TWI828715B - Fabrics and spun yarns comprising polyester staple fiber - Google Patents

Abstract

Disclosed herein are spun yarns comprising melt spun staple fiber comprising a first polymer and a second polymer, wherein the first polymer comprises poly(trimethylene terephthalate) or poly(butylene terephthalate) and the second polymer comprises poly(ethylene terephthalate) or Co-PET, wherein Co-PET is a poly(ethylene terephthalate) copolymer comprising isophthalic acid monomer; and wherein 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 from about 80:20 to about 10:90; or the the first polymer comprises poly(butylene terephthalate) and the weight ratio of the poly(butylene terephthalate) to the second polymer is in the range of about 90:10 to about 10:90. The spun yarn may further comprise a second staple fiber such as cotton or wool. The spun yarn is useful in preparing fabrics having advantageous properties.

Description

Fabrics and yarns containing polyester staple fibers

The present disclosure relates to spun yarns including melt-spun staple fibers containing a first polymer and a second polymer, and to fabrics including the spun yarns. The first polymer includes poly(trimethylene terephthalate) or poly(butylene terephthalate), and the second polymer includes poly(ethylene terephthalate) or Co-PET, wherein Co-PET is a poly(ethylene terephthalate) copolymer containing isophthalic acid monomer.

Poly(trimethylene terephthalate) (PTT) is a commercial fiber with desirable properties such as easy dispersion and dyeability at atmospheric pressure, relatively low flexural modulus, and relatively high elastic recovery and resilience . Methods for producing PTT staple fibers are known, however, shrinkage of partially oriented tows during storage prior to drawing, crimping and cutting often prevents consistent processing of PTT into staple fibers. Shrinkage is affected by storage time and storage temperature, and uncontrolled shrinkage causes denier unevenness and stretch breakage during the stretching process. As a result, the commercialization of PTT short fibers or blends of PTT short fibers and natural fibers has been limited.

In some textile end uses, staple fibers are preferred over continuous filaments. For example, staple fiber spun yarns for apparel fabrics require discontinuous fibers rather than continuous fibers to allow the use of textile staple processing equipment. Staple fibers also allow synthetic fibers to be blended with natural fibers such as wool, cotton and cellulose. The manufacture of staple fibers suitable for use in fabrics can present special problems, particularly in conventional split spinning/drawing processes where the drawing is performed in a separate step and the characteristics of the undrawn fiber such as dry heat shrinkage ) can change during storage as the undrawn fiber ages.

There is a continuing need for PTT-based staple fibers with good uniformity and toughness, as well as economical methods for producing such staple fibers. There is a continuing need for spun yarns containing PTT-based staple fibers that have good tenacity and elongation at break and that impart desirable qualities to fabrics containing such spun yarns.

Disclosed herein are melt-spun staple fibers, spun yarns containing the melt-spun staple fibers, and fabrics containing the spun yarns. In one embodiment, a spun yarn is disclosed, the spun yarn comprising melt-spun staple fibers, the melt-spun staple fibers comprising a first poly(trimethylene terephthalate) or poly(butylene terephthalate)-containing material. Polymer and a second polymer containing poly(ethylene terephthalate) or Co-PET, wherein Co-PET is a poly(ethylene terephthalate) copolymer containing isophthalic acid monomers and wherein 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 includes poly(butylene terephthalate), and the weight ratio of poly(butylene terephthalate) to the second polymer is from about 90:10 to about 10:90 within the range. In another embodiment of the spun yarn, the weight ratio of poly(trimethylene terephthalate) or poly(butylene terephthalate) to the second polymer is in the range of about 70:30 to 30:70 . In another embodiment, the spun yarn has a boiling water shrinkage of at least about 6% as determined according to ASTM D2259.

In one embodiment of the spun yarn, the melt-spun staple fibers comprise poly(trimethylene terephthalate) and poly(ethylene terephthalate). In another embodiment of the spun yarn, the melt-spun staple fibers comprise 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 contains from about 0.5 mol % to about 10 mol% of isophthalic acid monomer. In another embodiment of the spun yarn, the melt-spun staple fibers comprise poly(butylene terephthalate) and poly(ethylene terephthalate). In yet another embodiment of the spun yarn, the melt-spun staple fibers comprise poly(butylene terephthalate) and Co-PET. In one embodiment of the spun yarn, the first polymer includes poly(butylene terephthalate), and the second polymer includes Co-PET, and the Co-PET contains about 0.5 mol % based on the total polymer composition. to about 10 mol% of isophthalic acid monomer. In another embodiment of the spun yarn, the second polymer includes Co-PET, and the Co-PET contains from about 0.5 mol % to about 10 mol % isophthalic acid monomer based on the total polymer composition.

In one embodiment, the spun yarn further includes second staple fibers in an amount from about 5% to about 95% by weight based on the total weight of the spun yarn. In additional embodiments, the second staple fiber includes polylactic acid, acrylic, nylon, olefin, acetate, rayon, or polyester. In another embodiment, the second staple fiber includes 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 Wool, or mixtures thereof. In yet another embodiment, the second staple fiber includes cotton or wool.

In one embodiment, the second staple fiber includes cotton. In one embodiment, the spun yarn further includes a second staple fiber, the second staple fiber includes cotton, and the cotton is present in an amount from 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 yarn count of about 4 Ne to about 80 Ne.

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

In another embodiment, a fabric is disclosed that includes a spun yarn as disclosed herein. In one embodiment, the fabric has a softer hand and better drape than a fabric of the same fabric construction consisting of rayon, polyethylene terephthalate, ester, cotton, or combinations thereof . In one embodiment, compared to a fabric having the same fabric construction consisting of polyethylene terephthalate, cotton, rayon, or a combination thereof, the fabric has at least one of the following: i) as in accordance with Better abrasion resistance as determined by the ASTM D4966 standard test method; ii) a higher pilling rating as determined by the ASTM D4970 standard test method; or iii) a greater pilling rating as determined by the ASTM D1777 standard test method The bulkiness (bulk). In another embodiment, the fabric has better dyeability than a fabric of the same construction consisting of polyethylene terephthalate, cotton, rayon, or a combination thereof. In yet another embodiment, the fabric has better abrasion resistance than a fabric of the same fabric construction consisting of polyethylene terephthalate, cotton, rayon, or a combination thereof. In another embodiment, the fabric has less pilling (higher pilling) compared to a fabric having the same fabric construction consisting of polyethylene terephthalate, cotton, rayon, or a combination thereof. ball rating). In another embodiment, the fabric has greater loft than a fabric of the same fabric construction 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 fabric is a woven fabric having warp yarns and weft yarns, and the warp yarns, weft yarns, or both warp yarns and weft yarns each comprise a spun yarn as disclosed herein. In additional embodiments, the warp yarns comprise spun yarns as disclosed herein. In another embodiment, the weft yarns comprise spun yarns as disclosed herein. In yet another embodiment, the warp and weft yarns each comprise a spun yarn as disclosed herein. In another embodiment, the fabric is a knitted fabric. In one embodiment, the knitted fabric has a higher recovery rate than a knitted fabric with the same fabric construction composed of polyethylene terephthalate, cotton, rayon, or a combination thereof. Also disclosed herein are articles, such as clothing, including fabrics as disclosed herein.

