used, and the comonomer used to prepare the copolyester is a linear, cyclic, and branched aliphatic dicarboxylic acid having 4 to 12 carbon atoms ( For example butanedioic acid, pentanedioic acid, hexanoic acid, dodecanedioic acid, and 1,4-cyclo-hexanedicarboxylic acid); Aromatic dicarboxylic acids having 8 to 12 carbon atoms in addition to terephthalic acid (eg isophthalic acid and 2,6-naphthalenedicarboxylic acid); Linear, cyclic, and branched aliphatic diols having 2 to 8 carbon atoms (in addition to 1,3-propanediol, for example, ethanediol, 1,2-propanediol, 1,4-butanediol, 3-methyl- 1,5-pentanediol, 2,2-dimethyl-1,3-propanediol, 2-methyl-1,3-propanediol, and 1,4-cyclohexanediol); And aliphatic and aromatic ether glycols having 4 to 10 carbon atoms (eg, poly(ethylene ether) glycols having a molecular weight of less than about 460, including hydroquinone bis(2-hydroxyethyl) ether, or diethylene ether glycol). It is selected from the group consisting of. The comonomers are typically present in the copolyester at levels ranging from about 0.5 mole percent to about 15 mole percent, and may be present in amounts up to about 30 mole percent.

As used herein, the term “poly(butylene terephthalate)” or PBT refers to a polymer derived substantially only from 1,4-butanediol and terephthalic acid, also referred to as poly(butylene terephthalate) homopolymer. do. As used herein, the term “poly(butylene terephthalate) copolymer comprises repeating units derived from 1,4-butanediol and terephthalic acid and is used for additional monomers, e.g. PTT copolymers as disclosed herein. It refers to a polymer that also contains at least one additional unit derived from a comonomer.

As used herein, the term “poly(ethylene terephthalate)” or PET refers to a polymer derived substantially only from ethylene glycol and terephthalic acid (or equivalents such as dimethyl terephthalate), and poly(ethylene terephthalate) single Also referred to as a polymer. As used herein, the term “poly(ethylene terephthalate) copolymer” includes repeating units derived from ethylene glycol and terephthalic acid (or equivalent), and polymers that also contain at least one additional unit derived from additional monomers. Refers to.

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 comprising an ethylene terephthalate and an isophthalic acid monomer.

“Staple” refers to natural fibers, or fibers of length cut from filaments. The term staple (fiber) is used in the textile industry to distinguish natural fibers or cut artificial fibers from filaments. The man-made fibers are cut to a certain length, for example as long as 8 inches or as short as 1.5 inches or less, so they can be processed or flocked in cotton, wool, or worsted yarn spinning systems.

The term “melt spun staple fiber” refers to a staple fiber obtained by melting a fiber-forming material, extruding it through a spinneret, and then directly solidifying it by cooling; Such melt-spun fibers are stored, combined with other batches of similarly obtained melt-spun fibers, collectively drawn, crimped, heat treated for stabilization, and cut to obtain staple fibers.

The term “spun yarn” refers to a yarn produced by arranging the cut staple fibers in a number of steps, wherein the tow of the cut staple fibers is continuously drafted into a continuous strand of increasingly lower denier and stapled. The fibers are joined together by twist.

“Undrawn yarn” is a term customarily applied to undrawn fibers and is not intended to include fibers drawn and processed into a yarn product, such as yarns used to knit or weave fabrics. Does not. After melt spinning, the undrawn yarn accumulates until a total denier suitable for the drawing machine is produced. Accumulation can take up to 24 hours or more, including dormancy or storage time between steps. For example, it generally takes 6 hours or more to produce sufficient undrawn yarn for economic stretching in a draw line. Due to production schedules and other practical considerations, fibers can be stored for several days. Fibers exposed to such storage times are referred to as “aged” or “aged undrawn yarn”.

The “draw ratio”, or “draw down,” is the amount by which the filament is stretched after melt spinning. As used herein, “draw ratio” refers to the mechanical draw ratio, which is the ratio of the surface speed of a pulling roll to a forwarding roll (the roll that moves the fibers). As a result of pulling, some elongation occurs.

“Carding” is the process of opening, individualizing, aligning, and forming a bunch of staple fibers into a continuous, untwisted strand called a sliver. Carding machines consist of a series of rolls whose surface is covered with a number of protruding metal teeth or pins.

“Tow” means a large strand of fibrous filaments that have been cut into staples and collected in a loose, rope-like form prior to being formed into slivers, and produced continuously without a pronounced twist.

“Sliver” is a continuous strand of staple fibers that are loosely bundled without twisting. The sliver is carried by a card or a stretched frame. The production of sliver is the first step in textile work, which converts staple fibers into a form that can be stretched and eventually twisted into spun yarn.

The term “fabric” refers to a planar textile structure created by interlacing yarns, fibers, or filaments.

The term “woven fabric” means a fabric composed of interlaced warp and weft yarns. In the weaving process, the longitudinal or longitudinal warp is held in tension to the frame or loom, while the transverse weft (also referred to as woof) moves through the warp and is inserted up and down the warp.

The term “knitted fabric” refers to a fabric produced by interlooping yarns of one or more ends.

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

The term “dtex” is a unit of measure for the linear mass density of a fiber or yarn, and is defined as the mass in grams per 10,000 meters.

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

The term “sliver linear density” (after the carding step) is the number of 840 yard cut lengths of a sliver weighing 1 pound, expressed in imperial number Ne, or the weight in grams of a sliver of 1000 meters length, expressed in g/meter. Means.

The term “final sliver linear density” (after the stretching step) is the number of 840 yard cut lengths of a sliver weighing 1 pound, expressed in imperial number Ne, or the weight in grams of sliver of 1 meter, expressed in grams/meter. Means.

The term "% non-uniformity" refers to the average weight deviation of 400 meter long spun yarn, or 50 meter long roving or 50 meter length sliver as measured by Uster Uniformity Tester-3 (UT3), Expressed as a percentage. Measured by industrially established methods using UT-3 and 400 m long yarn or 25 m or 50 m long sliver or roving.

With respect to spun yarn, the term “defect” means the numerical sum of the number of thick areas, the number of thin areas, and the number of neps in a 1000 meter long yarn, as measured using a Uster uniformity tester. As used herein, the term “thick region” refers to the location of a yarn having a mass that is at least +150% of the average mass of the yarn of 8 mm cut length. As used herein, the term “thin area” refers to the location of a yarn having a mass that is 50% or less of the average mass of the yarn of 8 mm cut length. As used herein, the term “yep” refers to the position of a yarn having a mass that is at least 200% of the average mass of the yarn of 1 mm cut length.

The term “hairiness index” refers to the average of the total length of protruding fibers per 1 cm long yarn measured on a 400 m long yarn optically measured using a UT3 tester, in normalized units. Is expressed.

The present invention comprises a melt-spun staple fiber comprising a first polymer comprising poly(trimethylene terephthalate) or poly(butylene terephthalate) and a second polymer comprising poly(ethylene terephthalate) or Co-PET And Co-PET is a poly(ethylene terephthalate) copolymer containing an isophthalic acid monomer; The first polymer comprises poly(trimethylene terephthalate) and the weight ratio of poly(trimethylene terephthalate) to the second polymer ranges from about 80:20 to about 10:90; Or the first polymer comprises poly(butylene terephthalate) and the weight ratio of poly(butylene terephthalate) to the second polymer ranges from about 90:10 to about 10:90. The melt spun staple fiber lacks any distinct interface between the first polymer and the second polymer. The spun yarn has a boiling shrinkage of about 6% or more as determined according to ASTM D2259. Optionally, the spun yarn may comprise a second staple fiber, such as cotton or wool. Fabrics with desirable characteristics can be made from spun yarn.

The melt-spun staple fibers disclosed herein have improved toughness, crimp, and stability compared to PTT melt-spun staple fibers, and the properties of the melt-spun staple fibers are advantageously typically with PET during the staple-to-spun yarn conversion. It has been found to allow processing under the conditions used. In addition, the yarn comprising the melt-spun staple fibers disclosed herein, whether further comprising a second staple fiber or consists essentially of the melt-spun staple fiber alone, cotton-like aesthetic properties, good strength, and other desirable properties. It allows the creation of woven, knitted, and nonwoven fabrics having

In one embodiment, the melt-spun staple fibers of spun yarn comprise a first polymer comprising poly(trimethylene terephthalate). Poly(trimethylene terephthalate) suitable for use in melt-spun staple fibers is well known in the art and can be prepared, for example, by polycondensation of 1,3-propane diol with terephthalic acid or terephthalic acid equivalent. Optionally, 1,3-propane diol can be obtained biochemically from renewable sources (“biochemically-derived” 1,3-propanediol). Poly(trimethylene terephthalate) is commercially available from E. I. du Pont de Nemours and Company of Wilmington, Delaware under the trade name Sorona®. Optionally, PTT or its monomers can be obtained by recycling post-industrial or post-consumer materials (ie, fiber or plastic waste).

By “terephthalic acid equivalent” is meant a compound that acts substantially similar to terephthalic acid in reaction with polymer glycols and diols, as generally recognized by one of skill in the art. Terephthalic acid equivalents include, for example, esters (such as dimethyl terephthalate), and ester-forming derivatives such as acid halides (such as acid chlorides) and anhydrides. Terephthalic acid and terephthalic acid esters, such as dimethyl esters, are suitable. The method for producing poly(trimethylene terephthalate) is, for example, U.S. Patent No.6277947, U.S. Patent No.6326456, U.S. Patent No.6657044, U.S. Patent No.6353062, U.S. Patent No.6538076, and U.S. Patent No. 7531617.

Preferably the 1,3-propanediol used as a reactant in preparing the poly(trimethylene terephthalate) or as a component of the reactant is greater than about 99% by weight, for example, as determined by gas chromatography analysis. It has a purity of greater than about 99.9%. Purified 1,3-propanediol is disclosed in U.S. Patent No.7038092, U.S. Patent No.7098368, U.S. Patent No.7084311, and U.S. Patent No.7919658.

Poly(trimethylene terephthalate) suitable for use in melt-spun fibers may be poly(trimethylene terephthalate) homopolymers (substantially derived from 1,3-propane diol and terephthalic acid and/or equivalents) and copolymers. . In one embodiment, the poly(trimethylene terephthalate) contains at least about 70 mole percent of repeat units derived from 1,3-propane diol and terephthalic acid (and/or its equivalents, such as dimethyl terephthalate). Poly(trimethylene terephthalate) contains at least about 85 mol%, or at least about 90 mol%, or at least about 95 mol%, or about 99 mol of repeating units derived from 1,3-propane diol and terephthalic acid (or equivalent). % Or more, or about 100 mol%.

Poly(trimethylene terephthalate) may contain small amounts of other comonomers, and such comonomers are usually chosen so as not to significantly adversely affect their properties. Such other comonomers include, for example, 5-sodium-sulfoisophthalate at levels in the range of about 0.2 to 5 mole percent. Very small amounts of trifunctional comonomers such as trimellitic acid can be incorporated for viscosity control.

Poly(trimethylene terephthalate) may contain up to 30 mol% of repeat units made of other diols or diacids. Other diacids include, for example, isophthalic acid, 1,4-cyclohexane dicarboxylic acid, 2,6-naphthalene dicarboxylic acid, 1,3-cyclohexane dicarboxylic acid, succinic acid, glutaric acid, and Dipic acid, sebacic acid, 1,12-dodecane diacid, and derivatives thereof, such as the dimethyl, diethyl, or dipropyl esters of these dicarboxylic acids. Other diols include ethylene glycol, 1,4-butane diol, 1,2-propanediol, diethylene glycol, triethylene glycol, 1,3-butane diol, 1,5-pentane diol, 1,6-hexane diol, 1 ,2-, 1,3- and 1,4-cyclohexane dimethanol, and long-chain diols and polyols prepared from the reaction product of a diol or polyol with an alkylene oxide.

The poly(trimethylene terephthalate) may also contain up to about 5 mole percent of a sulfonate compound useful for imparting functional monomers, such as cationic dyeability. Specific examples of preferred sulfonate compounds include 5-lithium sulfoisophthalate, 5-sodium sulfoisophthalate, 5-potassium sulfoisophthalate, 4-sodium sulfo-2,6-naphthalenedicarboxylate, and tetramethylphos. Phonium 3,5-dicarboxybenzene sulfonate, tetrabutylphosphonium 3,5-dicarboxybenzene sulfonate, tributyl-methylphosphonium 3,5-dicarboxybenzene sulfonate, tetrabutylphosphonium 2,6-di Carboxinaphthalene-4-sulfonate, tetramethylphosphonium 2,6-dicarboxinaphthalene-4-sulfonate, ammonium 3,5-dicarboxybenzene sulfonate, and ester derivatives thereof such as methyl or dimethyl ester Included.

Poly(trimethylene terephthalate) typically has an intrinsic viscosity of at least about 0.5 deciliters/gram (dl/g) and typically no more than about 2 dl/g. In one embodiment, the poly(trimethylene terephthalate) has an intrinsic viscosity of about 0.7 dl/g or greater, such as 0.8 dl/g or greater, or such as 0.9 dl/g or greater, and typically about 1.5 dl/g Hereinafter, for example, it is 1.4 dl/g or less, and commercial products currently available have an intrinsic viscosity of 1.2 dl/g or less.

In another embodiment, the melt spun staple fibers of spun yarn comprise a first polymer comprising poly(butylene terephthalate). Poly(butylene terephthalate) suitable for use in melt-spun staple fibers is also well known in the art and can be prepared, for example, by polycondensation of 1,4-butanediol and terephthalic acid. Poly(butylene terephthalate) is commercially available from E. I. du Pont de Nemours and Company of Wilmington, Delaware under the trade name Crastin®.

Poly(butylene terephthalate) suitable for use in melt spun fibers may be homopolymers (substantially derived from 1,4-butanediol and terephthalic acid and/or equivalents) and copolymers. In one embodiment, the poly(butylene terephthalate) contains at least about 80 mole percent of repeat units derived from 1,4-butanediol and terephthalic acid. In another embodiment, the poly(butylene terephthalate) contains at least about 85 mol%, or at least about 90 mol%, or at least about 95 mol% of repeat units derived from 1,4-butanediol and terephthalic acid (or equivalent), Or about 99 mol% or more, or about 100 mol%. Poly(trimethylene terephthalate) may contain minor amounts of other comonomers or functional monomers. Optionally, PBT or its monomers can be obtained after industrial disposal or by recycling the material (ie, fiber or plastic waste) after consumer use.

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 making poly(ethylene terephthalate) is known, for example, as disclosed in U.S. Patent Nos. 3398124 and 3487049. Poly(ethylene terephthalate) suitable for use in making the melt-spun staple fibers disclosed herein are also commercially available. In one embodiment, the poly(ethylene terephthalate) is a homopolymer and is derived substantially from ethylene glycol and terephthalic acid and/or equivalents. Optionally, PET or its monomers can be obtained after industrial disposal or by recycling the material (ie, fiber or plastic waste) after consumer use.

In many applications, it may be desirable to modify the properties of the poly(ethylene terephthalate) by adding a third monomer. For example, copolymers of polyethylene terephthalate can be prepared from monomers of dimethyl terephthalate or terephthalic acid in combination with cyclohexane dimethanol, or in combination with cyclohexane dimethanol and ethylene glycol. In other cases, isophthalic acid can be used to replace some of the terephthalic acid monomers that interfere with crystallinity and lower the melting point of the copolymer referred to herein as “Co-PET”.

As used herein, “Co-PET” means ethylene glycol, terephthalic acid (or dimethyl terephthalate or other terephthalate ester) and isophthalic acid (or dimethyl isophthalate or other terephthalate ester), as known in the art. It refers to a poly(ethylene terephthalate) copolymer that can be prepared by condensation polymerization of. Co-PET can also be produced in the process of chopping, melting, refining, and re-pelletizing recycled poly(ethylene terephthalate) bottles to produce fiber-grade consumer post recycled Co-PET. Isophthalic acid monomers are typically present in the Co-PET at levels ranging from about 0.5 mole percent to about 15 mole percent, based on the total copolymer composition, and may be present in amounts up to about 30 mole percent. 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, 20 , 21, 22, 23, 24, 25, 26, 27, 28, 29, or 30 mole percent of isophthalic acid monomer. In one embodiment, the Co-PET useful in the melt-spun staple fibers disclosed herein is from about 1 mole% to about 5 mole%, or up to about 10 mole%, or up to about 15 mole% isophthalic acid based on the total copolymer composition. Contains monomers. In another embodiment, useful Co-PETs contain from about 0.5 mole percent to about 3 mole percent isophthalic acid monomer. The amount of isophthalic acid monomer in the Co-PET can be selected to provide the desired properties to the Co-PET. It is believed that the lower melting point of Co-PET can improve the compatibility of Co-PET with poly(trimethylene terephthalate) during 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-decanedicarboxylic acid, phthalic acid, dodecane Diacid, sulfonated isophthalic acid, oxalic acid, fumaric acid, maleic acid, itaconic acid, 1,4-cyclohexanedicarboxylic acid, 1,3-cyclohexanedicarboxylic acid, 1,2-cyclohexanedicarboxylic acid, And polyethylene terephthalate copolymers comprising mixtures thereof may be useful for making melt-spun staple fibers. Alternatively, ethylene glycol, terephthalic acid (or equivalent), and diols such as diethylene glycol, polyethylene glycol, butylene glycol, 1,4-cyclohexane dimethanol, 1,2-cyclohexanediol, 1,4-cyclo Polyethylene terephthalate copolymers comprising hexanediol, 1,3-cyclohexanediol, 1,5-pentanediol, 1,6-hexanediol, and mixtures thereof may be useful for making melt-spun staple fibers. .