In yet another embodiment, melt-spun staple fibers are disclosed, the fibers comprising a first polymer containing poly(trimethylene terephthalate) or poly(butylene terephthalate) and a first polymer containing poly(p-phenylene terephthalate). a second polymer of ethylene dicarboxylate) or Co-PET, wherein Co-PET is a poly(ethylene terephthalate) copolymer containing an isophthalic acid monomer, and the short fiber has a poly(ethylene terephthalate) copolymer of about A weight ratio of the first polymer to the second polymer in the range of 70:30 to about 30:70, and a dry heat shrinkage of less than 6% as measured by a dry heat shrinkage method. In one embodiment, the melt-spun staple fibers comprise poly(trimethylene terephthalate) and poly(ethylene terephthalate). In another embodiment, the melt-spun staple fibers comprise poly(trimethylene terephthalate) and Co-PET. In additional embodiments, the melt-spun staple fibers comprise poly(butylene terephthalate) and poly(ethylene terephthalate). In yet another embodiment, the melt-spun staple fibers comprise poly(butylene terephthalate) and Co-PET. In another embodiment, the second polymer includes Co-PET, and the Co-PET contains from about 0.5 mol % to about 10 mol % isophthalic acid monomer based on the total polymer composition. In yet another embodiment of melt-spun staple fibers, the weight ratio of the first polymer to the second polymer is in the range of about 70:30 to 50:50.

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

As used herein, the terms "embodiment" or "disclosure" are not meant to be limiting, but generally apply to any embodiment defined in the scope of the claim or described herein. These terms are used interchangeably herein.

In this disclosure, many terms and abbreviations are used. Unless otherwise specified, the following definitions apply.

The articles "a/an" and "the" before an element or component are intended to be non-limiting with respect to the number of instances (ie, occurrences) of the element or component. As used herein, "a" and "the" shall be understood to include one or at least one, and singular references to an element or component also include the plural unless the number is clearly intended to be singular.

The term "comprising" means the presence of a stated feature, integer, step, or component as mentioned in the claimed scope without the exclusion of one or more other features, integers, steps, components, or combinations thereof existence or addition. 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 include embodiments encompassed by the term "consisting of."

Where present, all ranges are inclusive and combinable. For example, when a range of "1 to 5" is recited, the recited range should be interpreted to include "1 to 4", "1 to 3", "1 to 2", "1 to 2 and 4 to 5", " 1 to 3 and 5" and so on.

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

Every maximum numerical limitation given throughout this specification is intended to include every lower numerical limitation, as if such lower numerical limitations were expressly written herein. Every minimum numerical limitation given throughout this specification will include every higher numerical limitation, as if such higher numerical limitations were expressly written herein. Every numerical range given throughout this specification will include every narrower numerical range that falls within such broader numerical range, as if such narrower numerical ranges were all expressly written herein.

By reading the following detailed description, those familiar with the art will more easily understand the features and advantages of the present disclosure. It will be understood that, for clarity, certain features of the disclosure described above and below in the context of separate implementations may also be provided in combination in a single element. Conversely, for the sake of brevity, various features of the disclosure that are described in the context of a single implementation may also be provided separately or in any sub-combination.

Unless expressly stated otherwise, the use of numerical values in each range specified in this application are stated as approximations as if both the minimum and maximum values in the stated range were preceded by the word "about." In this manner, slight variations above and below the stated ranges may be used to achieve substantially the same results as values within those ranges. Furthermore, such ranges are intended to be disclosed as a continuous range including every value between the minimum value and the maximum value.

As used in this article: "Poly(trimethylene terephthalate)" or PTT means a polymer containing repeating units derived from 1,3-propanediol and terephthalic acid (or equivalent). As used herein, the term "poly(trimethylene terephthalate) homopolymer" means a polymer of essentially only 1,3-propanediol and terephthalic acid (or equivalent). As used herein, the term "poly(trimethylene terephthalate)" also includes PTT copolymers, which is meant to contain repeating units derived from 1,3-propanediol and terephthalic acid (or equivalent) and also Polymers containing at least one additional unit derived from an additional monomer. Examples of PTT copolymers include copolyesters made using 3 or more reactants, each having two ester-forming groups. For example, copoly(trimethylene terephthalate) may be used, in which the comonomers used to make the copolyester are selected from the group consisting of: linear, cyclic, and branched-chain aliphatic dicarboxylic acids (such as succinic acid, glutaric acid, adipic acid, dodecanedioic acid, and 1,4-cyclohexanedicarboxylic acid); and Aromatic dicarboxylic acids with 8-12 carbon atoms (such as isophthalic acid and 2,6-naphthalenedicarboxylic acid); linear, cyclic and branched aliphatic diols with 2-8 carbon atoms ( In addition to 1,3-propanediol, for example, ethylene glycol, 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 with 4 to 10 carbon atoms (such as hydroquinone bis (2-Hydroxyethyl) ether, or poly(vinyl ether) glycol with a molecular weight less than about 460, including diethyl ether glycol). The comonomer is typically present in the copolyester in an amount ranging from about 0.5 mol% to about 15 mol%, and may be present in an amount up to about 30 mol%.

As used herein, the term "poly(butylene terephthalate)" or PBT means a polymer derived essentially only from 1,4-butanediol and terephthalic acid, and is also referred to as poly(butylene terephthalate) Butylene terephthalate) homopolymer. As used herein, the term "poly(butylene terephthalate) copolymer" means a polymer that contains repeating units derived from 1,4-butanediol and terephthalic acid and also contains additional monomers derived from A polymer of at least one additional unit (eg, a comonomer of a PTT copolymer as disclosed herein).

As used herein, the term "poly(ethylene terephthalate)" or PET means derived essentially only from ethylene glycol and terephthalic acid (or equivalents, such as dimethyl terephthalate) polymer, and is also known as poly(ethylene terephthalate) homopolymer. As used herein, the term "poly(ethylene terephthalate) copolymer" means a polymer containing repeating units derived from ethylene glycol and terephthalic acid (or equivalents) and also containing repeating units derived from additional monomers. A polymer of at least one additional unit of the body.

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

"Short fiber" refers to cut lengths of natural fibers or filaments. The term staple fiber is used in the textile industry to distinguish natural fibers or cut man-made fibers from filaments. Man-made fibers are cut to specific lengths, for example, as long as 8 inches or as short as 1.5 inches or less, so they can be processed on cotton, woolen or worsted yarn spinning systems, or flocked.

The term "melt-spun short fibers" means short fibers obtained by melting a fiber-forming substance, extruding it through a spinneret and solidifying it directly by cooling; storing such melt-spun fibers, and Other batches of melt-spun fibers obtained similarly were assembled and co-drawn, crimped, heat treated to stabilize, and cut to obtain staple fibers.

The term "spun yarn" means a yarn produced by aligning cut staple fibers in multiple steps, wherein the tows of cut staple fibers are successively drawn into continuous strands of increasingly smaller denier, And the short fibers are combined together by twisting.

"Undrawn yarn" is a term generally applied to undrawn fibers and is not intended herein to include yarns that have been drawn and processed into yarn products (such as those used in knitted or woven fabrics) of fiber. After melt spinning, the undrawn yarn is accumulated until the appropriate total denier for the draw frame is produced. Accumulation may take up to 24 hours or more, including sleep or storage time between steps. For example, it often takes 6 hours or more to make enough undrawn yarn on a drawing line to draw economically. Due to production planning and other practical considerations, the fiber can be stored for several days. Fibers that have been exposed to this storage time are called "aged" or "aged undrawn yarn".

"Draw ratio" or "draw ratio" is the amount by which the filament is stretched after melt spinning. As used herein, "draw ratio" refers to the machine draw ratio, which is the ratio of the surface speed of the pull roller to the advance roller (the roller that moves the fiber). The result of pulling is a certain degree of stretching.

Carding is the process of opening, individualizing, aligning and forming continuous untwisted strands of short fiber bundles called slivers. A carding machine consists of a series of rollers whose surfaces are covered with numerous protruding metal teeth or pins.

"Tow" means large strands of continuous man-made fiber filaments without explicit twist collected in loose rope form before being cut into staple fibers or formed into slivers.

"Slivers" are continuous strands of loosely assembled short fibers that are not twisted. The yarn sliver is output by carding machine or draw frame. The production of slivers is the first step in textile operations, converting short fibers into a form that can be stretched and ultimately twisted into spun yarns.

The term "fabric" means a planar textile structure produced by interweaving yarns, fibers or filaments.

The term "woven fabric" means a fabric composed of interwoven warp and weft yarns. During the weaving process, the lengthwise or longitudinal warp yarns are held in a fixed state of tension on the frame or loom, while the transverse weft yarns (also called wefts) are stretched through the warp yarns and inserted above and below the warp yarns.

The term "knitted fabric" means a fabric produced by interconnecting one or more ends of yarns into loops.

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

The term decitex (dtex) is a measure of the linear mass density of a fiber or yarn and is defined as the mass in grams per 10,000 meters.

The term "linear density" refers to the weight in grams of a one meter long sliver.

The term "linear density" (after the carding step) means the quantity of 840 yards of cut length of one pound of sliver, expressed in imperial count Ne, or the weight in grams of a 1000 meter long sliver, Expressed in grams/meter.

The term "final sliver linear density" (after the drawing step) means the quantity of 840 yards of cut length of one pound of sliver expressed in imperial count Ne, or the weight in grams of one meter of sliver , expressed in grams/meter.

The term "Unevenness %" means the average weight deviation of a 400 meter long spun yarn or a 50 meter long roving or a 50 meter long sliver as measured by a USTER Evenness Tester-3 (UT3), expressed as a percentage. express. Measurements are made by industrially established methods using UT-3 and 400 meters of yarn or 25 or 50 meters of sliver or roving.

The term "defects" in relation to spun yarn means the numerical sum of the number of thick areas, the number of thin areas and the number of neps in a 1000 meter length of yarn as measured using a USTER evenness tester. As used herein, the term "thick area" means a location on a spun yarn where the mass is greater than or equal to +150% of the average mass of the yarn for a cut length of 8 mm. As used herein, the term "thin area" means a location on a spun yarn where the mass is less than or equal to 50% of the average mass of the yarn for a cut length of 8 mm. As used herein, the term "nep" means a location on a spun yarn where the mass is greater than or equal to 200% of the average mass of the yarn of 1 mm cut length.

The term "hairiness index" refers to the average value of the total length of protruding fibers per 1 cm of yarn measured in 400 m of yarn, optically measured using a UT3 tester, and expressed in standardized units.

The present disclosure relates to spun yarns comprising melt-spun staple fibers comprising a first polymer comprising poly(trimethylene terephthalate) or poly(butylene terephthalate) and a poly(paraphenylene terephthalate)-containing first polymer. a second polymer of ethylene dicarboxylate) or Co-PET, wherein the Co-PET is a poly(ethylene terephthalate) copolymer comprising an isophthalic acid monomer; and wherein the first polymer Comprising poly(trimethylene terephthalate), and 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 first polymer includes poly(trimethylene terephthalate) (butylene terephthalate), and the weight ratio of poly(butylene terephthalate) to the second polymer is in the range of about 90:10 to about 10:90. Melt-spun staple fibers lack any significant interface between the first polymer and the second polymer. The spun yarn has a boiling water shrinkage of at least about 6% as determined according to ASTM D2259. If desired, the spun yarn may contain a second short fiber, such as cotton or wool. Fabrics with desired characteristics can be made from spun yarns.

It has been found that the melt-spun staple fibers disclosed herein have improved tenacity, crimp, and stability compared to PTT melt-spun staple fibers, and that the characteristics of the melt-spun staple fibers advantageously enable the formation of fibers during the conversion of the staple fibers into spun yarns. It is processed under the conditions normally used with PET. Furthermore, spun yarns containing the melt-spun staple fibers disclosed herein, whether further containing second staple fibers or consisting essentially solely of melt-spun staple fibers, can be produced with cotton-like aesthetics, good strength, and other desirable properties. Properties of woven fabrics, knitted fabrics and nonwoven fabrics.

In one embodiment, the melt-spun staple fibers of the 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 the polycondensation of 1,3-propanediol with terephthalic acid or terephthalic acid equivalents. Optionally, 1,3-propanediol can be obtained biochemically from renewable sources ("biologically derived" 1,3-propanediol). Poly(trimethylene terephthalate) is commercially available from E. I. du Pont de Nemours and Company, Wilmington, DE under the trademark Sorona®. If desired, PTT or its monomers can be obtained from the recycling of post-industrial or post-consumer materials (i.e. fiber or plastic waste).

"Terephthalic acid equivalent" means a compound that behaves substantially the same as terephthalic acid in the reaction of a polymeric diol with a diol, as is generally recognized by one of ordinary skill in the relevant art. Terephthalic acid equivalents include, for example, esters (such as dimethyl terephthalate) and ester-forming derivatives such as acid halides (eg, acid chloride) and anhydrides. Terephthalic acid and terephthalic acid esters, such as dimethyl ester, are suitable. Methods of preparing poly(trimethylene terephthalate) are disclosed, for example, in US 6277947, US 6326456, US 6657044, US 6353062, US 6538076, and US 7531617.

Preferably, the purity of 1,3-propanediol used as a reactant or as a component of a reactant in the preparation of poly(trimethylene terephthalate) is greater than about 99%, such as greater than about 99.9%, by weight, As determined by gas chromatography analysis. Purified 1,3-propanediol is disclosed in US 7038092, US 7098368, US 7084311, and US 7919658.