In one embodiment, Co-PET is a poly(ethylene terephthalate) copolymer comprising ethylene terephthalate and isophthalic acid monomers. 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 comprises a first polymer comprising poly(trimethylene terephthalate) or poly(butylene terephthalate) and a second polymer comprising poly(ethylene terephthalate) or Co-PET; The first polymer comprises poly(trimethylene terephthalate) and the weight ratio of poly(trimethylene terephthalate) to the second polymer ranges from about 80:20 to about 10:90; Or the first polymer comprises poly(butylene terephthalate) and the weight ratio of poly(butylene terephthalate) to the second polymer ranges from 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 comprises about 80% by weight of PTT and about 20% by weight. Contains PET. In one embodiment, the melt spun staple fibers comprise about 75% by weight PTT and about 25% by weight PET. In one embodiment, the melt spun staple fiber comprises about 70% by weight PTT and about 30% by weight PET. In another embodiment, the staple fiber comprises about 65% by weight PTT and about 35% by weight PET. In another embodiment, the staple fiber comprises about 60% by weight PTT and about 40% by weight PET. In a further embodiment, the staple fibers comprise about 55% by weight PTT and about 45% by weight PET. In a further embodiment, the staple fiber comprises about 50% by weight PTT and about 50% by weight PET. In another embodiment, the staple fiber comprises about 45% by weight PTT and about 55% by weight PET. In a separate embodiment, the staple fibers comprise about 40% by weight PTT and about 60% by weight PET. In another embodiment, the staple fiber comprises about 35% by weight PTT and about 65% by weight PET. In yet another embodiment, the staple fibers comprise about 30% by weight PTT and about 70% by weight PET. In one embodiment, the melt spun staple fibers comprise about 25% by weight PTT and about 75% by weight PET. In one embodiment, the melt spun staple fibers comprise about 20% by weight PTT and about 80% by weight PET. In one embodiment, the melt spun staple fibers comprise about 15% by weight PTT and about 85% by weight PET. In one embodiment, the melt spun staple fiber comprises about 10% by weight PTT and about 90% by weight PET.

In one embodiment, the melt-spun staple fiber comprises a poly(trimethylene terephthalate (PTT), and a poly(ethylene terephthalate) copolymer (Co-PET) comprising 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% by weight of PTT and about 20% by weight of Co-PET. The staple fibers comprise about 75 weight percent PTT and about 25 weight percent Co-PET In one embodiment, the melt spun staple fibers comprise about 70 weight percent PTT and about 30 weight percent Co-PET. In another embodiment, the melt-spun staple fiber comprises about 65% by weight PTT and about 35% by weight Co-PET In yet another embodiment, the melt-spun staple fiber comprises about 60% by weight PTT and about 40% by weight. In a further embodiment, the melt-spun staple fiber comprises about 55% by weight of PTT and about 45% by weight of Co-PET In a further embodiment, the melt-spun staple fiber is And about 50% by weight of PTT and about 50% by weight of Co-PET In another embodiment, the melt-spun staple fiber comprises about 45% by weight of PTT and about 55% by weight of Co-PET. In an embodiment, the melt spun staple fiber comprises about 40 weight percent PTT and about 60 weight percent Co-PET In another embodiment, the melt spun staple fiber comprises about 35 weight percent PTT and about 65 weight percent In another embodiment, the melt-spun staple fiber comprises about 30% by weight of PTT and about 70% by weight of Co-PET In one embodiment, the melt-spun staple fiber is about 25% by weight. % PTT and about 75% by weight Co-PET In another embodiment, the melt spun staple fiber is about 20% by weight PTT And about 80% by weight of Co-PET. In yet another embodiment, the melt spun staple fiber comprises about 15% by weight PTT and about 85% by weight Co-PET. In a further embodiment, the melt spun staple fiber comprises about 10% by weight PTT and about 90% by weight Co-PET.

In one embodiment, the melt-spun staple fiber comprises poly(butylene terephthalate) (PBT) and poly(ethylene terephthalate) (PET), wherein the melt-spun staple fiber comprises about 90% by weight of PBT and about 10% by weight. Contains PET. In another embodiment, the melt spun staple fiber comprises about 85% by weight PBT and about 15% by weight PET. In one embodiment, the melt spun staple fiber comprises about 80% by weight PBT and about 20% by weight PET. In one embodiment, the melt spun staple fibers comprise about 75% by weight PBT and about 25% by weight PET. In one embodiment, the melt spun staple fiber comprises about 70% by weight PBT and about 30% by weight PET. In another embodiment, the staple fiber comprises about 65% by weight PBT and about 35% by weight PET. In yet another embodiment, the staple fiber comprises about 60% by weight PBT and about 40% by weight PET. In a further embodiment, the staple fibers comprise about 55% by weight PBT and about 45% by weight PET. In a further embodiment, the staple fiber comprises about 50% by weight PBT and about 50% by weight PET. In another embodiment, the staple fiber comprises about 45% by weight PBT and about 55% by weight PET. In a separate embodiment, the staple fibers comprise about 40% by weight PBT and about 60% by weight PET. In another embodiment, the staple fibers comprise about 35% by weight PBT and about 65% by weight PET. In yet another embodiment, the staple fibers comprise about 30% by weight PBT and about 70% by weight PET. In one embodiment, the melt spun staple fiber comprises about 25% by weight PBT and about 75% by weight PET. In one embodiment, the melt spun staple fibers comprise about 20% by weight PBT and about 80% by weight PET. In one embodiment, the melt spun staple fiber comprises about 15% by weight PBT and about 85% by weight PET. In one embodiment, the melt spun staple fiber comprises about 10% by weight PBT and about 90% by weight PET.

In one embodiment, the melt-spun staple fiber comprises a poly(butylene terephthalate (PBT), and a poly(ethylene terephthalate) copolymer (Co-PET) comprising an isophthalic acid monomer (Co-PET), The weight ratio ranges from about 90:10 to about 10:90. In one embodiment, the melt spun staple fiber comprises about 85% by weight of PBT and about 15% by weight of Co-PET. The spun staple fiber comprises about 80 weight percent PBT and about 20 weight percent Co-PET In a further embodiment, the melt spun staple fiber comprises about 75 weight percent PBT and about 25 weight percent 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 comprises about 65 weight percent PBT and about 35 weight percent PBT. In another embodiment, the melt-spun staple fiber comprises about 60% by weight of PBT and about 40% by weight of Co-PET In a further embodiment, the melt-spun staple fiber is And about 55% by weight of PBT and about 45% by weight of Co-PET In a further embodiment, the melt spun staple fiber comprises about 50% by weight of PBT and about 50% by weight of Co-PET. In an 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 In another embodiment, the melt-spun staple fiber comprises about 35% by weight of PBT and about 65% by weight of Co-PET In another embodiment, the melt-spun staple fiber is about 30 Weight percent PBT and about 70 weight percent Co-PET. In one embodiment, the melt spun staple fiber comprises about 25 weight percent PBT and It contains about 75% by weight of Co-PET. In another embodiment, the melt spun staple fiber comprises about 20% by weight PBT and about 80% by weight Co-PET. In yet another embodiment, the melt spun staple fiber comprises about 15% by weight PBT and about 85% by weight Co-PET. In a further embodiment, the melt spun staple fiber comprises about 10% by weight PBT and about 90% by weight Co-PET.

Melt-spun staple fibers can be formed in a two-step process. In the first step, the polymers are combined, melted and extruded to form a filament comprising the polymer, and the filaments are cooled and collected as a tow. In the second step, the tow may be treated, crimped, annealed, and cut through at least one drawing step to produce staple fibers. Processes for making polyester staple fibers are 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) heating and mixing at the same time, (b) mixing in advance in a separate apparatus before heating, or (c) heating and then mixing. Mixing, heating, and forming can be carried out by conventional equipment designed for that purpose, such as an extruder. The temperature should be higher than the melting point of each polymer but lower than the lowest decomposition temperature. Suitable temperatures may be from about 140° C. to about 240° C., for example, about 200° C. or more and about 230° C. or less. In one embodiment, the melt temperature is less than 280°C.

In one embodiment, the polymers may be compounded in a desired ratio, eg in a compounding screw, to form pellets, which are then fed to a spinning machine extruder. In another embodiment, pellets can be made from each polymer individually, and the pellets are then blended together as a salt-and-pepper mixture using up to two feeders to a spinning machine extruder. . Alternatively, pellets can be made from each polymer individually, and the pellets are premixed together before feeding to a spinning machine extruder. In yet another embodiment, each polymer can be melted to form a molten polymer stream, followed by combining the molten polymer streams and forming pellets from the molten mixture. The term “pellet” is used generically herein, and is used regardless of shape to include products sometimes referred to as “chip” or “flake”.

If desired, additives may be added to poly(trimethylene terephthalate), to poly(butylene terephthalate), to poly(ethylene terephthalate), to Co-PET, or to a mixture of polymers. Useful additives include, for example, delusterants, nucleating agents, heat stabilizers, viscosity boosters, optical brighteners, antioxidants, antimicrobial agents, plasticizers, antistatic agents, lubricants, processing aids. , Flame retardants, dyes, TiO ₂ , or pigments may be included.

The combined first and second polymers (i.e., 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., for example about 255 It is extruded through a spinneret at a temperature of about 270°C or higher. The spun filaments are extruded into bundles comprising about 34 or more filaments per threadline, for example from about 175 filaments to about 6800 filaments, or even 6900 or more filaments. Undrawn filaments typically have a denier per filament in the range of about 3 to about 8, or more. Spinneret orifices are typically circular for circular fiber cross-sections, but various shapes of orifices can be used as needed for eg trilobal or delta cross-sections. The spun filaments have a denier in the range of about 3 to about 8 dpf and are collected as bundles (tows). Typically, the tow has a dry heat shrinkage of less than 6% as determined by the dry heat shrinkage method disclosed herein in the Examples.

In the second step of the process of making staple fibers, tow is fed from a series of cans or creels containing undrawn melt-spun yarn. A finish can be applied to facilitate downstream processing. The tow is then stretched while immersed in a heated water bath. Typically the feed rolls are kept at room temperature while the draw rolls can be heated. The stretched tow can be stabilized by passing it through a saturated steam chamber and optionally further stretched and annealed in a number of heated draw roll modules before passing through a room temperature roll module. Various simplifications of the draw zone are possible using fewer or more heaters and room temperature draw modules to optimally draw and stabilize the yarn in the crimp preparation. The crimping module typically uses a steam box to reduce the yarn modulus in preparation for crimping, and typically, the crimper is a mechanical stuffer box type crimper with a pneumatically actuated flapper gate. . The yarn tow is pulled into the crimper box by a series of drive rolls; As the flow out of the box is controlled by the back pressure on the flapper, the yarn is buckled and forms a crimp. The crimped tow is passed through an annealer section before being cut with staples.

The denier per final filament of the melt-spun staple fibers ranges from 1 to 2 for cotton system treatment and can be from 2 to 3 for parent system treatment.

The melt spun staple fibers disclosed herein provide processing advantages. For example, staple fibers can be treated with good productivity through opening, carding, and drawing steps in the manufacture of spun yarn. The melt-spun staple fibers disclosed herein can be run in a staple spinning process using conditions typical for PET staple spinning.

The drawn fibers can be cut into staples of any desired length. If the staple fibers are too short, it can be difficult to card. If the staple fibers are too long, it can be difficult to spun in cotton or wool system equipment. For use in cotton systems, staple fibers typically range in length from about 32 mm to about 51 mm, for example in the range from about 38 to 40 mm. For use in worsted yarn systems, staple fibers can typically have multiple cut lengths with an average cut length ranging from about 70 mm to about 100 mm, such as from about 80 mm to about 90 mm. The staple fibers may be crimped to have a full sinus arc of about 10 to about 18, for example about 11 to about 15 crimps per inch. For cotton systems, melt-spun staple fibers typically have a denier per filament of 1 to 2, a toughness greater than 4 g/denier, and an elongation at break of 20 as determined using the methods disclosed in the Examples below To 60%. In the case of worsted yarn systems, melt spun staple fibers typically have 2-4 deniers per filament, greater than 4 g/denier toughness, and 30-90% elongation at break.

The melt-spun staple fibers disclosed herein can be used to make spun yarns. In one embodiment, the spun yarn consists essentially of melt spun staple fibers and does not contain any other types of staple fibers. In another embodiment, the spun yarn comprises the melt spun staple fibers disclosed herein. In a further embodiment, the spun yarn further comprises second staple fibers in an amount of about 5% to about 95% by weight based on the total weight of the spun yarn. In one embodiment, the second staple fiber may comprise 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 may comprise at least one regenerated cellulose fiber. As used herein, the term “regenerated cellulose fiber” refers to a textile fiber made of regenerated cellulose, also referred to as rayon, and includes lyocell, viscose, Modal®, and Tencel® fibers. As used herein, “lyocell” refers to a form of rayon made of cellulose fibers made by dissolving bleached wood pulp using dry jet-wet spinning. As used herein, “viscose” means a regenerated manufactured fiber made of cellulose and obtained by the viscose process. As used herein, “Modal®” means fibers made from wood pulp from beech. As used herein, “Tencel®” refers to fibers made from eucalyptus wood.

In one embodiment, the spun yarn comprises melt-spun staple fibers comprising a first polymer comprising PTT or PBT and a second polymer comprising PET or Co-PET, wherein the weight ratio of the first polymer to the second polymer is about 80:20 to about 10:90, or about 70:30 to about 30:70, or about 60:40 to about 40:60; Or in the range of about 70:30 to about 50:50, and the spun yarn further comprises a second staple fiber comprising 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 from about 90:10 to about 10:90, such as about 90: In the range of 10 to about 80:20, and the spun yarn further comprises a second staple fiber comprising cotton. Based on the total weight of the spun yarn, cotton may be present in the spun yarn in an amount of about 5% to about 95% by weight, and melt spun staple fibers may be present in the spun yarn in an amount of about 95% to about 5% by weight. . For example, the yarn is about 5% by weight of cotton and about 95% by weight of melt-spun staple fibers, or about 10% by weight of cotton and about 90% by weight of melt-spun staple fibers, or about 15% by weight cotton and about 85% by weight melt-spun staple fibers, or about 20% by weight cotton and about 80% by weight melt-spun staple fibers, or about 25% by weight cotton and about 75% by weight melt-spun staples Fibers, or about 30% cotton and about 70% melt spun staple fibers, or about 35% cotton and about 65% melt spun staple fibers, or about 40% cotton and about 60% by weight Of melt-spun staple fibers, or about 45% by weight of cotton and about 55% by weight of melt-spun staple fibers, or about 50% by weight of cotton and about 50% by weight of melt-spun staple fibers, or about 55% by weight of cotton and About 45% by weight melt-spun staple fibers, or about 60% by weight cotton and about 40% by weight melt-spun staple fibers, or about 65% by weight cotton and about 35% by weight melt-spun staple fibers, or about 70% by weight % Cotton and about 30% by weight melt-spun staple fibers, or about 75% by weight cotton and about 25% by weight melt-spun staple fibers, or about 80% by weight cotton and about 20% by weight melt-spun staple fibers. It may contain. In another embodiment, the spun yarn may comprise more than 95% by weight melt spun staple fibers and less than 5% by weight of a second staple fiber comprising cotton. The relative amounts of cotton and melt spun staple fibers are selected to provide the desired characteristics to the spun yarns and fabrics made from spun yarns. The spun yarn may 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 including cotton may have a breaking strength of 10 cN/tex or more. In some embodiments, the yarn comprising cotton may have a breaking strength of 10 cN/tex or higher. The spun yarn including cotton may have an elongation at break of 4% or more. A method of determining the toughness and elongation at break is provided in the examples below.

In another embodiment, the spun yarn comprises melt-spun staple fibers comprising a first polymer comprising PTT or PBT and a second polymer comprising PET or Co-PET, wherein the weight ratio of the first polymer to the second polymer is about 80:20 to about 10:90, or about 70:30 to about 30:70, or about 60:40 to about 40:60; Or in the range of about 70:30 to about 50:50, and the spun yarn further comprises a second staple fiber comprising 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 from about 90:10 to about 10:90, such as about 90: In the range of 10 to about 80:20, and the spun yarn further comprises a second staple fiber comprising wool. The term “hair” refers to fibers from the wool of sheep or lamb. Based on the total weight of the spun yarn, wool may be present in an amount of about 5% to about 95% by weight, and melt spun staple fibers may be present in an amount of about 95% to about 5% by weight. For example, spun yarn is about 5% by weight of wool and about 95% by weight of melt-spun staple fibers, or about 10% by weight of wool and about 90% by weight of melt-spun staple fibers, or about 15% by weight wool and about 85% by weight melt-spun staple fibers, or about 20% by weight wool and about 80% by weight melt-spun staple fibers, or about 25% by weight wool and about 75% by weight melt-spun staples Fibers, or about 30% wool and about 70% melt spun staple fibers, or about 35% wool and about 65% melt spun staple fibers, or about 40% wool and about 60% by weight Of melt-spun staple fibers, or about 45% by weight of wool and about 55% by weight of melt-spun staple fibers, or about 50% by weight of wool and about 50% by weight of melt-spun staple fibers, or about 55% by weight of wool and About 45% by weight of melt-spun staple fibers, or about 60% by weight of wool and about 40% by weight of melt-spun staple fibers, or about 65% by weight of wool and about 35% by weight of melt-spun staple fibers, or about 70% by weight % Wool and about 30% by weight melt spun staple fibers, or about 75% wool and about 25% by weight melt spun staple fibers, or about 80% wool and about 20% by weight melt spun staple fibers, Or about 85% by weight of wool and about 15% by weight of melt spun staple fibers, or about 90% by weight of wool and about 10% by weight of melt staple fibers, or about 95% by weight of wool and about 5% by weight of melt spinning It may contain staple fibers. The relative amounts of wool and melt-spun staple fibers are selected to provide the desired characteristics to the spun yarns and fabrics made from spun yarns. Spun yarn has a consumption 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 be

In another embodiment, the spun yarn comprises melt-spun staple fibers comprising a first polymer comprising PTT or PBT and a second polymer comprising PET or Co-PET, wherein the weight ratio of the first polymer to the second polymer is about 80:20 to about 10:90, or about 70:30 to about 30:70, or about 60:40 to about 40:60; Or in the range of about 70:30 to about 50:50, and the spun yarn further comprises a second staple fiber comprising 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 from about 90:10 to about 10:90, such as about 90: In the range of 10 to about 80:20, and the spun yarn further comprises a second staple fiber comprising rayon. As used herein, “rayon” means textile fibers made from regenerated cellulose and includes lyocell, viscose, Modal®, and Tencel® fibers. In spun yarn, based on the total weight of the spun yarn, rayon may be present in an amount of about 5% to about 95% by weight, and melt spun staple fibers may be present in an amount of about 95% to about 5% by weight. For example, the yarn is about 5% by weight of rayon and about 95% by weight of melt-spun staple fibers, or about 10% by weight of rayon and about 90% by weight of melt-spun staple fibers, or about 15% by weight rayon and about 85% by weight melt-spun staple fibers, or about 20% by weight rayon and about 80% by weight melt-spun staple fibers, or about 25% by weight rayon and about 75% by weight melt-spun staples Fibers, or about 30% by weight rayon and about 70% by weight melt spun staple fibers, or about 35% by weight rayon and about 65% by weight melt spun staple fibers, or about 40% by weight rayon and about 60% by weight Of melt-spun staple fibers, or about 45% by weight of rayon and about 55% by weight of melt-spun staple fibers, or about 50% by weight of rayon and about 50% by weight of melt-spun staple fibers, or about 55% by weight of rayon and About 45% by weight melt-spun staple fibers, or about 60% by weight rayon and about 40% by weight melt-spun staple fibers, or about 65% by weight rayon and about 35% by weight melt-spun staple fibers, or about 70% by weight % Rayon and about 30% by weight melt-spun staple fibers, or about 75% by weight rayon and about 25% by weight melt-spun staple fibers, or about 80% by weight rayon and about 20% by weight melt-spun staple fibers, Or about 85% by weight rayon and about 15% by weight melt spun staple fibers, or about 90% by weight rayon and about 10% by weight melt staple fibers, or about 95% by weight rayon and about 5% by weight melt spun It may contain staple fibers. The relative amounts of rayon and melt spun staple fibers are selected to provide the spun yarns and fabrics made from spun yarns with the desired characteristics. The spun yarn may 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 melt-spun staple fibers comprising a first polymer comprising PTT or PBT and a second polymer comprising PET or Co-PET, wherein the weight ratio of the first polymer to the second polymer is about 80:20 to about 10:90, or about 70:30 to about 30:70, or about 60:40 to about 40:60; Or in the range of about 70:30 to about 50:50, and the spun yarn further comprises a second staple fiber comprising 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 from about 90:10 to about 10:90, such as about 90: In the range of 10 to about 80:20, and the spun yarn further comprises a second staple fiber comprising acrylic. As used herein, “acrylic fiber” refers to a synthetic fiber made of polyacrylonitrile having an average molecular weight of about 100,000 and having about 1900 monomer units. Based on the total weight of the spun yarn, acrylic fibers may be present in an amount of about 5% to about 95% by weight, and melt spun staple fibers may be present in an amount of about 95% to about 5% by weight. For example, the spun yarn is about 5% by weight of acrylic fibers and about 95% by weight of melt-spun staple fibers, or about 10% by weight of acrylic fibers and about 90% by weight of melt-spun staple fibers, based on the total weight of the spun yarn, Or about 15% by weight acrylic fiber and about 85% by weight melt-spun staple fiber, or about 20% by weight acrylic fiber and about 80% by weight melt-spun staple fiber, or about 25% by weight acrylic fiber and about 75% by weight % Melt-spun staple fibers, or about 30% by weight acrylic fibers and about 70% by weight melt-spun staple fibers, or about 35% by weight acrylic fibers and about 65% by weight melt-spun staple fibers, or about 40% by weight Of acrylic fibers and about 60% by weight of melt-spun staple fibers, or about 45% by weight of acrylic fibers and about 55% by weight of melt-spun staple fibers, or about 50% by weight of acrylic fibers and about 50% by weight of melt-spun staples Fibers, or about 55% by weight acrylic fibers and about 45% by weight melt-spun staple fibers, or about 60% by weight acrylic fibers and about 40% by weight melt-spun staple fibers, or about 65% by weight acrylic fibers and about 35% by weight melt-spun staple fibers, or about 70% by weight acrylic fibers and about 30% by weight melt-spun staple fibers, or about 75% by weight acrylic fibers and about 25% by weight melt-spun staple fibers, or about 80 Wt% acrylic fibers and about 20 wt% melt spun staple fibers, or about 85 wt% acrylic fibers and about 15 wt% melt spun staple fibers, or about 90 wt% acrylic fibers and about 10 wt% melt Staple fibers, or about 95% by weight acrylic fibers and about 5% by weight melt spun staple fibers. The relative amounts of acrylic fibers and melt-spun staple fibers are selected to provide the desired characteristics to the spun yarns and fabrics made from spun yarns. The spun yarn may 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 melt-spun staple fibers comprising a first polymer comprising PTT or PBT and a second polymer comprising PET or Co-PET, wherein the weight ratio of the first polymer to the second polymer is about 80:20 to about 10:90, or about 70:30 to about 30:70, or about 60:40 to about 40:60; Or in the range of about 70:30 to about 50:50, and the spun yarn further comprises a second staple fiber comprising 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 from about 90:10 to about 10:90, such as about 90: In the range of 10 to about 80:20, and the spun yarn further comprises a second staple fiber comprising PLA. As used herein, “polylactic acid fiber” refers to a manufactured fiber in which the fiber-forming material consists of 85% by weight or more of lactic acid ester units derived from natural sugars. Based on the total weight of the spun yarn, PLA may be present in an amount of about 5% to about 95% by weight, and melt spun staple fibers may be present in an amount of about 95% to about 5% by weight. For example, the spun yarn is about 5% by weight of PLA and about 95% by weight of melt-spun staple fibers, or about 10% by weight of PLA and about 90% by weight of melt-spun staple fibers, or about 15% by weight PLA and about 85% by weight melt-spun staple fibers, or about 20% by weight PLA and about 80% by weight melt-spun staple fibers, or about 25% by weight PLA and about 75% by weight melt-spun staples Fiber, or about 30% by weight PLA and about 70% by weight melt spun staple fibers, or about 35% by weight PLA and about 65% by weight melt spun staple fibers, or about 40% by weight PLA and about 60% by weight Of melt-spun staple fibers, or about 45% by weight of PLA and about 55% by weight of melt-spun staple fibers, or about 50% by weight of PLA and about 50% by weight of melt-spun staple fibers, or about 55% by weight of PLA and About 45% by weight melt-spun staple fibers, or about 60% by weight PLA and about 40% by weight melt-spun staple fibers, or about 65% by weight PLA and about 35% by weight melt-spun staple fibers, or about 70% by weight % PLA and about 30% by weight melt-spun staple fibers, or about 75% by weight PLA and about 25% by weight melt-spun staple fibers, or about 80% by weight PLA and about 20% by weight melt-spun staple fibers, Or about 85% by weight PLA and about 15% by weight melt spun staple fibers, or about 90% by weight PLA and about 10% by weight melt staple fibers, or about 95% by weight PLA and about 5% by weight melt spun It may contain staple fibers. The relative amounts of PLA and melt-spun staple fibers are selected to provide the desired characteristics to the spun yarns and fabrics made from spun yarns.

In another embodiment, the spun yarn comprises melt-spun staple fibers comprising a first polymer comprising PTT or PBT and a second polymer comprising PET or Co-PET, wherein the weight ratio of the first polymer to the second polymer is about 80:20 to about 10:90, or about 70:30 to about 30:70, or about 60:40 to about 40:60; Or in the range of about 70:30 to about 50:50, and the spun yarn further comprises a second staple fiber comprising 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 from about 90:10 to about 10:90, such as about 90: In the range of 10 to about 80:20, and the spun yarn further comprises a second staple fiber comprising nylon. As used herein, “nylon fiber” means a fiber made in which the fiber-forming material is a long chain synthetic polyamide in which less than 85% of the amide bonds are attached directly to two aliphatic groups. Based on the total weight of the spun yarn, nylon may be present in an amount of about 5% to about 95% by weight, and melt spun staple fibers may 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 melt-spun staple fibers, or about 10% by weight nylon and about 90% by weight melt-spun staple fibers, or about the total weight of the spun yarn. 15% by weight nylon and about 85% by weight melt-spun staple fibers, or about 20% by weight nylon and about 80% by weight melt-spun staple fibers, or about 25% by weight nylon and about 75% by weight melt-spun staples Fibers, or about 30% by weight nylon and about 70% by weight melt spun staple fibers, or about 35% by weight nylon and about 65% by weight melt spun staple fibers, or about 40% by weight nylon and about 60% by weight Of melt-spun staple fibers, or about 45% by weight nylon and about 55% by weight of melt-spun staple fibers, or about 50% by weight of nylon and about 50% by weight of melt-spun staple fibers, or about 55% by weight of nylon and About 45% by weight melt-spun staple fibers, or about 60% by weight nylon and about 40% by weight melt-spun staple fibers, or about 65% by weight nylon and about 35% by weight melt-spun staple fibers, or about 70% by weight % Nylon and about 30% by weight melt-spun staple fibers, or about 75% by weight nylon and about 25% by weight melt-spun staple fibers, or about 80% by weight nylon and about 20% by weight melt-spun staple fibers, Or about 85% by weight nylon and about 15% by weight melt spun staple fibers, or about 90% by weight nylon and about 10% by weight melt staple fibers, or about 95% by weight nylon and about 5% by weight melt spun It may contain staple fibers. The relative amounts of nylon and melt-spun staple fibers are selected to provide the desired characteristics to the spun yarns and fabrics made from spun yarns.

In another embodiment, the spun yarn comprises melt-spun staple fibers comprising a first polymer comprising PTT or PBT and a second polymer comprising PET or Co-PET, wherein the weight ratio of the first polymer to the second polymer is about 80:20 to about 10:90, or about 70:30 to about 30:70, or about 60:40 to about 40:60; Or in the range of about 70:30 to about 50:50, and the spun yarn further comprises a second staple fiber comprising 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 from about 90:10 to about 10:90, such as about 90: In the range of 10 to about 80:20, and the spun yarn further comprises a second staple fiber comprising an olefin. As used herein, “olefin fiber” refers to any long chain in which the fiber-forming material is composed of at least 85% by weight of ethylene, propylene, or other olefin units, except for amorphous (amorphous) polyolefins recognized as rubber fibers. It means a manufactured fiber which is a synthetic polymer. Based on the total weight of the spun yarn, olefin fibers may be present in an amount of about 5% to about 95% by weight, and melt spun staple fibers may 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 staple fibers, based on the total weight of the spun yarn, Or about 15% by weight olefin fibers and about 85% by weight melt-spun staple fibers, or about 20% by weight olefin fibers and about 80% by weight melt-spun staple fibers, or about 25% by weight olefin fibers and about 75% by weight. % Melt-spun staple fibers, or about 30% by weight olefin fibers and about 70% by weight melt-spun staple fibers, or about 35% by weight olefin fibers and about 65% by weight melt-spun staple fibers, or about 40% 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-spun staples Fibers, or about 55% by weight olefin fibers and about 45% by weight melt spun staple fibers, or about 60% by weight olefin fibers and about 40% by weight melt spun staple fibers, or about 65% by weight olefin fibers and about 35% by weight melt-spun staple fibers, or about 70% by weight olefin fibers and about 30% by weight melt-spun staple fibers, or about 75% by weight olefin fibers and about 25% by weight melt-spun staple fibers, or about 80 Wt% olefin fibers and about 20 wt% melt spun staple fibers, or about 85 wt% olefin fibers and about 15 wt% melt spun staple fibers, or about 90 wt% olefin fibers and about 10 wt% melt Staple fibers, or 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 characteristics to the spun yarns and fabrics made from spun yarns.

In another embodiment, the spun yarn comprises melt-spun staple fibers comprising a first polymer comprising PTT or PBT and a second polymer comprising PET or Co-PET, wherein the weight ratio of the first polymer to the second polymer is about 80:20 to about 10:90, or about 70:30 to about 30:70, or about 60:40 to about 40:60; Or in the range of about 70:30 to about 50:50, and the spun yarn further comprises a second staple fiber comprising 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 from about 90:10 to about 10:90, such as about 90: In the range of 10 to about 80:20, and the spun yarn further comprises a second staple fiber comprising acetate. As used herein, “acetate fiber” refers to a fiber produced in which the fiber-forming material is cellulose acetate and includes diacetate and triacetate. Diacetate is defined as cellulose acetate fibers in which more than 74% and less than 92% of the hydroxyl groups are acetylated (the degree of esterification is greater than 2.22 and less than 2.76). Triacetate is defined as cellulose acetate fibers in which more than 92% of the hydroxyl groups are acetylated (the degree of esterification is greater than 2.76 and less than 3.00). Based on the total weight of the spun yarn, acetate fibers may be present in an amount of about 5% to about 95% by weight, and melt spun staple fibers may be present in an amount of about 95% to about 5% by weight. For example, the spun yarn is about 5% by weight of acetate fibers and about 95% by weight of melt-spun staple fibers, or about 10% by weight of acetate fibers and about 90% by weight of melt-spun staple fibers, based on the total weight of the spun yarn, Or about 15% by weight acetate fibers and about 85% by weight melt-spun staple fibers, or about 20% by weight acetate fibers and about 80% by weight melt-spun staple fibers, or about 25% by weight acetate fibers and about 75% by weight. % Melt-spun staple fibers, or about 30% by weight acetate fibers and about 70% by weight melt-spun staple fibers, or about 35% by weight acetate fibers and about 65% by weight melt-spun staple fibers, or about 40% by weight Of acetate fibers and about 60% by weight melt-spun staple fibers, or about 45% by weight of acetate fibers and about 55% by weight melt-spun staple fibers, or about 50% by weight of acetate fibers and about 50% by weight of melt-spun staples Fibers, or about 55% by weight acetate fibers and about 45% by weight melt spun staple fibers, or about 60% by weight acetate fibers and about 40% by weight melt spun staple fibers, or about 65% by weight acetate fibers and about 35% by weight melt-spun staple fibers, or about 70% by weight acetate fibers and about 30% by weight melt-spun staple fibers, or about 75% by weight acetate fibers and about 25% by weight melt-spun staple fibers, or about 80 Wt% acetate fibers and about 20 wt% melt spun staple fibers, or about 85 wt% acetate fibers and about 15 wt% melt spun staple fibers, or about 90 wt% acetate fibers and about 10 wt% melt Staple fibers, or about 95% by weight acetate fibers and about 5% by weight melt spun staple fibers. The relative amounts of acetate fibers and melt spun staple fibers are selected to provide the desired characteristics to the spun yarns and fabrics made from spun yarns.

In another embodiment, the spun yarn comprises melt-spun staple fibers comprising a first polymer comprising PTT or PBT and a second polymer comprising PET or Co-PET, wherein the weight ratio of the first polymer to the second polymer is about 80:20 to about 10:90, or about 70:30 to about 30:70, or about 60:40 to about 40:60; Or in the range of about 70:30 to about 50:50, and the spun yarn comprises a second polyester, such as poly(ethylene terephthalate), poly(trimethylene terephthalate), or poly(butylene terephthalate). It further includes staple fibers. In a further embodiment, the first polymer comprises poly(butylene terephthalate) and the weight ratio of poly(butylene terephthalate) to the second polymer is from about 90:10 to about 10:90, such as about 90: In the range of 10 to about 80:20, and the spun yarn further comprises a second staple fiber comprising polyester. Based on the total weight of the spun yarn, polyester may be present in an amount of about 5% to about 95% by weight, and melt spun staple fibers may 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. Fibers, or about 15% by weight polyester fibers and about 85% by weight melt spun staple fibers, or about 20% by weight polyester fibers and about 80% by weight melt spun staple fibers, or about 25% by weight polyester Fibers and about 75% by weight melt-spun staple fibers, or about 30% by weight polyester fibers and about 70% by weight melt-spun staple fibers, or about 35% by weight polyester fibers and about 65% by weight melt-spun staples Fibers, or about 40% by weight polyester fibers and about 60% by weight melt spun staple fibers, or about 45% by weight polyester fibers and about 55% by weight melt spun staple fibers, or about 50% by weight polyester Fibers and about 50% by weight melt-spun staple fibers, or about 55% by weight polyester fibers and about 45% by weight melt-spun staple fibers, or about 60% by weight polyester fibers and about 40% by weight melt-spun staples Fibers, or about 65% by weight polyester fibers and about 35% by weight melt-spun staple fibers, or about 70% by weight polyester fibers and about 30% by weight melt-spun staple fibers, or about 75% by weight polyester Fibers and about 25% by weight melt-spun staple fibers, or about 80% by weight polyester fibers and about 20% by weight melt-spun staple fibers, or about 85% by weight polyester fibers and about 15% by weight melt-spun staples Fibers, or about 90% by weight polyester fibers and about 10% by weight melt staple fibers, or about 95% by weight polyester fibers and about 5% by weight melt spun staple fibers. The relative amounts of polyester fibers and melt spun staple fibers are selected to provide the desired characteristics to the spun yarns and fabrics made from spun yarns. The spun yarn may 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 cut to lengths as required for blending with the second fibers and subsequent processing in the cotton or wool system. For example, melt spun staple fibers and spun yarns comprising cotton, linen, polylactic acid, acrylic, nylon, olefin, acetate, polyester, or rayon fibers can typically be processed in a cotton system. Melt-spun staple fibers and spun yarns comprising wool, angora, mohair, or cashmere fibers can typically be processed in a wool system.