Poly(trimethylene terephthalate) suitable for use in melt-spun fibers may be poly(trimethylene terephthalate) homopolymer (derived essentially from 1,3-propylene glycol and terephthalic acid and/or equivalents) and copolymers. In one embodiment, the poly(trimethylene terephthalate) contains about 70 mol % or more derived from 1,3-propanediol and terephthalic acid (and/or equivalents thereof, such as diterephthalate Methyl ester) repeating unit. The poly(trimethylene terephthalate) may contain at least about 85 mol%, or at least about 90 mol%, or at least about 95 mol%, or at least about 99 mol%, or about 100 mol% derived from 1,3- Repeating units of propylene glycol and terephthalic acid (or equivalent).

Poly(trimethylene terephthalate) may contain small amounts of other comonomers, and such comonomers are generally selected so that they do not have a significant adverse effect on properties. Such other comonomers include, for example, sodium 5-sulfoisophthalate in an amount in the range of about 0.2 to 5 mol%. 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 repeating units made from other glycols or diacids. Other diacids include, for example, isophthalic acid, 1,4-cyclohexanedicarboxylic acid, 2,6-naphthalenedicarboxylic acid, 1,3-cyclohexanedicarboxylic acid, succinic acid, glutaric acid, hexane Diacids, sebacic acid, 1,12-dodecanedioic acid, and their derivatives, such as dimethyl, diethyl, or dipropyl esters of these dicarboxylic acids. Other glycols include ethylene glycol, 1,4-butanediol, 1,2-propanediol, diethylene glycol, triethylene glycol, 1,3-butanediol, 1,5-pentanediol, 1,6- Hexanediol, 1,2-, 1,3- and 1,4-cyclohexanedimethanol, and longer chain diols and polyols prepared from the reaction products of diols or polyols with alkylene oxides.

The poly(trimethylene terephthalate) may also include functional monomers, for example, up to about 5 mol % of a sulfonate compound that may be used to impart cationic dyeability. Specific examples of preferred sulfonate compounds include lithium 5-sulfoisophthalate, sodium 5-sulfoisophthalate, potassium 5-sulfoisophthalate, and 4-sulfo-2,6-naphthalene. Sodium diformate, tetramethylphosphonium 3,5-dicarboxybenzenesulfonate, tetrabutylphosphonium 3,5-dicarboxybenzenesulfonate, methyltributylmethylphosphonium 3,5-dicarboxybenzenesulfonate, 2,6 -Tetrabutylphosphonium dicarboxynaphthalene-4-sulfonate, tetramethylphosphonium 2,6-dicarboxynaphthalene-4-sulfonate, ammonium 3,5-dicarboxybenzenesulfonate, and their ester derivatives, such as methane methyl ester or dimethyl ester.

The intrinsic viscosity of poly(trimethylene terephthalate) is typically about 0.5 deciliters per gram (dl/g) or higher, and typically about 2 dl/g or lower. In one embodiment, the poly(trimethylene terephthalate) has an intrinsic viscosity of about 0.7 dl/g or higher, such as 0.8 dl/g or higher, or such as 0.9 dl/g or higher, and typically is About 1.5 dl/g or less, such as 1.4 dl/g or less, and currently available commercial products have intrinsic viscosities of 1.2 dl/g or less.

In another embodiment, the melt-spun staple fibers of the 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 the polycondensation of 1,4-butanediol and terephthalic acid. Poly(butylene terephthalate) is commercially available under the trademark Crastin® from DuPont Co. of Wilmington, DE.

Poly(butylene terephthalate) suitable for use in melt-spun fibers may be homopolymers (derived essentially from 1,4-butanediol and terephthalic acid and/or equivalents) and copolymers. In one embodiment, poly(butylene terephthalate) contains about 80 mol% or more repeating units derived from 1,4-butanediol and terephthalic acid. In another embodiment, the poly(butylene terephthalate) may contain at least about 85 mol%, or at least about 90 mol%, or at least about 95 mol%, or at least about 99 mol%, or about 100 mol % of repeating units derived from 1,4-butanediol and terephthalic acid (or equivalent). Poly(trimethylene terephthalate) may contain small amounts of other comonomers or functional monomers. If desired, PBT or its monomers can be obtained from the recycling of post-industrial materials or post-consumer materials (i.e. fiber or plastic waste).

Polyethylene terephthalate (PET) is a polyester that can be prepared by the condensation polymerization of ethylene glycol and terephthalic acid (or dimethyl terephthalate or other terephthalate esters). Methods for preparing poly(ethylene terephthalate) are known, for example as disclosed in US 3398124 and US 3487049. Poly(ethylene terephthalate) suitable for making the melt-spun staple fibers disclosed herein is also commercially available. In one embodiment, poly(ethylene terephthalate) is a homopolymer and is derived essentially from ethylene glycol and terephthalic acid and/or equivalents. Optionally, PET or its monomers can be obtained from the recycling of post-industrial or post-consumer materials (i.e. fiber or plastic waste).

In many applications, it may be desirable to modify the properties of poly(ethylene terephthalate) by adding a third monomer. For example, copolymers of polyethylene terephthalate may be composed of dimethyl terephthalate or terephthalic acid monomers combined with cyclohexanedimethanol, or with cyclohexanedimethanol and ethylene glycol. Prepared with a combination of alcohols. In other cases, isophthalic acid can be used to replace a portion of the terephthalic acid monomers, which destroys crystallinity and lowers the melting point of the copolymer, referred to herein as "Co-PET."

As used herein, “Co-PET” refers to a product made from ethylene glycol, terephthalic acid (or dimethyl terephthalate or other terephthalate esters), and isophthalic acid (or isophthalic acid). Poly(ethylene terephthalate) copolymers prepared by the condensation polymerization of dimethyl phthalate or other terephthalates), as is known in the art. Co-PET can also be produced in a process where recycled poly(ethylene terephthalate) bottles are shredded, melted, purified and re-pelletized to produce fiber-grade post-consumer recycled Co-PET. Isophthalic acid monomer is typically present in Co-PET in an amount ranging from about 0.5 mol% to about 15 mol%, based on total polymer composition, and may be present in an amount up to about 30 mol%. For example, Co-PET can contain about 0.5, 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, or 30 mol% isophthalic acid monomer. In one embodiment, Co-PET useful in the melt-spun staple fibers disclosed herein contains from about 1 mol% to about 5 mol%, or up to about 10 mol%, or up to about 15 mol% based on the total polymer composition. of isophthalic acid monomer. In another embodiment, useful Co-PET contains from about 0.5 mol% to about 3 mol% 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. The lower melting point of Co-PET is believed to improve the compatibility of Co-PET and poly(trimethylene terephthalate) during melt spinning. Co-PET is commercially available.