To form a spun yarn, melt-spun staple fibers and optionally at least one second staple fiber are preferentially given, for example by stack mixing, a process of opening, mixing and layering fiber bales. Blend. Fiber bundles can be opened into smaller sized fiber tufts using, for example, a series of coarse opening machines followed by a fine opening machine in a blow room. The smaller fiber bundles are then carded to form continuous fiber strands called slivers, with almost all of the fibers oriented along the sliver axis. Slivers from carding machines can have very large mass/length fluctuations, so typically multiple carding slivers (i.e. 6) are combined at the same time, using e.g. stretch frame machines or other methods known in the art By drafting positively (i.e. 6X), the fibers in the resulting sliver are further oriented. The sliver transferred from the final stretched frame has a minimum mass/length variation, but has a high linear density compared to the linear density required for the final spun yarn, so the linear density of the sliver is reduced in the stretching process. Typically the drawing process operates in two stages in which partial drafting and twisting are performed to make the roving. The roving is converted to spun yarn by further drafting it in the final spinning machine using known processes such as rings, open ends, air jets, and vortex spinning. Spun yarn can be wound into small packages called cops through a ring spinning process; Several cobs can be combined and wound up into a larger final package called a cone.

Woven and knitted fabrics can be made from the spun yarns disclosed herein. Examples of stretch fabrics include circular knits, flat knits, and warp knits, and plain weaves, twill weaves, and weaves. Articles such as garments can be made from fabrics comprising the spun yarns disclosed herein. Nonwoven fabrics may be made from the staple fibers disclosed herein and may be useful for articles such as wipes, diapers, napkins, and personal care items. Non-woven fabrics can also be used as a base material for coated fabrics and in a variety of other applications, such as clothing and home furnishings.

The spun yarns disclosed herein are useful for making fabrics such as woven or knitted fabrics. In one embodiment, the fabric comprising a spun yarn as disclosed herein is a woven fabric having warp and weft yarns. In one embodiment, the warp yarn comprises spun yarn as disclosed herein. In another embodiment, the weft yarn comprises spun yarn as disclosed herein. In a further embodiment, the warp and weft yarns each comprise spun yarns as disclosed herein. The woven fabric may further comprise additional yarns or continuous filaments, for example on the warp, on the weft, or on both the warp and weft yarns. In another embodiment, a yarn as disclosed herein is useful for warp yarns, and yarns comprising natural fibers are useful for weft yarns. In another embodiment, a yarn as disclosed herein is useful for warp yarns, and yarns comprising synthetic fibers are useful for weft yarns. In another embodiment, a yarn comprising natural fibers is used for the warp yarn and a yarn yarn as disclosed herein is used for the weft yarn. In a further embodiment, a yarn comprising synthetic fibers is used for the warp yarn and a yarn yarn as disclosed herein is used for the weft yarn. In another embodiment, spun yarns as disclosed herein are used for warp and also for weft yarns. Knitted fabrics can be made using the spun yarns disclosed herein alone or in combination with spun yarns comprising natural or synthetic fibers. Woven fabrics comprising spun yarns as disclosed herein may, for example, have a fabric weight in the range of about 80 g/m ² to about 600 g/m ² .

Fabrics comprising spun yarns as disclosed herein are made of spun yarns of PET, cotton, rayon, PTT, or a combination thereof and may provide advantages over fabrics of the same structure lacking the melt-spun staple fibers disclosed herein. have. For example, fabrics comprising spun yarns comprising melt-spun staple fibers as disclosed herein, as indicated by greater fabric thickness, as well as larger bulk, as well as fabrics of PET, cotton, rayon, or combinations thereof It can have a softer touch (i.e. it can feel softer). The fabric including the spun yarn disclosed herein may have better dyeability than a fabric of the same structure made of PET, cotton, rayon, or a combination thereof. Compared to PET fabrics of similar structure, the fabrics disclosed herein can be dyed darker, darker, and at lower temperatures. When dyed at lower temperatures, the fabrics disclosed herein may have better dye pickup than PET fabrics, which provides cost savings through energy savings. For example, when dyed at the same time, fabrics comprising spun yarns disclosed herein can be dyed darker than PET fabrics (i.e., lower L* values as measured under a D65 light source), and even dyed at 100°C. Even when compared to PET fabric dyed at 130 ℃ can be dyed darker than PET fabric. The property of picking up more dye, picking up dye at lower temperatures, and dyeing darker can be referred to as the "better dyeability" of the fabric. The woven fabrics disclosed herein may also have an improved drape, as evidenced by, for example, larger drape area and drape factor values, as determined by method BS 5058, for example. A combination of softer feel and improved drape is particularly desirable in fabrics. Additionally, the fabrics disclosed herein exhibited less fluff (higher fluff rating values) than fabrics of the same structure made of PET, cotton, rayon, or combinations thereof, as determined by the ASTM D4970 method, for example, It showed better wear resistance. The fabrics disclosed herein may also have better tear strength in the warp and/or weft direction than fabrics of the same structure made of PET, cotton, rayon, or combinations thereof. A knitted fabric comprising a spun yarn as disclosed herein may have a higher recovery rate than a knitted fabric of the same structure made of polyethylene terephthalate, cotton, rayon, or a combination thereof.

Non-limiting examples of embodiments disclosed herein include:

1. A first polymer comprising poly(trimethylene terephthalate) (PTT) or poly(butylene terephthalate) (PBT) and a second polymer comprising poly(ethylene terephthalate) (PET) or Co-PET As a spun yarn comprising melt-spun staple fibers comprising, Co-PET is a poly(ethylene terephthalate) copolymer comprising an isophthalic acid monomer; The first polymer comprises poly(trimethylene terephthalate) and the weight ratio of poly(trimethylene terephthalate) to the second polymer ranges from about 80:20 to about 10:90; Or the first polymer comprises poly(butylene terephthalate) and the weight ratio of poly(butylene terephthalate) to the second polymer ranges from about 90:10 to about 10:90.

2. The spun yarn of Embodiment 1, wherein the first polymer comprises poly(trimethylene terephthalate) and the second polymer comprises poly(ethylene terephthalate).

3. The spun yarn of Embodiment 1 or 2, wherein the first polymer comprises poly(trimethylene terephthalate) and the second polymer comprises Co-PET.

4. The spun yarn of Embodiment 1, wherein the first polymer comprises poly(butylene terephthalate) and the second polymer comprises poly(ethylene terephthalate).

5. The spun yarn of Embodiment 1 or 4, wherein the first polymer comprises poly(butylene terephthalate) and the second polymer comprises Co-PET.

6. The second polymer comprises Co-PET, and the Co-PET contains from about 0.5 mol% to about 10 mol% of isophthalic acid monomer based on the total copolymer composition. .

7. The spun yarn of Embodiments 1, 2, 3, 4, 5, or 6, wherein the weight ratio is in the range of about 70:30 to about 30:70.

8. The spun yarn of Embodiments 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 of Embodiments 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, wherein the weight ratio of poly(trimethylene terephthalate) or poly(butylene terephthalate) to the second polymer ranges from about 70:30 to about 30:70. , Or the spinning yarn of the spinning yarn of 7.

11. The spun yarn of Embodiments 1, 2, 3, 4, 5, 6, 7, 8, 9, or 10, having a boiling shrinkage of at least about 6% as determined according to ASTM D2259.

12. Embodiments 1, 2, 3, 4, 5, 6, 7, 8, 9, further comprising a second staple fiber in an amount of about 5% to about 95% by weight based on the total weight of the spun yarn. , 10, or 11 spun yarn.

13. The second staple fiber is the spun yarn of Embodiment 12, comprising polylactic acid, acrylic, nylon, olefin, acetate, rayon, polyester, cotton, linen, wool, angora, mohair, alpaca, cashmere, or mixtures thereof. .

14. The spun yarn of Embodiment 12, wherein the second staple fiber comprises cotton or wool.

15. The spun yarn of Embodiments 12, 13, or 14, wherein the second staple fiber comprises cotton.

16. The spun yarn of embodiments 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, or 15, having a cotton count of about 4 Ne to about 80 Ne .

17. The spun yarn of Embodiments 12, 13, or 14, wherein the second staple fiber comprises wool.

18. The spun yarn of embodiments 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, or 17, in which the number of consumption is in the range of 7 Nm to 120 Nm .

19. A fabric comprising the spun yarn of Embodiments 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, or 18.

20. The fabric of embodiment 19, wherein the fabric has a softer feel and better drape than a fabric of the same fabric structure consisting of rayon, polyethylene terephthalate, cotton, or combinations thereof.

21. The fabric of Embodiments 19 or 20, wherein the fabric has better dyeability than a fabric of the same fabric structure consisting of polyethylene terephthalate, cotton, rayon, or combinations thereof.

22. The fabric of Embodiments 19, 20, or 21, wherein the fabric has better abrasion resistance as determined according to ASTM D4966 standard test method than a fabric of the same fabric structure consisting of polyethylene terephthalate, cotton, rayon, or combinations thereof. .

23. Embodiment 19, wherein the fabric has less fluff (higher fluff rating value) as determined according to the ASTM D4970 standard test method than a fabric of the same fabric structure consisting of polyethylene terephthalate, cotton, rayon, or combinations thereof. , 20, 21, or 22 fabrics.

24. Embodiments 19, 20, 21, 22, wherein the fabric has a larger bulk as determined according to ASTM D1777 standard test method than a fabric of the same fabric structure consisting of polyethylene terephthalate, cotton, rayon, or combinations thereof. Or 23 fabrics

25. The fabric is more than a fabric of the same fabric structure consisting of polyethylene terephthalate, cotton, rayon, or a combination thereof.

i) better wear resistance as determined according to ASTM D4966 standard test method;

ii) higher fluff rating values as determined according to ASTM D4970 standard test method; or

iii) Larger bulk as determined according to ASTM D1777 standard test method

The fabric of embodiments 19, 20, or 21 having one or more of.

26. The fabric of Embodiments 19, 20, 21, 22, 23, 24, or 25, wherein the fabric is a woven fabric with warp and weft yarns.

27. The warp includes the yarn of embodiments 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, or 18, embodiments 26 fabrics.

28. The weft includes the spun yarn of Embodiments 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, or 18, embodiment Fabric of 26 or 27.

29. Each of the warp and weft includes the spun yarn of Embodiments 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, or 18 , The fabric of embodiments 26, 27, or 28.

30. The fabric of Embodiments 19, 20, 21, 22, 23, 24, or 25, wherein the fabric is a knitted fabric.

31. The fabric of embodiment 30, wherein the knitted fabric has a higher recovery rate as determined according to method BS 4294 than a knitted fabric of the same fabric structure consisting of polyethylene terephthalate, cotton, rayon, or combinations thereof.

32. An article comprising the fabric of Embodiments 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, or 31.

33. The article of embodiment 32, wherein the article is a garment.

34. A melt-spun staple fiber comprising a first polymer comprising poly(trimethylene terephthalate) or poly(butylene terephthalate) and a second polymer comprising poly(ethylene terephthalate) or Co-PET, wherein Co -PET is a poly(ethylene terephthalate) copolymer comprising an isophthalic acid monomer; Staple fibers

a) the weight ratio of poly(trimethylene terephthalate) to the second polymer is in the range of about 80:20 to about 10:90; or

The weight ratio of poly(butylene terephthalate) to the second polymer ranges from about 90:10 to about 10:90;

b) Melt-spun staple fibers with dry heat shrinkage of less than 6% as determined by the dry heat shrinkage method.

35. The melt spun staple fiber of embodiment 34, wherein the weight ratio of poly(trimethylene terephthalate) or poly(butylene terephthalate) to the second polymer ranges from about 70:30 to about 30:70.

36. The melt spun staple fiber of embodiment 34, wherein the weight ratio of poly(trimethylene terephthalate) or poly(butylene terephthalate) to the second polymer ranges from about 70:30 to about 50:50.

37. The melt spun staple fibers of embodiments 34, 35, or 36, wherein the first polymer comprises poly(trimethylene terephthalate) and the second polymer comprises poly(ethylene terephthalate).

38. The melt spun staple fibers of Embodiments 34, 35, or 36, wherein the first polymer comprises poly(trimethylene terephthalate) and the second polymer comprises Co-PET.

39. The melt spun staple fibers of Embodiments 34, 35, or 36, wherein the first polymer comprises poly(butylene terephthalate) and the second polymer comprises poly(ethylene terephthalate).

40. The melt spun staple fibers of Embodiments 34, 35, or 36, wherein the first polymer comprises poly(butylene terephthalate) and the second polymer comprises Co-PET.

41.Embodiments 34, 35, 36, 38, wherein the second polymer comprises Co-PET, wherein the Co-PET contains from about 0.5 mol% to about 10 mol% isophthalic acid monomer based on the total copolymer composition. Or 40 melt-spun staple fibers.

Example

As used herein, “Comp. Ex.” means a comparative example; “Ex.” means Examples; “Rpm” means revolutions per minute; “Wt%” means weight percent; “DL/g” is deciliters per gram; “G” is grams; “Mg” is milligrams; “℃” means temperature in degrees Celsius; “Min” is the minute; “H” is time; “S” is seconds; “Lb” is a pound; “Kg” is kilograms; “Mm” is millimeters; “M” is the meter; “Gpl” is grams per liter; “M/min” is meters per minute; “Mol” is mole; “Kg” is kilograms; “Ppm” is parts per million; “Hz” is hertz; “CN” is centinewton; “Rpm” is the number of revolutions per minute; “Wt” is the weight; “Dpf” is denier per filament; “G/d” is grams per denier; “Ne” means cotton count (imperial) and is a measure of linear density defined as the number hank (850 yards or 770 meters) of skein material weighing 1 pound (0.45 kg); “Nm” means the metric count and refers to the number of 1000 meters per kilogram of yarn; “Dtex” means decitex; “AATCC” means the American Association of Textile Chemists and Colorists; “ASTM” means the American Society for Testing and Materials; “BS” means British Standards Institution.

material

Unless otherwise stated, all materials were used as received.

Polytrimethylene terephthalate (PTT) containing 0.3% TiO ₂ and having an intrinsic viscosity of 0.96 dL/g was obtained as merge K2266 from EI du Pont de Nemours and Company (Wilmington, Delaware).

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 was manufactured by Lake City P.O. Box 939 was obtained from Nan Ya Plastics Corporation, America. The Co-PET composition was determined by NMR analysis and provided based on the total copolymer composition. Co-PET had an intrinsic viscosity of 0.80 dL/g.

Fiber-grade consumer post-use recycled Co-PET containing 1.1 mol% IPA monomer, 49.1 mol% TPA monomer, and 49.9 mol% EG monomer was produced by William William of Spartanburg P.O.box 171898, Spartanburg, SC 29301, USA. Obtained from Barnet & Son, LLC. The Co-PET composition was determined by NMR analysis and provided based on the total copolymer composition. Co-PET had an intrinsic viscosity of 0.76 dL/g.

Way

The “Co-PET” composition was determined by NMR analysis using the following procedure. The Co-PET pellet was cryoground in a powder-like form, then about 18 mg was weighed and placed in an NMR tube, 5:1 CDCl ₃ :TFA-D (5:1 deuterated chloroform/deuterated trifluoro. Acetic acid) was added to a total volume of 0.6 mL. The sample was vortexed to dissolve the Co-PET. Proton NMR spectra were obtained within 30 minutes of dissolution.

Proton NMR spectra were obtained on a 500 MHz Bruker Avance III HD NMR equipped with a 5 mm CPQCI (indirect) cryoprobe at 30°C. The following parameters were used for acquisition: 30 sec recycle delay, 4 sec acquisition time, 8.0 sec 90 degree pulse, 10000 Hz spectral window, 79998 points, collected and averaged a total of 64 scans/transient. The spectrum refers to the chloroform-d residual proton signal at 7.24 ppm, treated with lb of 0.10 Hz, and filled with zeros up to 512k.

The Co-PET composition was calculated from the integral for the signal at approximately 8.7 ppm, 8.1 ppm, and 4.8 ppm, respectively, corresponding to isophthalic acid, terephthalic acid, and ethylene glycol between the terephthalic acid groups. The isophthalic acid signal used represents 1 mole of proton, so its integral was already relative. The terephthalic acid integral represents 4 moles of terephthalic acid protons and contains 2 moles of isophthalic acid protons; Two times the relative integral of isophthalic acid was subtracted, and the remainder was then divided by 4 to determine the relative integral of terephthalic acid. The ethylene glycol-related integral corresponds to 4 moles of ethylene glycol protons, and the measured integral was divided by 4 to determine the relative integral. The three relative integrals were summed, each corresponding relative integral divided by the sum and multiplied by 100% to calculate the relative mole percent value.

The following procedure, referred to herein as the dry heat shrink method, was used to calculate the dry heat shrinkage of the undrawn melt spun fibers. A 50 cm diameter, 10-loop skein was prepared and its length was measured under 20 g weight. Two such loops were exposed to 40[deg.] C. for 20 hours under zero imposed tension and allowed to contract. After cooling the loop to 21° C. at 65% relative humidity, the length was re-measured under 20 g weight. Dry heat shrinkage as a percentage was calculated as follows:

% Drying heat shrinkage = (initial length-length after heating) *100

Initial length

In the case of melt-spun staple fibers, the fiber properties were determined using the Automatic Single-Fiber Test System FAVIMAT+ using the following method. Denier was determined according to ASTM D1577 Standard Test Method for Linear Density of Textile Fibers. Toughness and elongation at break were determined according to ASTM D3822 Tensile Properties of Single Textile Fibers.

The crimp properties of staple fibers are characterized by crimp shrinkage, crimp stability, and crimp recovery rate. Crimp shrinkage is the difference in length of crimped fibers compared to uncrimped fibers. Crimp shrinkage can be calculated as [(L1-L0)/L1]*100 by measuring the crimp length under a low load of 0.001 cN/dtex, L0 and the length of the crimping unwound under heavy load of 0.1 cN/dtex, and L1.

Crimp stability is a measure of the stability of the crimp under a specified load. This can be measured by determining the rate of recovery of the staple length when the load is removed. Using L2 as the length of the staple fibers (measured under 0.001 cN/dtex) 60 seconds after applying a heavier load of 0.1 cN/dtex for 10 seconds (to determine L1), [(L1-L2/( The crimp stability can be calculated as L1-L0)]*100.