In some embodiments, polyethylene terephthalate copolymers containing additional monomers in addition to isophthalic acid may be used. Examples include ethylene glycol, terephthalic acid (or equivalent), and compounds such as succinic acid, adipic acid, azelaic acid, sebacic acid, glutaric acid, 1,10-decanedicarboxylic acid, phthalic acid, Formic acid, dodecanedioic acid, sulfonated isophthalic acid, oxalic acid, fumaric acid, maleic acid, itaconic acid, 1,4-cyclohexanedicarboxylic acid, 1,3-cyclohexanedicarboxylic acid Polyethylene terephthalate copolymers of dicarboxylic acids such as 1,2-cyclohexanedicarboxylic acid and mixtures thereof can be used to prepare melt-spun short fibers. Alternatively, contain ethylene glycol, terephthalic acid (or equivalent), and compounds such as diethylene glycol, polyethylene glycol, butylene glycol, 1,4-cyclohexanedimethanol, 1,2-cyclohexane Polyterephthalic acid of diols such as diols, 1,4-cyclohexanediol, 1,3-cyclohexanediol, 1,5-pentanediol, 1,6-hexanediol, and mixtures thereof Glycol ester copolymers can be used to prepare melt-spun staple fibers.

In one embodiment, the Co-PET system includes a poly(ethylene terephthalate) copolymer of 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 another embodiment, Co-PET is a poly(ethylene terephthalate) copolymer composed of poly(ethylene terephthalate) and isophthalic acid monomers.

The melt-spun staple fiber includes a first polymer containing poly(trimethylene terephthalate) or poly(butylene terephthalate) and a first polymer containing poly(ethylene terephthalate) or Co-PET. a second polymer; and wherein the first polymer comprises poly(trimethylene terephthalate), and the weight ratio of the poly(trimethylene terephthalate) to the second polymer is from about 80:20 to about 10:90 within the range; or the first polymer includes poly(butylene terephthalate), and the weight ratio of poly(butylene terephthalate) to the second polymer is from about 90:10 to about 10 : Within the range of 90. In one embodiment, the melt-spun staple fibers comprise poly(trimethylene terephthalate) (PTT) and poly(ethylene terephthalate) (PET), and the melt-spun staple fibers comprise about 80% by weight of PTT and about 20% by weight 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 fibers comprise about 70% by weight PTT and about 30% by weight PET. In another embodiment, the staple fibers comprise about 65% by weight PTT and about 35% by weight PET. In yet another embodiment, the staple fibers comprise about 60% by weight PTT and about 40% by weight PET. In additional embodiments, the staple fibers comprise about 55% by weight PTT and about 45% by weight PET. In another embodiment, the staple fibers comprise about 50% by weight PTT and about 50% by weight PET. In another embodiment, the staple fibers comprise 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 fibers comprise 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 fibers comprise about 10% by weight PTT and about 90% by weight PET.

In one embodiment, the melt-spun staple fibers comprise poly(trimethylene terephthalate) (PTT) and poly(ethylene terephthalate) copolymer including isophthalic acid monomer (Co-PET), And the weight ratio of PTT to Co-PET is in the range of about 80:20 to about 10:90. In one embodiment, the melt-spun staple fiber contains about 80% by weight PTT and about 20% by weight Co-PET. In additional embodiments, the melt-spun staple fibers comprise about 75 wt% PTT and about 25 wt% Co-PET. In one embodiment, the melt-spun staple fibers comprise about 70 wt% PTT and about 30 wt% of Co-PET. In another embodiment, the melt-spun staple fibers comprise about 65 wt% PTT and about 35 wt% Co-PET. In yet another embodiment, the melt-spun staple fibers comprise about 60 wt% PTT and about 40% by weight Co-PET. In another embodiment, the melt-spun staple fibers comprise about 55% by weight PTT and about 45% by weight Co-PET. In another embodiment, the melt-spun staple fibers Comprising about 50 wt% PTT and about 50 wt% Co-PET. In another embodiment, the melt-spun staple fibers comprise about 45 wt% PTT and about 55 wt% Co-PET. In a separate embodiment In , the melt-spun staple fibers comprise about 40% by weight PTT and about 60% by weight Co-PET. In another embodiment, the melt-spun staple fibers comprise about 35% by weight PTT and about 65% by weight Co-PET In yet another embodiment, the melt-spun staple fibers comprise about 30 wt% PTT and about 70 wt% Co-PET. In one embodiment, the melt-spun staple fibers comprise about 25 wt% PTT and about 75 wt% % Co-PET. In another embodiment, the melt-spun staple fibers comprise about 20 wt% PTT and about 80 wt% Co-PET. In yet another embodiment, the melt-spun staple fibers comprise about 15 wt% of PTT and about 85% by weight Co-PET. In additional embodiments, the melt-spun staple fibers comprise about 10% by weight PTT and about 90% by weight Co-PET.

In one embodiment, the melt-spun staple fibers comprise poly(butylene terephthalate) (PBT) and poly(ethylene terephthalate) (PET), and the melt-spun staple fibers comprise about 90 wt. % PBT and approximately 10 wt% PET. In another embodiment, the melt-spun staple fibers comprise about 85% by weight PBT and about 15% by weight PET. In one embodiment, the melt-spun staple fibers comprise 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 fibers comprise about 70% by weight PBT and about 30% by weight PET. In another embodiment, the staple fibers comprise about 65% by weight PBT and about 35% by weight PET. In yet another embodiment, the staple fibers comprise about 60% by weight PBT and about 40% by weight PET. In additional embodiments, the staple fibers comprise about 55% by weight PBT and about 45% by weight PET. In another embodiment, the staple fibers comprise about 50% by weight PBT and about 50% by weight PET. In another embodiment, the staple fibers comprise 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 fibers comprise 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 fibers comprise about 15% by weight PBT and about 85% by weight PET. In one embodiment, the melt-spun staple fibers comprise about 10% by weight PBT and about 90% by weight PET.

In one embodiment, the melt-spun staple fibers comprise poly(butylene terephthalate) (PBT) and poly(ethylene terephthalate) copolymer (Co- PET), and the weight ratio of PBT to Co-PET ranges from about 90:10 to about 10:90. In one embodiment, the melt-spun staple fibers comprise about 85% by weight PBT and about 15% by weight Co-PET. In another embodiment, the melt-spun staple fibers comprise about 80% by weight PBT and about 20% by weight Co-PET. In additional embodiments, the melt-spun staple fibers comprise about 75% by weight PBT and about 25% by weight Co-PET. In one embodiment, the melt-spun staple fibers comprise about 70% by weight PBT and about 30% by weight Co-PET. In another embodiment, the melt-spun staple fibers comprise about 65% by weight PBT and about 35% by weight Co-PET. In yet another embodiment, the melt-spun staple fibers comprise about 60% by weight PBT and about 40% by weight Co-PET. In additional embodiments, the melt-spun staple fibers comprise about 55% by weight PBT and about 45% by weight Co-PET. In another embodiment, the melt-spun staple fibers comprise about 50% by weight PBT and about 50% by weight Co-PET. In another embodiment, the melt-spun staple fibers comprise about 45% by weight PBT and about 55% by weight Co-PET. In a separate embodiment, the melt-spun staple fibers comprise about 40% by weight PBT and about 60% by weight Co-PET. In another embodiment, the melt-spun staple fibers comprise about 35% by weight PBT and about 65% by weight Co-PET. In yet another embodiment, the melt-spun staple fibers comprise about 30% by weight PBT and about 70% by weight Co-PET. In one embodiment, the melt-spun staple fibers comprise about 25% by weight PBT and about 75% by weight Co-PET. In another embodiment, the melt-spun staple fibers comprise about 20% by weight PBT and about 80% by weight Co-PET. In yet another embodiment, the melt-spun staple fibers comprise about 15% by weight PBT and about 85% by weight Co-PET. In additional embodiments, the melt-spun staple fibers comprise about 10% by weight PBT and about 90% by weight Co-PET.

Melt-spun staple fibers can be formed in a two-stage process. In the first stage, the polymers are combined, melted, extruded to form polymer-containing filaments, the filaments are cooled, and collected as tows. In the second stage, the tow may be processed by at least one of drawing, crimping, annealing and cutting to produce short fibers. Methods for producing polyester staple fibers are known, for example as disclosed in US 5,308,564.

The first polymer (PTT or PBT) and the second polymer (PET or Co-PET) can be combined by any known technique. Polymers can be combined in a variety of ways, for example they can be (a) heated and mixed simultaneously, (b) premixed in a separate device before heating, or (c) heated and then mixed. Mixing, heating and shaping can be carried out by conventional equipment designed for this purpose, such as extruders. The temperature should be above the melting point of each polymer but below the minimum decomposition temperature. Suitable temperatures may range from about 140°C to about 240°C, such as at least about 200°C to up to about 230°C. In one embodiment, the melting temperature is below 280°C.

In one embodiment, the polymers can be compounded in desired ratios to form pellets, such as in a compounding screw, and the pellets are then fed into a spinning machine extruder. In another embodiment, the pellets can be made from each polymer separately and then blended together as a salt and pepper type mixture using up to two feeders into the spinner extruder. Alternatively, the pellets can be made from each polymer separately and the pellets are premixed together before being fed to the spinner extruder. In yet another embodiment, each polymer can be melted to form a molten polymer stream, and then the molten polymer streams can be combined and pellets formed from the molten mixture. The term "pellet" is used generically herein and is used regardless of shape, and thus it includes products sometimes referred to as "chips" or "flakes."

If desired, additives may be added to poly(trimethylene terephthalate), poly(butylene terephthalate), poly(ethylene terephthalate), Co-PET, or polymers. in the mixture. Useful additives may include, for example, matting agents, nucleating agents, heat stabilizers, tackifiers, optical brighteners, antioxidants, antimicrobial agents, plasticizers, antistatic agents, lubricants, processing aids , flame retardants, dyes, TiO ₂ , or pigments.

The combined first and second polymers (i.e., PTT and PET blend, PTT and Co-PET blend, PBT and PET blend, or PBT and Co-PET blend) are passed through a spinneret at about 250° C. to Extrusion at a temperature of about 275°C, such as at least about 255°C and up to about 270°C. The spun filaments are extruded in bundles, each threadline containing at least about 34 filaments, such as about 175 filaments to about 6800 filaments, or even 6900 filaments or more. Lots of filaments. Undrawn filaments typically have a denier/filament in the range of about 3 to about 8 or higher. Spinneret holes are usually circular for round fiber cross-sections, but various hole shapes can be used as desired, such as trilobal or triangular 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 measured by the dry heat shrinkage method disclosed herein in the Examples.

In the second stage of the method of producing staple fibers, the tow is fed from a set of cans or creels containing undrawn molten spun yarns. Finishing agents can be applied to facilitate downstream processing. The tow is then drawn while immersed in a heated water bath of dilute finish. Generally, the feed roll is kept at room temperature while the stretch roll can be heated. The drawn tow is stabilized by passing it through a saturated steam chamber and may be further drawn and annealed, if desired, on a plurality of heated draw roll dies and then passed through the room temperature roll dies. Various simplifications of the stretching zone can be achieved using fewer or more heaters or room temperature stretching modules to optimally stretch and stabilize the yarn in preparation for crimping. Crimping modules typically use a steam box, which reduces the modulus of the yarn in preparation for crimping. Typically, the crimping machine is a mechanical stuffing box type crimping machine with a baffle door, driven by pneumatic pressure. The yarn tow is pulled into the crimping main casing by a set of driven rollers; because the outflow from the box is controlled by the back pressure on the baffle, the yarn bends and forms crimps. The crimped tow is passed through an annealed section and then cut into short fibers.

For cotton spinning system processing, the final denier/filament of melt-spun staple fiber can be in the range of 1-2, while for wool spinning system processing, it can be in the range of 2-3.

The melt-spun staple fibers disclosed herein provide processing advantages. For example, short fibers can be processed with good productivity through the opening, carding and drawing steps in spun yarn manufacturing. The melt-spun staple fibers disclosed herein can function in a staple fiber spinning process using typical PET staple fiber spinning conditions.

The drawn fibers can be cut into staple fibers of any desired length. If the staple fibers are too short, they may be difficult to comb. If it is too long, it may be difficult to spin on cotton or wool spinning system equipment. For use in cotton spinning systems, the length of the staple fibers is typically in the range of about 32 mm to about 51 mm, such as in the range of about 38 to 40 mm. For use in worsted systems, the staple fibers typically have multiple cut lengths, with an average cut length in the range of about 70 mm to about 100 mm, such as in the range of about 80 mm to about 90 mm. The staple fiber may be crimped into a full sinus arc having about 10 to about 18, such as about 11 to about 15 crimps per inch. For cotton spinning systems, melt-spun staple fibers typically have a tenacity of 1-2 denier/filament, greater than 4 g/denier, and an elongation at break of 20%-60%, as determined using the method disclosed in the Examples below. of. For worsted systems, melt-spun staple fibers typically have 2-4 denier/filament, a tenacity greater than 4 g/denier, and an elongation at break of 30%-90%.

The melt-spun staple fibers disclosed herein can be used to make spun yarns. In one embodiment, the spun yarn consists essentially of melt-spun staple fibers and does not contain any other type of staple fiber. In another embodiment, the spun yarns comprise the melt-spun staple fibers disclosed herein. In another embodiment, the spun yarn further includes a second staple fiber in an amount from 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 another embodiment, the second staple fiber includes at least one natural fiber selected from cotton, linen, wool, angora, mohair, alpaca, or cashmere. In another embodiment, the second staple fiber may comprise at least one synthetic fiber. In another embodiment, the second staple fiber includes 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 cellulosic fibers" means textile fibers made from regenerated cellulose, also known as rayon, and includes lyocell, viscose, Modal® fibers, and Tencel® fibers . As used herein, "lyocell" means a form of rayon composed of cellulosic fibers produced by dissolving bleached wood pulp using dry jet wet spinning. As used herein, "viscose" means regenerated man-made fibers made from cellulose and obtained by the viscose process. As used herein, "Modal®" means fiber made from the wood pulp of the beech tree. As used herein, "Tecel®" means fiber made from eucalyptus.