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

Melt Spun 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 was dried in a vacuum oven at 120° C. under a nitrogen blanket for 16 hours, and then 34 of a circular cross section using a twin screw extruder spinning machine. -It was melt-extruded with a filament yarn bundle. The extruder melting zone temperature was maintained between 180 and 255°C. The polymer throughput was 14.06 g/min with a winder speed of 1250 m/m giving a spin denier per filament of 2.9.

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

Example 1

Undrawn 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 fed in a twin-screw extruder (from Nan Ya Plastics) with polyethylene terephthalate co-ethylene isophthalate (Co-) with an intrinsic viscosity of 0.80 dL/g. PET) and 50/50 weight ratio were melt-blended to form compound pellets. The extruder throughput was 150 lb/h (68.04 kg/h, 0.0189 kg/s), and the melt temperature at the extruder outlet was less than 285° C. as measured with a hand-held thermocouple.

The PTT:Co-PET blended pellets were dried in a vacuum oven at 120° C. for 16 hours under a nitrogen blanket and melt-extruded into 34-filament yarn bundles of circular cross section using a twin screw extruder spinning machine. The extruder melting zone temperature was maintained between 180 and 255°C. The polymer throughput was 14.06 g/min or 21.52 g/min. For each throughput, the winder speed was 750 m/m or 1250 m/m, giving spin deniers per filament in the range of 3.3 to 7.7. The dry heat shrinkage of the yarn bundle (tow) was measured to be in the range of 1.2% to 3.1%. This amount of dry heat shrinkage in the undrawn fibers is very low and indicates the stability of the material during storage. The results are shown in the table below.

[Table 1] Example 1 Spinning Conditions and Drying Heat Shrinkage of Tow

Example 2

Undrawn melt-spun fiber containing PTT and Co-PET

Fibers containing 0.3% TiO ₂ and an intrinsic viscosity of 0.96 dL/g of polytrimethylene terephthalate in a twin screw extruder containing 1.1 mol% IPA monomer, 49.1 mol% TPA monomer, and 49.9 mol% EG monomer- Blended pellets were formed by melt blending at a 50/50 weight ratio with recycled Co-PET after grade consumer use. Co-PET had an intrinsic viscosity of 0.76 dL/g. The extruder throughput was 150 lb/h (0.0189 kg/s) and the melt temperature at the extruder outlet was less than 285° C. as measured with a hand-held thermocouple.

The PTT:Co-PET blended pellets were dried in a vacuum oven at 120° C. for 16 hours under a nitrogen blanket and melt-extruded into 34-filament yarn bundles of circular cross section using a twin screw extruder spinning machine. The extruder melting zone temperature was maintained between 180 and 255°C. The polymer throughput was 14.06 g/min or 21.52 g/min. For each throughput, the winder speed was 750 m/m or 1250 m/m giving a spin denier per filament of 3.3 to 7.7. The drying heat shrinkage of the yarn bundle was measured to be in the range of 1.2% to 2.5%. This amount of dry heat shrinkage in the undrawn fibers is very low and indicates the stability of the material during storage. The results are shown in the table below.

[Table 2] Example 2 Spinning Conditions and Drying Heat Shrinkage of Tow

Example 3

Melt-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 melt blended with Co-PET (from Nan Ya Plastics) at a 50/50 weight ratio in a twin screw extruder to form compound pellets. The extruder throughput was 150 lb/h (0.0189 kg/s) and the melt temperature at the extruder outlet was less than 285° C. as measured with a hand-held thermocouple. The ingredients were blended at 145° C. for 20 hours.

6800 circular cross-section filaments were spun using a single-extruder spinning machine with radial quench. The extruder melting zone temperature was maintained at 252-274°C. The polymer throughput was 0.379 g/min/hole 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 supplied to the draw-crimp-cut/bale module. Staple melt spun fibers were produced using a typical cotton count staple process using a multistage drawing, crimping machine, annealer, and cutter. The tow was immersed in a 22° C. finish bath (0.5% concentration, commercially available from Schill+Seilacher as Seilacher). The tow is first drawn in a 0.5% concentration finish bath at 80°C between a 22°C feed roll operating at 36 m/m and a heated draw roll at 75°C operating at 110.88 m/m to achieve a first stage draw ratio of 3.08. Provided. The stretched tow was pulled through a steam chest at 100° C. by a downstream heated roll operating at 165° C. at 110.88 m/m. The tow was passed through another series of rolls heated to 165° C. operating at 99.8 m/m. The finish (6% concentration) was sprayed and the tow was passed through a cold drum roll at 25° C. operating at 99.8 m/m. The tow was placed in a steam box at 100° C. before entering the 50 mm crimper. The crimping machine speed was 100 m/m. The crimper roller temperature and pressure were 65° C. and 0.8 bar, respectively. The crimped tow was annealed at 100° C. for 8 min in a plate belt dryer, and the crimped tow was finally cut to produce staple melt spun fibers having the following properties:

Denier per filament (dpf) = 1.2, coefficient of variation (CV) = 8.79%

Toughness = 4.89 g/d, CV = 8.79%

Elongation = 45.97%, CV = 19.59%

Staple length = 37 to 38 mm

Number of crimps (fully-curved arc) = 12/inch

Crimp stability = 67.09%, CV = 22.1%

Finish on yarn = 0.26%

Example 4

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 melt blended with Co-PET (from Nan Ya Plastics) at a 50/50 weight ratio in a twin screw extruder to form compound pellets. The extruder throughput was 150 lb/h (0.0189 kg/s) and the melt temperature at the extruder outlet was less than 285° C. as measured with a hand-held thermocouple. The ingredients were blended at 145° C. for 20 hours.

6800 circular cross-section filaments were spun using a single-extruder spinning machine with radial quenching. The extruder melting zone temperature was maintained at 252-274°C. The polymer throughput was 0.493 g/min/hole and the feed roll speed was 600 m/m. The spinning dpf was 7.2. The spun fibers were collected in a can. Ten cans, a total of 489,600 deniers, were supplied to the draw-crimp-cut/bale module. Melt-spun staple fibers were produced using a typical modal count staple process using a multistage drawing, crimping machine, annealer, and cutter. The tow was immersed in a 22° C. finish bath (0.5% concentration, commercially available from Schill+Seilacher as Seilacher). The tow is first drawn in a 0.5% concentration finish bath at 80°C between a 22°C feed roll operating at 30 m/m and a heated draw roll at 75°C operating at 109.3 m/m to achieve a first stage draw ratio of 3.64. Provided. The tow was pulled by a downstream heated roll operating at 165° C. at 103.9 m/m. The finish (6% concentration) was sprayed and the tow was passed through a cold drum roll at 25° C. operating at 101.9 m/m. The tow was placed in a steam box at 100° C. before entering the 50 mm crimp. The crimping machine speed was 110.6 m/m. The crimper roller temperature and pressure were 65° C. and 1.3 bar, respectively. The crimped tow was annealed at 100° C. for 8 min in a plate belt dryer, and the crimped tow was finally cut to produce staples with the following properties:

dpf = 2.5, CV = 6.98%

Toughness = 3.83 g/d, CV = 8.74%

Elongation = 69.72%, CV = 25.26%

Staple length = multi-cut length from 82 to 125 mm, average 84 mm

Number of crimps (fully-curved arc) = 14/inch

Crimp stability = 91.19%, CV = 8.31%

Finishing material on yarn = 0.21%

Commercially obtained yarn

Table 3 lists commercially available yarns and abbreviations used for them in the table below. Some of these yarns were used to prepare the fabrics of the comparative examples.

[Table 3] Abbreviations for commercially obtained yarns.

Examples of spun yarn produced in a cotton system

The spun yarns of Examples 5 to 10 were prepared using the melt-spun staple fibers from Example 3. Intermediate materials such as spun yarn and sliver obtained in the manufacture of spun yarn were evaluated using the following method:

Toughness was measured at 5 m/min using a CRE type tensile testing machine (eg Uster Tensorapid -3) with a jaw speed of 5 m/min and a specimen length of 50 cm.

Elongation at break%-measured using a CRE type tensile testing machine (e.g. Uster Tensorapid -3) with a jaw speed of 5 m/min and a specimen length of 50 cm.

Example 5

20s Ne spun yarn containing 100% melt spun fiber

According to the following procedure, a cotton yarn was manufactured using a cotton spinning system.

Melt spun staple fibers from Example 3 were taken from the bale and mixed by hand. The average staple fiber length was 40 mm and the denier was 1.2 D. The fibers were mixed and layered in a stack mixing process, and then conditioned at 65% relative humidity and 25° C. for 24 hours. The material was pulled vertically and fed to a blow room line typically used to spun synthetic fibers to take the fiber mass from the stack. In this process, the size of the fiber tuft is divided from about 150 mg to about 30 mg. The following parameters were used:

공급 롤러 및 비터(beater) 블레이드 설정 =1.7 mm

Feed roller and beater blade setting =1.7 mm

랩 선형 밀도(Lap linear density) 약 400 g/미터

Lap linear density approx. 400 g/meter

모든 폐기물 수집 설정은 ‘0’에 근접한다.

All waste collection settings are close to '0'.

조대 개섬 비터(Coarse opening beater) 속도 = 400 rpm

Coarse opening beater speed = 400 rpm

미세 개섬 비터 속도 = 450 rpm

Fine opening beater speed = 450 rpm

Next, a 30 mg fiber bunch was carded into a single fiber, and the fibers were arranged into continuous fiber strands (sliver) oriented along the length of the sliver. The following parameters were used:

기계 유형, 모델 : 카드 프레임, L R C 1/3

Machine type, model: card frame, LRC 1/3

M/c 생성 속도 = 70 미터/min

M/c generating speed = 70 meters/min

공급 플레이트 및 릭커(Licker) 게이지 = 32 thou (1000분의 1 인치)

Supply plate and Licker gauge = 32 thou (1 in 1000th of an inch)

플랫 게이지 = 14,14,14,12,12 thou

Flat gauge = 14,14,14,12,12 thou

트럼펫 크기 = 4.0 mm 이상

Trumpet size = 4.0 mm or more

슬리버 선형 밀도 = 4.5 g/미터

Sliver linear density = 4.5 g/meter

릭커 속도 = 650 rpm

Ricker speed = 650 rpm

실린더 속도 = 350 rpm

Cylinder speed = 350 rpm

플랫 속도 = 6 인치/min

Flat speed = 6 inches/min

최종 슬리버 선형 밀도 = 5.0 g/미터

Final sliver linear density = 5.0 g/meter

In a stretch flame machine, six carding slivers were doubling together and simultaneously drafted in the same amount (6X) to further orient the fibers in the resulting sliver. The first step is referred to as breaker drawing and the second step is referred to as finisher drawing. The following parameters were used:

기계 유형 및 모델: 연신 프레임, L R RSB 851

Machine type and model: Stretch frame, LR RSB 851

하부 롤러 게이지 전방/후방 = 44/48 mm

Lower roller gauge front/rear = 44/48 mm

트럼펫 직경 = 3.8 mm

Trumpet diameter = 3.8 mm

슬리버 선형 밀도 = 4.5 g/미터

Sliver linear density = 4.5 g/meter

상부 코츠 경도(Top cots hardness) = 83° 도

Top cots hardness = 83° degrees

브레이크 드래프트(Break draft) = 브레이커에서 1.4, 피니셔 연신 프레임에서 1.4

Break draft = 1.4 at the breaker, 1.4 at the finisher stretch frame

웨브 장력 드래프트 = 1

Web tension draft = 1

크릴 장력 드래프트 = 1.02

Krill Tension Draft = 1.02

전달 속도 = I 연신 프레임에서 250 MPM, II 연신 프레임에서 350 MPM

Transmission rate = 250 MPM in I stretch frame, 350 MPM in II stretch frame

더블링 = I 및 II 연신 프레임 모두에 대해 6

Doubling = 6 for both I and II stretch frames

최종 슬리버 선형 밀도 = 5.00 g/미터

Final sliver linear density = 5.00 g/meter

불균일성 % = 피니셔 슬리버에서 1.88

Inhomogeneity% = 1.88 in finisher sliver

Next, the roving was made from the sliver transferred from the final stretched frame in the speed frame machine. A partial twist is also provided in the speed frame to impose strength on the roving. The following parameters were used:

기계 유형 및 모델: 스피드 프레임, LF 4200

Machine type and model: Speed frame, LF 4200

스페이서 크기 = 5.5 mm

Spacer size = 5.5 mm

스핀들 속도 = 1000 rpm

Spindle speed = 1000 rpm

꼬임 계수(Twist multiplier) = 0.70

Twist multiplier = 0.70

로빙 행크 = 0.75 s Ne

Roving Hank = 0.75 s Ne

롤러 게이지 = 48/55/62 mm

Roller gauge = 48/55/62 mm

크래들(Cradle) = 36 mm

Cradle = 36 mm

The roving was found to have a Uster value (non-uniformity) of 3.16% and a Uster% (% non-uniformity) of 3.26.

In addition, the roving was drafted in a ring frame spinning machine to produce a spun yarn with a count of 20 s Ne. The following parameters were used:

기계 유형 및 모델 = 링 프레임, LR G 5/1

Machine type and model = Ring frame, LR G 5/1

롤러 게이지 = 42.5/65 mm

Roller gauge = 42.5/65 mm

새들 게이지(Saddle gauge) =51/66 mm

Saddle gauge =51/66 mm

코츠 경도 (전방/후방 F/B) = 68/83°

Cot's hardness (front/rear F/B) = 68/83°

브레이크 드래프트 = 1.22

Brake draft = 1.22

꼬임 계수/인치당 꼬임수 = 3.6 /16.09

Twist factor/twist per inch = 3.6 /16.09

트래블러 크기 : 1/0 M1HO

Traveler size: 1/0 M1HO

스핀들 속도 : 15500 rpm

Spindle speed: 15500 rpm

The spun yarn was wound around a ring frame in a small package called a cobb, each weighing about 50 g. Multiple cobs were merged and any yarn defects eliminated, and finally cone wound on a winding machine using the following parameters:

속도 =1000 m/min

Speed =1000 m/min

원사 장력 = 원사 파단 하중의 5 내지 6%

Yarn tension = 5 to 6% of yarn breaking load

패키지 경도 - 최소

Package hardness-minimum

콘 중량 = 1.0 kg 이상

Cone weight = 1.0 kg or more

The final spun yarn was evaluated for tensile properties and% unevenness in Uster tensorapid-3 and Uster unevenness tester-3. The results are shown in Table 4.

The yarn wound on the final machine seemed to be alive and could become entangled as a result of the twist imparted in the spinning process. Since entanglement can lead to yarn breakage during fabric manufacture, the cones were conditioned for 50 minutes at a maximum temperature of 70° C. in an autoclave to make the yarn structurally stable.

Example 6

40s Ne spun yarn containing 100% melt spun fiber

A spun yarn was prepared using the melt-spun staple fibers from Example 3, according to the procedure of Example 5, except for the following differences:

The linear density of the final sliver was 4.75 g/meter and the% non-uniformity was 1.75.

Roving was prepared as in Example 5, except that the roving hank was 1.2 s Ne.

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

The spun yarn was rolled into a cone at 1500 m/min.

The properties of the spun yarn are provided in Table 4.

Example 7

20s Ne spun yarn containing 40/60 melt spun fiber/cotton (wt/wt)

Spun yarn was prepared using melt-spun staple fibers and cotton from Example 3 (Shankar 6 Variety Indian cotton obtained from North India, for example Punjab and Haryana). Cotton staples had an average length of 31 mm and a fineness (fiber linear density) of 4.1 micrograms/inch as measured using the airflow method. A spun yarn was prepared according to the procedure of Example 5, except for the following differences:

In the manual mixing step, two layers of cotton sliver taken from the 100% cotton yarn spinning process after the combing machine and divided into small tuft sizes of 25 to 30 mg were placed on top of one layer of melt spinning staple fibers.

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

Roving was prepared as in Example 5, except that the twist coefficient was 0.85 and the roving hank was 0.7 s Ne.

As in Example 5, the roving was further drafted, except that the number of twists per inch was 16.99.

The properties of the spun yarn are provided in Table 4.

Example 8

40s Ne spun yarn containing 40/60 melt spun fiber/cotton (wt/wt)

A spun yarn was prepared using melt-spun staple fibers and cotton from Example 3 (Shankar 6 variety Indian cotton commercially available from Northern India). Cotton staples had an average length of 31 mm and a linear density of 4.1 micrograms/inch. A spun yarn was prepared according to the procedure of Example 5, except for the following differences:

In the manual mixing step, two layers of cotton sliver taken from the 100% cotton yarn spinning process after the combing machine and divided into small tuft sizes of 25 to 30 mg were placed on top of one layer of melt spinning staple fibers.

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

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

Roving was prepared as in Example 5, except that the twist coefficient was 0.85 and the roving hank was 1.2 s Ne.

Roving was further drafted as in Example 5, except that the number of twists per inch was 24.02, the traveler size was 4/0 M1HO, and the spindle speed was 16500 rpm.

The spun yarn was rolled into a cone at 1500 m/min.

The properties of the spun yarn are provided in Table 4.

Example 9

20s Ne spun yarn containing 40/60 melt spun fiber/Tencel

Spun yarn was prepared using melt-spun staple fibers from Example 3 and commercially available Tencel® staple fibers (Lenzing). Tencel® staple fibers had an average length of 40 mm and a denier of 1.2 D. A spun yarn was prepared according to the procedure of Example 5, except for the following differences:

In the manual mixing step, two layers of Tencel® fibers (divided by small tuft sizes of 25 to 30 mg) were placed on top of one layer of melt spun staple fibers.

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

Roving was manufactured as in Example 5, except that the twist coefficient was 0.85.

As in Example 5, the roving was further drafted, except that the number of twists per inch was 16.99.

The properties of the spun yarn are provided in Table 4.