In one embodiment, the spun yarns comprise melt-spun staple fibers comprising a first polymer comprising PTT or PBT and a second polymer comprising PET or Co-PET, wherein the first polymer is polymerized with the second polymer. The weight ratio of the materials is in the following range: about 80:20 to about 10:90, or about 70:30 to about 30:70, or about 60:40 to about 40:60; or about 70:30 to about 50: 50, and the spun yarn further contains a second short fiber containing cotton. In another embodiment, the first polymer includes poly(butylene terephthalate), and the weight ratio of poly(butylene terephthalate) to the second polymer is between about 90:10 and In the range of about 10:90, for example about 90:10 to about 80:20, the spun yarn further includes a second short fiber containing cotton. Cotton may be present in the spun yarn in an amount from about 5% to about 95% by weight, and melt-spun staple fibers may be present in the spun yarn in an amount from about 95% to about 5% by weight, based on the total weight of the spun yarn. For example, the spun yarn may contain about 5 wt. % cotton and about 95 wt. % melt-spun staple fibers, or about 10 wt. % cotton and about 90 wt. % melt-spun staple fiber, based on the total weight of the spun yarn. % cotton and about 85 wt% melt-spun staple fibers, or about 20 wt% cotton and about 80 wt% melt-spun staple fibers, or about 25 wt% cotton and about 75 wt% melt-spun staple fibers, Or about 30 wt% cotton and about 70 wt% melt-spun staple fibers, or about 35 wt% cotton and about 65 wt% melt-spun staple fibers, or about 40 wt% cotton and about 60 wt% melt-spun staple fibers. Spun staple fibers, or about 45 weight percent cotton and about 55 weight percent melt-spun staple fibers, or about 50 weight percent cotton and about 50 weight percent melt-spun staple fibers, or about 55 weight percent cotton and about 45 Weight percent melt-spun staple fibers, or about 60 weight percent cotton and about 40 weight percent melt-spun staple fibers, or about 65 weight percent cotton and about 35 weight percent melt-spun staple fibers, or about 70 weight percent Cotton and about 30 wt% melt-spun staple fibers, or about 75 wt% cotton and about 25 wt% melt-spun staple fibers, or about 80 wt% cotton and about 20 wt% melt-spun staple fibers. In another embodiment, the spun yarn may comprise greater than 95 weight percent melt-spun staple fibers and less than 5 weight percent cotton-containing secondary staple fibers. The relative amounts of cotton and melt-spun staple fibers are selected to provide the desired properties for the spun yarns and fabrics made from the yarns. The cotton count (Ne) of the spun yarn may be about 4 to about 70, such as about 4 to about 60, or about 4 to about 50, or about 10 to about 60, or about 20 to about 60. Spun yarns containing cotton may have a fracture toughness of at least 10 cN/tex. In some embodiments, the cotton-containing spun yarn can have a fracture toughness of at least 10 cN/tex. Spun yarns containing cotton may have an elongation at break of at least 4%. Methods for determining toughness and elongation at break are 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 first polymer is in contact with the second polymer. The weight ratio of the polymer is in the following range: about 80:20 to about 10:90, or about 70:30 to about 30:70, or about 60:40 to about 40:60; or about 70:30 to about 50 : 50, and the spun yarn further contains a second short fiber containing wool. In another embodiment, the first polymer includes poly(butylene terephthalate), and the weight ratio of poly(butylene terephthalate) to the second polymer is between about 90:10 and In the range of about 10:90, such as about 90:10 to about 80:20, the spun yarn further includes a second short fiber containing wool. The term "wool" refers to fibers derived from the down of sheep or lambs. Wool may be present in an amount from about 5% to about 95% by weight, and melt-spun staple fibers may be present in an amount from about 95% to about 5% by weight, based on the total weight of the spun yarn. For example, the spun yarn may contain about 5 wt. % wool and about 95 wt. % melt-spun staple fibers, or about 10 wt. % wool and about 90 wt. % melt-spun staple fiber, based on the total weight of the spun yarn. % 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 staple fibers, Or about 30 wt% wool and about 70 wt% melt-spun staple fibers, or about 35 wt% wool and about 65 wt% melt-spun short fibers, or about 40 wt% wool and about 60 wt% melt-spun staple fibers. Spun short fibers, or about 45% by weight of wool and about 55% by weight of melt-spun short fibers, or about 50% by weight of wool and about 50% by weight of melt-spun short fibers, or about 55% by weight of wool and about 45 Weight % melt-spun staple fibers, or about 60 weight % wool and about 40 weight % melt-spun staple fibers, or about 65 weight % wool and about 35 weight % melt-spun staple fibers, or about 70 weight % Wool and about 30% by weight of melt-spun staple fibers, or about 75% by weight of wool and about 25% by weight of melt-spun staple fibers, or about 80% by weight of wool and about 20% by weight of 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-spun staple fibers, or about 95% by weight of wool and about 5% by weight of melt-spun staple fiber fiber. The relative amounts of wool and melt-spun staple fibers are selected to provide the desired properties for the spun yarns and fabrics made from the yarns. The worsted count (Nm) of the spun yarn may be about 7 to about 120, such as 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 100. 75.