Example 10

40s Ne spun yarn containing 40/60 melt spun fiber/Tencel

Spun yarn was prepared using melt-spun staple fibers from Example 3 and commercially available Tencel® staple fibers (Lenzing). Tencel® staples had an average length of 40 mm and a denier of 1.2 D. A spun yarn was prepared according to the procedure of Example 5, except for the following differences:

In the manual mixing step, two layers of Tencel® fibers (divided by small tuft sizes of 25 to 30 mg) were placed on top of one layer of melt spun staple fibers.

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

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

Roving was prepared as in Example 5, except that the twist coefficient was 0.85 and the roving hank was 1.2 s Ne. Roving was further drafted as in Example 5, except that the number of twists per inch was 24.02, the traveler size was 4/0 M1HO, and the spindle speed was 16500 rpm.

The spun yarn was rolled into a cone at 1500 m/min. The properties of the spun yarn are provided in Table 4.

[Table 4] Properties of the yarns of Examples 5 to 10 and the comparative yarns obtained commercially

The results in Table 4 show that a spun yarn comprising 100% melt spun staple fibers alone or in combination with cotton or Tencel® has sufficient toughness and elongation at break for the weaving or knitting process.

The melt-spun staple fibers of Example 3, poly(ethylene terephthalate) staples, or spun yarns (Examples 5 and 6) consisting only of poly(trimethylene terephthalate) staples were boiled water shrinkage according to ASTM D2259. It was tested by the test method. Immerse the length of the yarn skein, attached to the indicated dead weight, in boiling water (100°C, 30 min in an autoclave, MLR 1:40, where “MLR” means the material to liquid ratio). It was measured before and after immersion, and the difference in skein length divided by skein length before boiling is reported in Table 5 as% shrinkage. PET yarn and PTT yarn were obtained commercially.

[Table 5] Shrinkage of boiling water of spun yarn

The highest% boiling water shrinkage was observed for the spun yarn of Example 6 containing only melt-spun staple fibers, the lowest boiling water shrinkage was observed for the spun yarn containing PET, and the median% for the spun yarn containing PTT. The shrinkage value was observed. This provides more fabric bulk after processing for the melt-spun staple fiber-based fabric, which is desirable.

Woven fabric examples

The fabric was evaluated using the following method:

Fabric Weight (greige and processed)-ASTM D3776 Standard test method for mass per unit area of fabric (weight)

Dimensional stability (after 3 washings, for both warp and weft directions)-Dimensional change of fabric after AATCC 135 home washing

Wicking-vertical wicking of AATCC 197 textiles

Tear Strength (for both warp and weft directions)-Standard Test Method for Tear Strength of Fabrics by ASTM D1424 Falling Pendulum (Elmendorf Type) Device

Thickness-ASTM D1777 Standard Test Method for Thickness of Textile Materials

Lint Grade (1000 rounds)-Standard Test Method for Lint Resistance and Other Related Surface Changes of ASTM D4970 Textile Fabrics: Martindale Tester

Abrasion (5000 rounds)-ASTM D4966 Textile Fabric Standard Test Method for Abrasion Resistance (Martindale Abrasion Tester Method)

Drape-Method for evaluation of drape of BS 5058 fabric

Colorfastness to rubbing-AATCC 8 Colorfastness to Crocking

Color fastness to washing-AATCC 61-2A (49 ℃, 45 min, 1.5 gpl)

Bursting Strength (circular knit)-ASTM D3786 Standard Test Method for Bursting Strength of Textile Fabric Circular Knits

Elongation and recovery rate (circular knitted fabric)-Test method for elongation and recovery properties of BS 4294 (5 kg) fabric

The percent shrinkage (from fabric, from greasy fabric to processed fabric) was determined as follows. The gray paper was marked with a permanent marker to mark a 30 cm line in the fabric length (tilt direction) and a 30 cm line in the fabric width (weft direction). The fabric was then dyed and processed, and the length of the permanent marker line was remeasured. For each of the length (warp) and width (weft) directions, the difference in line length before and after dyeing and processing was divided by 30 and multiplied by 100 to calculate percent shrinkage. This method is referred to herein as the percent shrinkage method.

Softness evaluation (also referred to as subjective hand value)-Subjective texture value evaluation was conducted by evaluating the texture of the fabric by 12 experts in the field. South India, Coimbatore, India It was tested by the Textile Research Association (SITRA). This is a widely used method in the textile industry for evaluating the flexibility of fabrics. Fabrics were labeled A and B and provided to independently rank fabrics based on their perception of fabric softness. Softer fabrics were ranked as '1' by each expert, and less soft fabrics were ranked as '2'. This was done for the 100% PET fabric and the fabrics of Examples 11 and 14. Twelve readings were averaged to give the final ranking. Fabrics with lower rank averages were given final rank 1 (softer) and fabrics with higher rank averages were given rank 2.

Woven fabrics as shown in Table 6 were prepared using the spun yarns of Examples 5 to 10. Twill (3/1) bottom weight fabric and plain (1/1) shirting fabric were prepared using the spun yarn disclosed herein as warp and weft (weft) yarns; Comparative fabrics were prepared using commercially available spun yarns for warp and weft yarns. For each woven fabric, the same yarn was used for both warp and weft. Fabric evaluation results are presented in Tables 7 and 8. Unless otherwise stated, results are reported for processed fabrics.

Example 11

A bottom weight twill fabric was prepared using the spun yarn from Example 5 as warp and weft yarns. The warp was sized prior to beaming using a CCI single end sizing machine using Elvanol-T25 PVA sizing agent. Using a warper at 350 m/min, a final beam was made with 2150 ends, a width of 18 inches, and an end length of 3.5 meters. Use the following denting scheme:

Elongation: 4 shaft

Stretch type (straight stretch (1, 2, 3, & 4)

Denting: 2 ends/dent

Reed count: 75 dents/2 inches

A 3/1 LHT twill fabric was woven on a CCI sample loom at a loom speed of 40 pick/min. The pick value was set to 63 picks/inch. A 2 m long and 49.5 cm wide grange fabric was obtained.

The greasy fabric was desized as follows on an RBE lab Jigger machine. The fabric sample was loaded onto a jigger filled with water (2 L), NaOH (2 gpl), and wetting agent; Levocol CESR (wetting agent) was added (5 gpl) and the bath temperature was raised to 90°C. The fabric was allowed to run in the bath for 60 minutes, then the bath was drained, refilled with fresh water, and the temperature of the bath was raised to 85°C. The fabric was washed with hot water for 15 minutes and the bath was drained. The bath was again filled with water and the fabric was run through it for 15 minutes (cold water washing). Drain the bath, fill with water and neutralize by adding acetic acid (1 gpl); The fabric was allowed to run for 15 minutes in this bath. Thereafter, the bath was drained, refilled with fresh water, and allowed to run the fabric for 15 minutes in a cold water bath. The fabric was then unloaded on a jigger, dried in 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 profile: heated to 70° C. and held for 10 minutes, then the temperature was raised to 130° C. at 1.5° C./min and held for 30 minutes, then Lower the temperature to 70℃ at 1.5℃/min and drain. After dyeing, the fabric was reductively washed with Hydros and NaOH (2 gpl each) at 90° C. for 20 minutes. The fabric was then 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 dyed fabric was padded with a finishing agent (softener) and then heat set at 160° C. for 45 seconds in an RBE lab stenter.

The fabric structure is shown in Table 6. The wicking test result was 100%. Compared to the fabric of Comparative Example B, the fabric of Example 11 was found to have a softer feel (i.e., better pliability). Other fabric properties are shown in Tables 7 and 8.

Comparative Example B

Warp and weft a commercially available 20s Ne 100% PET staple spun yarn (“P1”) according to the procedure in Example 11, except that the dent plan uses 4 ends/dents and the lead count is 50 dents/2 inches. Used as a comparative bottom weight woven 3/1 LHT twill fabric was prepared. As in Example 11, the gray paper fabric was dyed, processed and heat set.

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

Example 12

According to the procedure of Example 11, but except for the following, a bottom weight twill fabric was prepared using the spun yarn from Example 7 as warp and weft yarns. The greasy fabric was desized and bleached in a jigger machine, heat set in a stenter, then dyed with a disperse dye mixture, and then further dyed with a reactive dye under cotton dyeing conditions.

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

Comparative Example C

Comparative bottom weight woven 3/1 LHT twill fabric was prepared as in Example 12, except that commercially available 20s Ne 40/60 PET/cotton staple spun yarn (“PC1”) was used as warp and weft yarn.

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

Example 13

According to the procedure of Example 12, except that a peroxide killer was not used at the end of the bleaching step, the spun yarn from Example 9 was used as warp and weft to prepare a bottom weight twill fabric.

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

Comparative Example D

Comparative bottom weight woven 3/1 LHT twill fabric was prepared according to the procedure of Example 12, except that commercially available 20s Ne 40/60 PET/Tencel® staple spun yarn (“PT1”) was used as warp and weft yarns. . The gray paper fabric was dyed, processed, and heat set as in Example 12, except that a second dyeing step with reactive dyes was performed under Tencel® dyeing conditions.

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

Example 14

The spun yarn from Example 6 was used as warp and weft yarns to prepare a plain weave shirting fabric. The procedure was as described in Example 11 but with the following differences: After warping, the beam contained 1680 ends and the lead count was 84 dents/2 inches.

The fabric structure is shown in Table 6. The wicking test result was 100%. Compared to the fabric of Comparative Example E, the fabric of Example 14 was found to have a better (softer) feel. Other fabric properties are shown in Tables 7 and 8.

Comparative Example E

A comparative plain weave shirting fabric was prepared according to the procedure of Example 11, except that commercially available 40s Ne 100% PET staple spun yarn (“P2”) was used as warp and weft yarns. After the canon, the beam contained 1680 ends and the lead count was 84 dents/2 inches. A 2 m long and 47.7 cm gray fabric was obtained.

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

Example 15

The spun yarn from Example 8 was used as warp and weft yarns to prepare a plain weave shirting fabric. The procedure was as described for Example 12, except that a peroxide killer was not used at the end of the bleaching step.

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

Comparative Example F

A comparative plain weave sheathing fabric was prepared according to the procedure in Example 11, except that commercially available 40s Ne 40/60 PET/cotton staple spun yarn (“PC2”) was used as warp and weft yarns and the procedure had the following additional differences. Made: After canon, the beam contained 1748 ends and the lead count was 92 dents/2 inches. A 2 m long and 48.7 cm wide gray paper fabric was obtained and dyed as described in Example 12.

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

Example 16

The spun yarn from Example 10 was used as warp and weft yarns to prepare a plain weave shirting fabric. The procedure was as described for Example Wfab-1, except that the beam included 1748 ends after the canon, the lead count was 92 dents/2 inches, and the pick value was set to 62 picks/inch. . A 2 m long and 48.7 cm wide gray paper fabric was obtained and dyed as described in Example 12.

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

Comparative Example G

A comparative shuttering fabric was prepared according to the procedure in Example 11, except that commercially available 40s Ne 40/60 PET/Tencel® staple spun yarn (“PT2”) was used as warp and weft yarns and the procedure had the following additional differences. Prepared: After canonization, the beam contained 1748 ends, the lead count was 92 dents/2 inches, and the pick value was set to 62 picks/inch. A 2 m long and 48.7 cm wide gray paper fabric was obtained and dyed as described in Example 12.

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

[Table 6] Woven Fabric Structure

[Table 7] Woven Fabric Evaluation Results (Part 1)

[Table 8] Woven Fabric Evaluation Results (Part 2)

The results in the preceding table indicate that the fabrics comprising the spun yarns disclosed herein provide a number of advantages over the fabrics of the comparative examples. As indicated by the greater thickness of the fabrics of the examples compared to the comparative fabrics of similar structures, the woven fabrics comprising the spun yarns disclosed herein have a larger bulk. The woven fabrics of the examples also exhibit less fluff (higher fluff rating values), better abrasion resistance (lower% weight loss), and better drape (higher drape coefficient values) than the fabrics of the comparative examples. Additionally, the fabrics of the examples may also be dyed darker (lower L* values with a D65 light source). A combination of improved feel (softer feel) and better drape is particularly desirable for fabrics.

Circular Knit Fabric Example

Circular knitted fabrics as shown in Table 9 were prepared using the spun yarns of Examples 5 to 10 as knitting yarns; Comparative fabrics were prepared using commercially available spun yarns. For all circular knitted fabrics made using 20s Ne count yarns, the machine gauge was 20”. For all circular knitted fabrics made using 40s Ne count yarns, the machine gauge was 24”. Fabric evaluation results are presented in Tables 9 and 10. Unless otherwise stated, results are reported for processed fabrics.

Example 17

Using the spun yarn from Example 5, circular knitted fabrics were made on a Mesdan lab knitter. The greasy fabric was heat set in an RBE stenter at 160° C. for 45 seconds, and then scoured in an HTHP Beaker dyeing machine using the following procedure. The fabric was scoured at 90° C. for 60 minutes by adding NaOH (2 gpl) and wetting agent Levocol CESR (5 gpl). The fabric was washed at 85° C. for 15 minutes, then with cold water for 15 minutes, then with a neutralizing solution containing acetic acid (1 gpl) for 15 minutes, followed by another cold water wash for 15 minutes.

The refined fabric was then dyed with a disperse dye mixture using the following time and temperature profile in the same machine: heated to 70° C. and held for 10 minutes, then the temperature was raised to 130° C. at 1.5° C./min for 30 minutes. After holding for a while, the temperature is lowered to 70°C at 1.5°C/min and drained. After dyeing, the fabric was reductively washed with Hydros and NaOH (2 gpl each) at 90° C. for 20 minutes. The fabric was then 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. The dyed fabric was padded with a finishing agent (softener) and then heat-set at 160° C. for 45 seconds in a lab stenter.

The fabric structure is shown in Table 9. The wicking test result was 100%. Compared to the fabric of Comparative Example H, the fabric of Example 17 was found to have a softer feel (i.e., better pliability). Other fabric properties are shown in Tables 9 and 10.

Comparative Example H

A comparative knitted fabric was prepared according to the procedure of Example 17 except that commercially available 20s Ne 100% PET staple spun yarn (“P1”) was used.

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

Example 18

After dyeing with a disperse dye, the Mesdan wrap was edited according to the procedure of Example 17, except that the fabric was dyed with a reactive dye mixture added with salt (60 gpl) in the same machine using the following time and temperature profile. A circular knitted fabric was prepared using the spun yarn from Example 7 on a loom: heated to 60° C. and held for 30 minutes, then soda ash (15 gpl) was added and held for 30 minutes before draining. The fabric was then washed with cold water for 10 minutes, then with acetic acid (1 gpl) for 15 minutes, followed by hot soaping with Albatex AD (2 gpl), during which the temperature was raised to 90°C. Hold for 15 minutes. The fabric was then washed with hot water (85° C.) for 15 minutes and then with cold water for 10 minutes. The dye was fixed using Levocol HCF (0.5 gpl), during which the temperature was raised to 50° C. and held for 20 minutes. The dyed fabric was padded with a finishing agent, followed by heat setting at 160° C. for 45 seconds in a lab stenter.

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

Comparative Example I

A comparative knitted fabric was prepared according to the procedure of Example 18, except that commercially available 20s Ne 40/60 PET/cotton staple spun yarn (“PC1”) was used.

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

Example 19

A circular knitted fabric was made using the spun yarn from Example 9 in a Mesdan wrap knitting machine according to the procedure of Example 18.

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

Comparative Example J

A comparative knitted fabric was prepared according to the procedure of Example 18, except that commercially available 20s Ne 40/60 PET/Tencel® staple spun yarn (“PT1”) was used.

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

Example 20

Circular knitted fabrics were prepared on a Mesdan wrap knitting machine using the spun yarn 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 wicking test result was 100%. Compared to the fabric of Comparative Example K, the fabric of Example 20 was found to have a better feel (i.e., better flexibility). Other fabric properties are shown in Tables 9 and 10.

Comparative Example K

A comparative knitted fabric was prepared according to the procedure of Example 17, except that commercially available 40s Ne 100% PET staple spun yarn (“P2”) and a different disperse dye mixture were used.

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

Example 21

Circular knitted fabrics were prepared on a Mesdan wrap 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 wicking test result was 100%. Other fabric properties are shown in Tables 9 and 10.

Comparative Example L

A comparative knitted fabric was prepared according to the procedure of Example 18 except that commercially available 40s Ne 40/60 PET/cotton staple spun yarn (“PC2”), different disperse dye mixtures, and different reactive dye mixtures were used.

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

Example 22

Circular knitted fabrics were prepared on a Mesdan wrap knitting machine using the spun yarn from Example 10 according to the procedure of Example 18, except for different disperse dye mixtures and different reactive dye mixtures.

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

Comparative Example M

A comparative knitted fabric was prepared according to the procedure of Example 18 except that commercially available 40s Ne 40/60 PET/Tencel® staple spun yarn (“PT2”), a different disperse dye mixture, and different reactive dyes were used.

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

[Table 9] Circular knitted fabric (CK) fabric structure and evaluation results

[Table 10] Evaluation results of circular knitted fabric (CK) fabric (continued)

The results in Tables 9 and 10 show that the circular knitted fabrics of the examples provide advantages over the fabrics of the comparative examples. For example, a circular knitted fabric comprising a spun yarn comprising melt-spun staple fibers disclosed herein has a larger bulk compared to the fabric of the comparative example, as indicated by the larger thickness of the fabric. The circular knitted fabrics of the examples also exhibit less fluff (higher fluff rating values) and better abrasion resistance (lower% weight loss). Additionally, the fabrics of the examples have better stretch recovery rates than the comparative fabrics in both a shorter recovery time and a longer time recovery time.

Example 23

2/64s Nm spun yarn containing 70/30 wool/melt spun staple fibers

According to the following procedure, spun yarn was manufactured using a worsted yarn spinning system.

The spun yarn of Example 23 was prepared using the melt-spun staple fibers from Example 4. Melt-spun staple fibers of 2.5 denier and 84 mm average length were taken and converted from cotton card spinning systems to sliver according to the general carding process commonly used in spinning mills. These slivers were blended with a wool top (20.5 microns, 68 mm average length Australian Merino) and spun in a worsted yarn spinning system at a 70/30 (wt/wt) wool/melt spinning staple fiber blend ratio. I did. The nominal spinning count for the spun yarn was 2/64s Nm.

Example 24

A bottom weight twill fabric was prepared using the spun yarn from Example 23 as warp and weft yarns. The warp was sized prior to beaming using a CCI single ended sizing machine using Elvanol-T25 PVA sizing agent and softening agent. A final beam with 1770 ends, a width of 18 inches, and an end length of 3.5 meters was prepared using a static match at 350 m/min. Use the following denting scheme:

Elongation: 3 shaft

Stretch type (straight stretch (1, 2, & 3)

Denting: 3 ends/dent

Lead count: 60 dent/2 inch

A 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 2 m long and 50 cm wide gray paper fabric was obtained.

A similar procedure as in Example 11 was used, except that Albatex AD was used with Levocol CESR, to desize the greasy fabric in a jigger machine. The fabric was then subjected to a hot water wash (85° C. for 15 minutes), a cold water wash (15 minutes), a neutralization step with acetic acid (15 minutes), and another cold water wash (15 minutes). The fabric was dried flat in 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 profile: heated to 70° C. and held for 10 minutes, then the temperature was raised to 130° C. at 1.5° C./min and held for 30 minutes, then Lower the temperature to 70℃ at 1.5℃/min and drain. The fabric was reductively washed with Hydros and NaOH (1 gpl each) at 90° C. for 20 minutes. The fabric was then 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 acidic dye mixture using the following time and temperature profile: heated to 70° C. and held for 10 minutes, then the temperature was raised to 98° C. at 1.5° C./min and held for 45 minutes, then Lower the temperature to 70℃ at 1.5℃/min and drain. The fabric was washed with cold water (10 minutes), treated with acetic acid (1 gpl for 15 minutes), hot soaped with Albatex AD (90° C. for 15 minutes), washed with hot water (85° C. for 15 minutes). ), washed with cold water (10 min) and then contacted with Levocol HCF (0.5 gpl) at 50° C. for 20 min to fix the dye.

The fabric was decatizing in an autoclave (130 ^° C. for 3 minutes), then padded with a finishing agent, then heat set at 160° C. for 45 seconds in a lab stenter, and then decatized again in an autoclave. (130° C. for 3 minutes).

Gray and processed fabrics were evaluated. The result is as follows:

Gray fabric structure: 96*54 (end/inch * pick/inch)

Fabricated fabric structure: 114*63 (end/inch * pick/inch)

Gray fabric weight: 198 g/m ²

Processed fabric weight: 249 g/m ²

Dimensional Stability (%):

Length -2.8%;

Width -1.7%

Wicking test: 100%

Tear strength: warp 1984 g, weft 896 g

Elongation %: 42.7

1-minute recovery rate (%): 83.1

30-minute recovery rate (%): 90.9

60-minute recovery rate (%): 93.51

Example 25

Undrawn melt-spun fiber containing PTT and Co-PET

Pellets of polytrimethylene terephthalate (PTT) containing 0.3% TiO ₂ and an intrinsic viscosity of 0.96 dL/g and polyethylene terephthalate co-ethylene isophthalate (from Nan Ya Plastics) with an intrinsic viscosity of 0.80 dL/g ( Co-PET) were individually dried at 120° C. under a nitrogen blanket in a vacuum oven for 16 hours. The dried pellets of PTT and the dried pellets of Co-PET were blended together in a small drum by manual shaking and rolling action of the drum at the ratios given in Table 11. Each of the salt-and-pepper blends so produced were melt-extruded into bundles of 34-filament yarns of circular cross section using a twin screw extruder spinning machine. The extruder melting zone temperature was maintained between 180 and 265°C. Polymer throughput, winder speed, spun denier per filament, and dry heat shrinkage of yarn bundles (tows) are provided in Table 11.

[Table 11] Example 25 Spinning Conditions and Drying Heat Shrinkage of Tow

Example 26

Undrawn melt-spun fiber containing Co-PET and PBT

Pellets of polyethylene terephthalate co-ethylene isophthalate (Co-PET) (from Nan Ya Plastics) with an intrinsic viscosity of 0.80 dL/g and CRASTIN® 6130C NC010 polybutylene terephthalate (PBT) with an intrinsic viscosity of 1.15 dL/g ) Pellets were individually dried at 120° C. under a nitrogen blanket in a vacuum oven for 16 hours. The dried pellets of PTT and PBT were blended together in a small drum by manual shaking and rolling action of the drum at the ratios given in Table 12. Each of the salt-and-pepper blends so produced were melt-extruded into bundles of 34-filament yarns of circular cross section using a twin screw extruder spinning machine. The extruder melting zone temperature was maintained between 180 and 265°C. Polymer throughput, winder speed, spun denier per filament, and dry heat shrinkage of yarn bundles (tows) are provided in Table 12.

[Table 12] Example 26 Spinning Conditions and Drying Heat Shrinkage of Tow

Example 27

Melt-spun staple fibers containing a salt-and-pepper blend of 20% by weight PTT and 80% by weight Co-PET

Polytrimethylene terephthalate (from Nan Ya Plastics) and co-PET were simultaneously fed into a 7590 hole spinnerette in a 20:80 weight ratio using a twin screw extruder. Polytrimethylene terephthalate contained 0.3% TiO ₂ and had an intrinsic viscosity of 0.96 dL/g. Circular cross-section filaments were spun at an extruder throughput of 100 kg/h using radial quenching. The extruder melting zone temperature was maintained at 252-263°C. The polymer throughput was 0.220 g/min/hole and the feed roll speed was 650 m/m. The spinning dpf was nominally 3.4. The spun fibers were collected in a can.

Sixteen cans, a total of 412,896 deniers, were supplied to the draw-crimp-cut/bale module. Staple melt spun fibers were produced using a typical cotton count staple process using a multistage drawing, crimping machine, annealer, and cutter. The tow was immersed in a finish bath at 22° C. (0.5% concentration, commercially available from CHT as Duron 3176). The tow is first drawn in a 0.5% concentration finish bath at 75°C between an 18°C feed roll operating at 30 m/m and a heated draw roll at 80°C operating at 84 m/m to achieve a first stage draw ratio of 2.8. Provided. The stretched tow was pulled through a steam chest at 100° C. by a downstream heated roll operating at 165° C. at 88.20 m/m. The tow was passed through another series of rolls heated to 165° C. operating at 88.20 m/m. The finish (2% concentration, Duron 14 + Duron 1105 PE, 30/70 active material, both obtained from CHT) was sprayed and the tow was passed over a cold drum roll at 25° C. operating at 86.44 m/m. The tow was placed in a steam box at 100° C. before entering the 40 mm crimper. The crimping machine speed was 90.76 m/m. The crimper roller temperature and pressure were 65° C. and 0.8 bar, respectively. The crimped tow was annealed at 100° C. for 4 min in a plate belt dryer, and the crimped tow was finally cut to produce staple melt spun fibers having the following properties (determined using the method disclosed herein above):

Denier per filament (dpf) = 1.28, coefficient of variation (CV) = 15.47%

Toughness = 5.24 g/d, CV = 13.05%

Elongation = 53.37%, CV = 39.14%

Staple length = 38 mm

Number of crimps (fully-curved arc) = 12.9/inch

Crimp stability = 64.08%, CV = 17.67%

Finishing material on yarn = 0.26%

Example 28

Melt-spun staple fibers containing a salt-and-pepper blend of 50% by weight PTT and 50% by weight Co-PET

Polytrimethylene terephthalate and co-PET (from Nan Ya Plastics) were simultaneously fed through a 7590 hole spinnerette in a 50:50 weight ratio using a single screw extruder. Polytrimethylene terephthalate contained 0.3% TiO ₂ and had an intrinsic viscosity of 0.96 dL/g. Circular sectional filaments were spun at an extruder throughput of 122.2 kg/h using radial quenching. The extruder melting zone temperature was maintained at 252-263°C. The polymer throughput was 0.268 g/min/hole and the feed roll speed was 792 m/m. The spinning dpf was nominally 3.4. The spun fibers were collected in a can.

Sixteen cans, a total of 412,896 deniers, were supplied to the draw-crimp-cut/bale module. Staple melt spun fibers were produced using a typical cotton count staple process using a multistage drawing, crimping machine, annealer, and cutter. The tow was immersed in a finish bath at 22° C. (0.5% concentration, commercially available from CHT as Duron 3176). The tow is first drawn in a 0.5% concentration finish bath at 75°C between an 18°C feed roll operating at 30 m/m and a heated draw roll at 80°C operating at 87 m/m to achieve a first stage draw ratio of 2.9. Provided. The stretched tow was pulled through a steam chest at 100° C. by a downstream heated roll operating at 165° C. at 92.22 m/m. The tow was passed through another series of rolls heated to 165° C. operating at 90.38 m/m. The finish (2% concentration, Duron 14 + Duron 1105 PE, 30/70 active material, both obtained from CHT) was sprayed and the tow was passed over a cold drum roll at 25° C. operating at 90.38 m/m. The tow was placed in a steam box at 100° C. before entering the 40 mm crimper. The crimping machine speed was 94.89 m/m. The crimper roller temperature and pressure were 65° C. and 0.8 bar, respectively. The crimped tow was annealed at 100° C. for 4 min in a plate belt dryer, and the crimped tow was finally cut to produce staple melt spun fibers having the following properties (determined using the method disclosed herein above):

Denier per filament (dpf) = 1.31, coefficient of variation (CV) = 10.13%

Toughness = 4.66 g/d, CV = 9.72%

Elongation = 53.86%, CV = 25.47%

Staple length = 38 mm

Full-sinus arc = 13.1/inch

Crimp stability = 79.51%, CV = 9.45%

Finishing material on yarn = 0.20%

Example 29

Melt-spun staple fibers containing a salt-and-pepper blend of 50% by weight PTT and 50% by weight Co-PET

Polytrimethylene terephthalate and co-PET (from Nan Ya Plastics) were simultaneously fed through a 7590 hole spinnerette in a 50:50 weight ratio using a single screw extruder. Polytrimethylene terephthalate contained 0.3% TiO ₂ and had an intrinsic viscosity of 0.96 dL/g. Circular sectional filaments were spun at an extruder throughput of 122.2 kg/h using radial quenching. The extruder melting zone temperature was maintained at 252-263°C. The polymer throughput was 0.268 g/min/hole and the feed roll speed was 400 m/m. The spinning dpf was nominally 6.4. The spun fibers were collected in a can.

Eight cans, a total of 388,608 deniers, were supplied to the draw-crimp-cut/bale module. Staple melt spun fibers were produced using a typical spent count staple process using a multistage drawing, crimping machine, annealer, and cutter. The tow was immersed in a finish bath at 22° C. (0.5% concentration, commercially available from CHT as Duron 3176). The tow is first drawn in a 0.5% concentration finish bath at 75°C between an 18°C feed roll operating at 30 m/m and a heated draw roll at 80°C operating at 114 m/m to achieve a first stage draw ratio of 3.8. Provided. The stretched tow was pulled through a steam chest at 100° C. with a downstream heated roll operating at 165° C. at 108.3 m/m. The tow was passed through another series of rolls heated to 165° C. operating at 106.1 m/m. The finish (2% concentration, Duron 14 + Duron 1105 PE, 30/70 active material, both obtained from CHT) was sprayed and the tow was passed over a cold drum roll at 25° C. operating at 107.2 m/m. The tow was placed in a steam box at 100° C. before entering the 40 mm crimper. The crimping machine speed was 112.56 m/m. The crimper roller temperature and pressure were 65° C. and 0.8 bar, respectively. The crimped tow was annealed at 100° C. for 4 min in a plate belt dryer, and the crimped tow was finally cut to melt spinning staples of multiple cut lengths having the following properties (determined using the method disclosed herein above) Fiber was produced:

Denier per filament (dpf) = 2.08, coefficient of variation (CV) = 7.47%

Toughness = 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 (fully-curved arc) = 12/inch

Crimp stability = 72.11%, CV = 12.8%

Finishing material on yarn = 0.09%

Example 30

Melt-spun staple fibers containing a salt-and-pepper blend of 20% by weight PBT and 80% by weight Co-PET

Simultaneous feeding of CRASTIN® 6130C NC010 polybutylene terephthalate (PBT) and co-PET (from Nan Ya Plastics) with an intrinsic viscosity of 1.15 dL/g through a 7590 hole spinnerette in a 20:80 weight ratio using a single screw extruder I did. Circular cross-section filaments were spun at an extruder throughput of 100 kg/h using radial quenching. The extruder melting zone temperature was maintained at 252-263°C. The polymer throughput was 0.220 g/min/hole and the feed roll speed was 650 m/m. The spinning dpf was nominally 3.18. The spun fibers were collected in a can.

Sixteen cans, a total of 386,179 denier, were supplied to the draw-crimp-cut/bale module. Staple melt spun fibers were produced using a typical cotton count staple process using a multistage drawing, crimping machine, annealer, and cutter. The tow was immersed in a finish bath at 22° C. (0.5% concentration, commercially available from CHT as Duron 3176). The tow is first drawn in a 0.5% concentration finish bath at 75°C between an 18°C feed roll operating at 30 m/m and a heated draw roll at 80°C operating at 88.2 m/m to achieve a first stage draw ratio of 2.94. Provided. The stretched tow was pulled through a steam chest at 100° C. with a downstream heated roll operating at 165° C. at 92.61 m/m. The tow was passed through another series of rolls heated to 165° C. operating at 92.61 m/m. The finish (2% concentration, Duron 14 + Duron 1105 PE, 30/70 active material, both obtained from CHT) was sprayed and the tow was passed over a cold drum roll at 25° C. operating at 90.76 m/m. The tow was placed in a steam box at 100° C. before entering the 40 mm crimper. The crimping machine speed was 95.30 m/m. The crimper roller temperature and pressure were 65° C. and 0.8 bar, respectively. The crimped tow was annealed at 100° C. for 4 min in a plate belt dryer, and the crimped tow was finally cut to produce staple melt spun fibers having the following properties (determined using the method disclosed herein above):

Denier per filament (dpf) = 1.24, coefficient of variation (CV) = 13.51%

Toughness = 5.36 g/d, CV = 11.77%

Elongation = 47.07%, CV = 39.30%

Staple length = 40 mm

Number of windings (completely curved arc) = 10.4 / inch

Crimp stability = 56.2%, CV = 13.9%

Finishing material on yarn = 0.31%

Example 31

Melt-spun staple fibers containing a salt-and-pepper blend of 50% by weight PBT and 50% by weight Co-PET

Simultaneous feeding of CRASTIN® 6130C NC010 polybutylene terephthalate (PBT) and co-PET (from Nan Ya Plastics) with an intrinsic viscosity of 1.15 dL/g through a 7590 hole spinnerette in a 50:50 weight ratio using a single screw extruder I did. Circular sectional filaments were spun at an extruder throughput of 122.2 kg/h using radial quenching. The extruder melting zone temperature was maintained at 252-263°C. The polymer throughput was 0.268 g/min/hole and the feed roll speed was 792 m/m. The spinning dpf was nominally 3.42. The spun fibers were collected in a can.

Sixteen cans, a total of 415,324 deniers, were supplied to the draw-crimp-cut/bale module. Staple melt spun fibers were produced using a typical cotton count staple process using a multistage drawing, crimping machine, annealer, and cutter. The tow was immersed in a finish bath at 22° C. (0.5% concentration, commercially available from CHT as Duron 3176). The tow is first drawn in a 0.5% concentration finish bath at 75°C between an 18°C feed roll operating at 30 m/m and a heated draw roll at 80°C operating at 87.90 m/m to achieve a first stage draw ratio of 2.93. Provided. The stretched tow was pulled through a steam chest at 100° C. by a downstream heated roll operating at 165° C. at 94.93 m/m. The tow was passed through another series of rolls heated to 165° C. operating at 94.93 m/m. The finish (2% concentration, Duron 14 + Duron 1105 PE, 30/70 active material, both obtained from CHT) was sprayed and the tow was passed over a cold drum roll at 25° C. operating at 93.03 m/m. The tow was placed in a steam box at 100° C. before entering the 40 mm crimper. The crimping machine speed was 97.69 m/m. The crimper roller temperature and pressure were 65° C. and 0.8 bar, respectively. The crimped tow was annealed at 100° C. for 4 min in a plate belt dryer, and the crimped tow was finally cut to produce staple melt spun fibers having the following properties (determined using the method disclosed herein above):

Denier per filament (dpf) = 1.17, coefficient of variation (CV) = 13.6%

Toughness = 5.48 g/d, CV = 12.38%

Elongation = 39.74%, CV = 27.57%

Staple length = 40 mm

Number of crimps (fully-curved arc) = 11.8/inch

Crimp stability = 60.23%, CV = 8.30%

Finishing material on yarn = 0.24%

Example 32

40s Ne spun yarn containing 100% melt spun fiber

A spun yarn was prepared using the melt-spun staple fibers from Example 28, according to the procedure of Example 5, except for the following differences:

The linear density of the final sliver was 4.75 g/meter and the% non-uniformity was 1.75.

The roving hank was 1.2 s Ne.

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

The spun yarn was rolled into a cone at 1500 m/min. The properties of the spun yarn are provided in Table 13. The properties of the spun yarn of this example and the following examples were determined using the method disclosed herein above.

Example 33

40s Ne spun yarn containing 100% melt spun fiber

According to the procedure of Example 32, a spun yarn was prepared using the melt-spun staple fibers from Example 27. The properties of the spun yarn are provided in Table 13.

Example 34

40s Ne spun yarn containing 100% melt spun fiber

According to the procedure of Example 32, a spun yarn was prepared using the melt-spun staple fibers from Example 31. The properties of the spun yarn are provided in Table 13.

Example 35

40s Ne spun yarn containing 100% melt spun fiber

According to the procedure of Example 32, a spun yarn was prepared using the melt-spun staple fibers from Example 30. The properties of the spun yarn are provided in Table 13.

Example 36

40s Ne spun yarn containing 40/60 (wt/wt) melt spun fiber/cotton

A spun yarn was prepared using melt-spun staple fibers from Example 28 and cotton (Shankar 6 Variety Indian cotton commercially available from North India). 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 prepared according to the procedure of Example 32. The properties of the spun yarn are provided in Table 13.

Example 37

40s Ne spun yarn containing 40/60 (wt/wt) melt spun fiber/cotton

A spun yarn was prepared using melt-spun staple fibers from Example 27 and cotton (Shankar 6 Variety Indian cotton commercially available from North India). 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 prepared according to the procedure of Example 8. The properties of the spun yarn are provided in Table 13.

Example 38

40s Ne spun yarn containing 40/60 (wt/wt) melt spun fiber/cotton

A spun yarn was prepared using melt-spun staple fibers from Example 31 and cotton (Shankar 6 Variety Indian cotton commercially available from North India). 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 prepared according to the procedure of Example 8. The properties of the spun yarn are provided in Table 13.

Example 39

40s Ne spun yarn containing 40/60 (wt/wt) melt spun fiber/cotton

A spun yarn was prepared using melt-spun staple fibers from Example 30 and cotton (Shankar 6 Variety Indian cotton commercially available from Northern India). 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 prepared according to the procedure of Example 8. The properties of the spun yarn are provided in Table 13.

Example 40

40s Ne spun yarn containing 40/60 melt spun fiber/Tencel

Spun yarn was prepared using melt-spun staple fibers from Example 28 and commercially available Tencel® staple fibers (Lenzing). Tencel® staples had an average length of 40 mm and a denier of 1.2 D. A spun yarn was prepared according to the procedure of Example 10. The properties of the spun yarn are provided in Table 13.

Example 41

40s Ne spun yarn containing 40/60 melt spun fiber/Tencel

Spun yarn was made using melt-spun staple fibers from Example 27 and commercially available Tencel® staple fibers (Lenzing). Tencel® staples had an average length of 40 mm and a denier of 1.2 D. A spun yarn was prepared according to the procedure of Example 10. The properties of the spun yarn are provided in Table 13.

Example 42

40s Ne spun yarn containing 40/60 melt spun fiber/Tencel

Spun yarn was prepared using melt-spun staple fibers from Example 31 and commercially available Tencel® staple fibers (Lenzing). Tencel® staples had an average length of 40 mm and a denier of 1.2 D. A spun yarn was prepared according to the procedure of Example 10. The properties of the spun yarn are provided in Table 13.

Example 43

40s Ne spun yarn containing 40/60 melt spun fiber/Tencel

Spun yarn was made using melt-spun staple fibers from Example 30 and commercially available Tencel® staple fibers (Lenzing). Tencel® staples had an average length of 40 mm and a denier of 1.2 D. A spun yarn was prepared according to the procedure of Example 10. The properties of the spun yarn are provided in Table 13.

Example 44

2/68s Nm spun yarn containing 45/55 wool/melt spun staple fibers

According to the following procedure, spun yarn was manufactured using a worsted yarn spinning system.

The spun yarn of Example 44 was prepared using the melt-spun staple fibers from Example 29. Melt-spun staple fibers of 2.5 denier and 84 mm average length were taken and converted from cotton card spinning systems to sliver according to the general carding process commonly used in spinning mills. This sliver was blended with a wool top (20.5 micron, 68 mm average length Australian Merino) and spun in a worsted yarn spinning system at a 45/55 (wt/wt) wool/melt spinning staple fiber blend ratio. The nominal spinning count for the spun yarn was 2/68 s Nm.

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

[Table 13] Properties of the spun yarn of Examples 32 to 44

The results of Table 13 are compared with the results of Tables 4 and 5, salt-and-pepper blended PET/PTT 50:50 melt spinning PET/PTT 50:50 melt spinning with the toughness of spinning yarn containing staples It shows that it is similar to the toughness of a yarn containing staples. The percent boiling water shrinkage is higher for spun yarns comprising salt-and-pepper PET/PTT 50:50 melt-spun staples compared to yarns comprising blended PET/PTT 50:50 melt-spun staples. All other characteristics were found to be similar.

Woven fabric examples

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

Example 45

A plain weave (1/1) shearing fabric was prepared using the spun yarn from Example 32 as warp and weft yarns. The warp was sized prior to beaming using a CCI single end sizing machine using Elvanol-T25 PVA sizing agent. A final beam with 1680 ends, a width of 18 inches, and an end length of 3.5 meters was prepared using a static match at 350 m/min. Use the following denting scheme:

Elongation: 4 shaft

Stretch type (straight stretch (1, 2, 3, & 4)

Denting: 2 ends/dent

Lead count: 84 dents/2 inches

A 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 greasy fabric was desized as follows on an RBE lab Jigger machine. The fabric sample was loaded onto a jigger filled with water (2 L), NaOH (2 gpl), and wetting agent; Levocol CESR (wetting agent) was added (5 gpl) and the bath temperature was raised to 90°C. The fabric was allowed to run in the bath for 60 minutes, then the bath was drained, refilled with fresh water, and the temperature of the bath was raised to 85°C. The fabric was washed with hot water for 15 minutes and the bath was drained. The bath was again filled with water and the fabric was run through it for 15 minutes (cold water washing). Drain the bath, fill with water and neutralize by adding acetic acid (1 gpl); The fabric was allowed to run for 15 minutes in this bath. Thereafter, the bath was drained, refilled with fresh water, and allowed to run the fabric for 15 minutes in a cold water bath. The fabric was then unloaded on a jigger, dried in 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 profile: heated to 70° C. and held for 10 minutes, then the temperature was raised to 130° C. at 1.5° C./min and held for 30 minutes, then Lower the temperature to 70℃ at 1.5℃/min and drain. After dyeing, the fabric was reductively washed with Hydros and NaOH (2 gpl each) at 90° C. for 20 minutes. The fabric was then 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 dyed fabric was padded with a finishing agent (softener) and then heat set at 160° C. for 45 seconds in an RBE lab stenter.

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

Example 46

According to the procedure given in Example 45, the spun yarn from Example 33 was used as warp and weft to make a plain weave shirting fabric. The fabric structure is shown in Table 14. The wicking test result was 100%. Other fabric properties are shown in Tables 15 and 16.

Example 47

According to the procedure given in Example 45, the spun yarn from Example 34 was used as warp and weft to make a plain weave shirting fabric. The fabric structure is shown in Table 14. The wicking test result was 100%. Other fabric properties are shown in Tables 15 and 16.

Example 48

According to the procedure given in Example 45, the spun yarn from Example 35 was used as warp and weft to make a plain weave shirting fabric. The fabric structure is shown in Table 14. The wicking test result was 100%. Other fabric properties are shown in Tables 15 and 16.

Example 49

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

Example 50

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

Example 51

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

Example 52

A plain weave fabric was prepared using the spun yarn from Example 39 as warp and weft according to the procedure of Example 49, but with the following exceptions. The greasy fabric was desized and bleached in a jigger machine, heat set in a stenter, then dyed with a disperse dye mixture, and then further dyed with a reactive dye under cotton dyeing conditions.

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

Example 53

According to the procedure of Example 49, except that the peroxide killer was not used at the end of the bleaching step, the spun yarn from Example 40 was used as warp and weft yarns to prepare a plain weave shirting fabric. The pick value on the loom was set to 65 picks/inch.

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

Example 54

Following the procedure of Example 53, a plain weave fabric was prepared using the spun yarn from Example 41 as warp and weft yarns. The fabric structure is shown in Table 14. The wicking test result was 100%. Other fabric properties are shown in Tables 15 and 16.

Example 55

Following the procedure of Example 53, a plain weave fabric was prepared using the spun yarn from Example 42 as warp and weft yarns. The fabric structure is shown in Table 14. The wicking test result was 100%. Other fabric properties are shown in Tables 15 and 16.

Example 56

Following the procedure of Example 53, a plain weave fabric was prepared using the spun yarn from Example 42 as warp and weft yarns. The fabric structure is shown in Table 14. The wicking test result was 100%. Other fabric properties are shown in Tables 15 and 16.

Example 57

Using the spun yarn from Example 34 as warp and weft yarns, a 2/1 twill structured suiting fabric was prepared. The warp was sized prior to beaming using a CCI single ended sizing machine using Elvanol-T25 PVA sizing agent and softening agent. A final beam with 1518 ends, a width of 18 inches, and an end length of 3.5 meters was prepared using a static match at 350 m/min. Use the following denting scheme:

Elongation: 3 shaft

Stretch type (straight stretch (1, 2, & 3))

Denting: 3 ends/dent

Lead count: 51.5 dent/2 inch

A 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 2 m long and 48.3 cm wide grange fabric was obtained.

A similar procedure as in Example 49 was used, except that Albatex AD with Levocol CESR was used, to desize the greasy fabric in a jigger machine. The fabric was then subjected to a hot water wash (85° C. for 15 minutes), a cold water wash (15 minutes), a neutralization step with acetic acid (15 minutes), and another cold water wash (15 minutes). The fabric was dried flat in 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 profile: heated to 70° C. and held for 10 minutes, then the temperature was raised to 130° C. at 1.5° C./min and held for 30 minutes, then Lower the temperature to 70℃ at 1.5℃/min and drain. The fabric was reductively washed with Hydros and NaOH (1 gpl each) at 90° C. for 20 minutes. The fabric was then 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 acidic dye mixture using the following time and temperature profile: heated to 70° C. and held for 10 minutes, then the temperature was raised to 98° C. at 1.5° C./min and held for 45 minutes, then Lower the temperature to 70℃ at 1.5℃/min and drain. The fabric was washed with cold water (10 minutes), treated with acetic acid (1 gpl for 15 minutes), hot soaped with Albatex AD (90° C. for 15 minutes), washed with hot water (85° C. for 15 minutes). ), washed with cold water (10 min) and then contacted with Levocol HCF (0.5 gpl) at 50° C. for 20 min to fix the dye.

The fabric was decatized in an autoclave (130 ^° C. for 3 minutes), then padded with a finishing agent, Levofin HYP-5gpl Levocol PNLI-10 gpl, then heat set at 160° C. for 45 seconds in a lab stenter, and then Decatize again in autoclave (130° C. for 3 minutes).

Gray and processed fabrics were evaluated. Fabric structure and test results are given in Tables 14, 15, and 16. The wicking test result was 100%.

Table 14 Woven Fabric Structure for Fabric Examples 45-57

[Table 15] Results of woven fabric evaluation for Fabric Examples 45 to 57 (first half)

[Table 16] Results of woven fabric evaluation for Fabric Examples 45 to 57 (second half)

The results shown in Tables 14, 15 and 16, and also earlier Tables 6, 7 and 8 indicate that the yarn disclosed herein can be used to make woven fabrics with desirable properties.

Circular Knit Fabric Example

Using the spun yarns of Examples 32 to 44 as knitting yarns, circular knitted fabrics as shown in Table 17 were prepared. For all circular knitted fabrics made using 40s Ne count yarns, the machine gauge was 24”. The fabric evaluation results are presented in Table 18. Unless otherwise stated, results are reported for processed fabrics.

Examples 58, 59, 60, and 61

Using the spun yarns from Examples 32, 33, 34, and 35, respectively, circular knitted fabrics were made on a Mesdan wrap knitting machine. The greasy fabric was heat set in an RBE stenter at 160° C. for 45 seconds and then refined in an HTHP beaker dyeing machine using the following procedure. The fabric was scoured at 90° C. for 60 minutes by adding NaOH (2 gpl) and wetting agent Levocol CESR (5 gpl). The fabric was washed at 85° C. for 15 minutes, then with cold water for 15 minutes, then with a neutralizing solution containing acetic acid (1 gpl) for 15 minutes, followed by another cold water wash for 15 minutes.

The refined fabric was then dyed with a disperse dye mixture using the following time and temperature profile in the same machine: heated to 70° C. and held for 10 minutes, then the temperature was raised to 130° C. at 1.5° C./min for 30 minutes. After holding for a while, the temperature is lowered to 70°C at 1.5°C/min and drained. After dyeing, the fabric was reductively washed with Hydros and NaOH (2 gpl each) at 90° C. for 20 minutes. The fabric was then 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. The dyed fabric was padded with a finishing agent (softener) and then heat-set at 160° C. for 45 seconds in a lab stenter. Fabric structure and test results are presented in Tables 17 and 18. The wicking test result was 100% for all fabrics.

Examples 62, 63, 64, and 65

After dyeing with a disperse dye, the Mesdan wrap was edited according to the procedure of Example 58, except that the fabric was dyed with a reactive dye mixture to which salt (60 gpl) was added in the same machine using the following time and temperature profile. Circular knitted fabrics were prepared using each of the spun yarns from Examples 36, 37, 38, and 39 on a loom: heated to 60° C. and held for 30 minutes, then soda ash (15 gpl) was added and held for 30 minutes. Drained after being done. The fabric was then washed with cold water for 10 minutes, then with acetic acid (1 gpl) for 15 minutes, followed by hot soaping with Albatex AD (2 gpl), during which the temperature was raised to 90° C. and held for 15 minutes. I did. The fabric was then washed with hot water (85° C.) for 15 minutes and then with cold water for 10 minutes. The dye was fixed using Levocol HCF (0.5 gpl), during which the temperature was raised to 50° C. and held for 20 minutes. The dyed fabric was padded with a finishing agent, followed by heat setting at 160° C. for 45 seconds in a lab stenter. Fabric structure and test results are presented in Tables 17 and 18. The wicking test result was 100% for all fabrics.

Examples 66, 67, 68, and 69

The spun yarns from Examples 40, 41, 42, and 43 were prepared 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. Each was used to make a circular knitted fabric on a Mesdan wrap knitting machine. Fabric structure and test results are presented in Tables 17 and 18. The wicking test result was 100% for all fabrics.

Example 70

A circular knitted fabric was made using the spun yarn from Example 44 on a Mesdan wrap knitting machine according to the procedure of Example 14. Fabrics were dyed and processed according to Example 57. Fabric structure and test results are presented in Tables 17 and 18. The wicking test result was 100% for all fabrics.

[Table 17] Circular knitted fabric (CK) fabric structure and evaluation results for Examples 58 to 70

[Table 18] Evaluation results of circular knitted fabrics (CK) fabrics for Examples 58 to 70 (continued)

The results shown in Tables 17 and 18, and also earlier in Tables 9 and 10, indicate that the yarn disclosed herein can be used to make circular knitted fabrics with desirable properties.

Claims (20)

Melt spun staple fiber comprising a first polymer comprising poly(trimethylene terephthalate) or poly(butylene terephthalate) and a second polymer comprising poly(ethylene terephthalate) or Co-PET ) Comprising a spun yarn, wherein Co-PET is a poly(ethylene terephthalate) copolymer containing an isophthalic acid monomer;
The first polymer comprises poly(trimethylene terephthalate) and the weight ratio of the poly(trimethylene terephthalate) to the second polymer is in the range of about 80:20 to about 10:90; or
The first polymer comprises poly(butylene terephthalate) and the weight ratio of the poly(butylene terephthalate) to the second polymer ranges from about 90:10 to about 10:90. The spun yarn of claim 1, wherein the first polymer comprises poly(trimethylene terephthalate) and the second polymer comprises poly(ethylene terephthalate). The method of claim 1, wherein the first polymer comprises poly(trimethylene terephthalate) and the second polymer comprises Co-PET, and the Co-PET is from about 0.5 mol% to about the total copolymer composition. Spun yarn containing 10 mol% of isophthalic acid monomer. The yarn of claim 1, wherein the first polymer comprises poly(butylene terephthalate) and the second polymer comprises poly(ethylene terephthalate). The method of claim 1, wherein the first polymer comprises poly(butylene terephthalate) and the second polymer comprises Co-PET, and the Co-PET is from about 0.5 mol% to about the total copolymer composition. Spun yarn containing 10 mol% of isophthalic acid monomer. The spun yarn according to claim 3 or 5, wherein the spun yarn has a boil off shrinkage of at least about 6% as 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 of claim 1, further comprising second staple fibers in an amount of about 5% to about 95% by weight based on the total weight of the spun yarn. The method of claim 8, 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, cotton yarn. The spun yarn of claim 9, wherein the second staple fiber comprises cotton or wool. A fabric comprising the spun yarn of claim 1. 12. The fabric of claim 11, wherein the first polymer comprises poly(trimethylene terephthalate) and the second polymer comprises poly(ethylene terephthalate). 12. The fabric of claim 11, wherein the first polymer comprises poly(trimethylene terephthalate) and the second polymer comprises Co-PET. 12. The fabric of claim 11, wherein the first polymer comprises poly(butylene terephthalate) and the second polymer comprises poly(ethylene terephthalate). 12. The fabric of claim 11, wherein the first polymer comprises poly(butylene terephthalate) and the second polymer comprises Co-PET. The method of claim 11, wherein the fabric
Than a fabric of the same fabric structure consisting of polyethylene terephthalate, cotton, rayon, or a combination thereof.
i) better wear resistance as determined according to ASTM D4966 standard test method;
ii) a higher pill rating value as determined according to ASTM D4970 standard test method; or
iii) larger bulk as determined according to ASTM D1777 standard test method
Having at least one of, a fabric. 12. The fabric of claim 11, wherein the fabric is a woven fabric having a warp and a weft, and the warp, the weft, or both the warp and the weft each comprise the spun yarn of claim 1. 12. The fabric of claim 11, wherein the fabric is a knitted fabric. 19. The fabric of claim 18, wherein the fabric has a higher recovery rate as determined according to method BS 4294 than a knitted fabric of the same fabric structure consisting of polyethylene terephthalate, cotton, rayon, or combinations thereof. An article comprising the fabric of claim 11.