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 first polymer is in contact with the second polymer. The weight ratio of the polymer is in the following range: about 80:20 to about 10:90, or about 70:30 to about 30:70, or about 60:40 to about 40:60; or about 70:30 to about 50 : 50, and the spun yarn further contains a second short fiber containing rayon. In another embodiment, the first polymer includes poly(butylene terephthalate), and the weight ratio of poly(butylene terephthalate) to the second polymer is between about 90:10 and In the range of about 10:90, for example about 90:10 to about 80:20, the spun yarn further includes a second short fiber containing rayon. As used herein, "rayon" means textile fibers made from regenerated cellulose, and includes lyocell, viscose, Modal® fibers, and Tencel® fibers. In the spun yarn, the rayon may be present in an amount of about 5% to about 95% by weight, and the melt-spun staple fibers may be present in an amount of about 95% to about 5% by weight, based on the total weight of the spun yarn. For example, the spun yarn may contain about 5 wt. % rayon and about 95 wt. % melt-spun staple fibers, or about 10 wt. % rayon and about 90 wt. % melt-spun staple fiber, based on the total weight of the spun yarn. 15 wt% rayon and about 85 wt% melt-spun staple fibers, or about 20 wt% rayon and about 80 wt% melt-spun staple fibers, or about 25 wt% rayon and about 75 wt% Melt-spun staple 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 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 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 of rayon and about 20% by weight of melt-spun staple fibers, or about 85% by weight of rayon and about 15% by weight of melt-spun staple fibers, or about 90% by weight of rayon and about 10% by weight of melt-spun staple fibers fiber, or about 95% by weight rayon and about 5% by weight melt-spun staple fibers. The relative amounts of rayon and melt-spun staple fibers are selected to provide the desired properties for the spun yarns and fabrics made from the yarns. The yarn count (Ne) of the spun yarn may be from about 4 to about 80, such as from about 10 to about 60, or from 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 first polymer is in contact with the second polymer. The weight ratio of the polymer is in the following range: about 80:20 to about 10:90, or about 70:30 to about 30:70, or about 60:40 to about 40:60; or about 70:30 to about 50 : 50, and the spun yarn further contains a second short fiber containing acrylic acid. In another embodiment, the first polymer includes poly(butylene terephthalate), and the weight ratio of poly(butylene terephthalate) to the second polymer is between about 90:10 and In the range of about 10:90, such as about 90:10 to about 80:20, the spun yarn further includes a second short fiber containing acrylic acid. As used herein, "acrylic fiber" refers to a synthetic fiber made from polyacrylonitrile of about 1900 monomer units with an average molecular weight of about 100,000. The acrylic fibers may be present in an amount from about 5% to about 95% by weight, and the melt-spun staple fibers may be present in an amount from about 95% to about 5% by weight, based on the total weight of the spun yarn. For example, the spun yarn may contain about 5 wt. % acrylic fibers and about 95 wt. % melt-spun staple fibers, or about 10 wt. % acrylic fibers and about 90 wt. % melt-spun staple fibers, based on the total weight of the spun yarn. 15 wt% acrylic fibers and about 85 wt% melt-spun staple fibers, or about 20 wt% acrylic fibers and about 80 wt% melt-spun staple fibers, or about 25 wt% acrylic fibers and about 75 wt% Melt-spun staple fibers, or about 30 wt% acrylic fibers and about 70 wt% melt-spun staple fibers, or about 35 wt% acrylic fibers and about 65 wt% melt-spun staple fibers, or about 40 wt% acrylic fiber 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 staple fibers, or about 55 wt. % acrylic fibers and about 45 wt. % melt-spun staple fibers, or about 60 wt. % acrylic fibers and about 40 wt. % melt-spun staple fibers, or about 65 wt. % acrylic fibers and about 35 wt. % 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% by weight 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-spun staple fibers. 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 properties for the spun yarns and fabrics made from the yarns. The yarn count (Ne) of the spun yarn may be from about 4 to about 80, such as from about 10 to about 60, or from 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 first polymer is in contact with the second polymer. The weight ratio of the polymer is in the following range: about 80:20 to about 10:90, or about 70:30 to about 30:70, or about 60:40 to about 40:60; or about 70:30 to about 50 : 50, and the spun yarn further contains second short fibers containing polylactic acid (PLA). In another embodiment, the first polymer includes poly(butylene terephthalate), and the weight ratio of poly(butylene terephthalate) to the second polymer is between about 90:10 and In the range of about 10:90, for example about 90:10 to about 80:20, the spun yarn further includes a second short fiber containing PLA. As used herein, "polylactic acid fiber" refers to a man-made fiber in which the fiber-forming material consists of at least 85% by weight of lactic acid ester units derived from naturally occurring sugars. The PLA may be present in an amount from about 5% to about 95% by weight, and the melt-spun staple fibers may be present in an amount from about 95% to about 5% by weight, based on the total weight of the spun yarn. For example, based on the total weight of the spun yarn, the spun yarn may contain about 5 wt. % PLA and about 95 wt. % melt-spun staple fibers, or about 10 wt. % PLA and about 90 wt. % 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 staple fibers, Or about 30 wt% PLA and about 70 wt% melt-spun staple fibers, or about 35 wt% PLA and about 65 wt% melt-spun staple fibers, or about 40 wt% PLA and about 60 wt% melt-spun staple fibers. Spun staple fibers, or about 45 wt% PLA and about 55 wt% melt-spun staple fibers, or about 50 wt% PLA and about 50 wt% melt-spun staple fibers, or about 55 wt% PLA and about 45 Weight percent melt-spun staple fibers, or about 60 weight percent PLA and about 40 weight percent melt-spun staple fibers, or about 65 weight percent PLA and about 35 weight percent melt-spun staple fibers, or about 70 weight percent PLA and about 30 wt% melt-spun staple fibers, or about 75 wt% PLA and about 25 wt% melt-spun staple fibers, or about 80 wt% PLA and about 20 wt% 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-spun staple fibers, or about 95% by weight PLA and about 5% by weight melt-spun staple fibers fiber. The relative amounts of PLA and melt-spun staple fibers are selected to provide the desired properties for the spun yarns and fabrics made from the 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 first polymer is in contact with the second polymer. The weight ratio of the polymer is in the following range: about 80:20 to about 10:90, or about 70:30 to about 30:70, or about 60:40 to about 40:60; or about 70:30 to about 50 : 50, and the spun yarn further contains a second short fiber containing nylon. In another embodiment, the first polymer includes poly(butylene terephthalate), and the weight ratio of poly(butylene terephthalate) to the second polymer is between about 90:10 and In the range of about 10:90, for example about 90:10 to about 80:20, and the spun yarn further includes a second short fiber containing nylon. As used herein, "nylon fiber" means a man-made fiber in which the fiber-forming material is a long-chain synthetic polyamide in which less than 85% of the amide linkages are directly attached to two aliphatic groups. The nylon may be present in an amount from about 5% to about 95% by weight, and the melt-spun staple fibers may be present in an amount from about 95% to about 5% by weight, based on the total weight of the spun yarn. For example, based on the total weight of the spun yarn, the spun yarn may contain about 5 wt. % nylon and about 95 wt. % melt-spun staple fibers, or about 10 wt. % nylon and about 90 wt. % 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 staple fibers, Or about 30 wt% nylon and about 70 wt% melt-spun staple fibers, or about 35 wt% nylon and about 65 wt% melt-spun staple fibers, or about 40 wt% nylon and about 60 wt% melt-spun staple fibers. Spun staple fibers, or about 45 wt% nylon and about 55 wt% melt-spun staple fibers, or about 50 wt% nylon and about 50 wt% melt-spun staple fibers, or about 55 wt% nylon and about 45 Weight percent melt-spun staple fibers, or about 60 weight percent nylon and about 40 weight percent melt-spun staple fibers, or about 65 weight percent nylon and about 35 weight percent melt-spun staple fibers, or about 70 weight percent Nylon and about 30 wt% melt-spun staple fibers, or about 75 wt% nylon and about 25 wt% melt-spun staple fibers, or about 80 wt% nylon and about 20 wt% melt-spun staple fibers, or about 85 wt% nylon and about 15 wt% melt-spun staple fibers, or about 90 wt% nylon and about 10 wt% melt-spun staple fibers, or about 95 wt% nylon and about 5 wt% melt-spun staple fiber fiber. The relative amounts of nylon and melt-spun staple fibers are selected to provide the desired properties for the spun yarns and fabrics made from the 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 first polymer is in contact with the second polymer. The weight ratio of the polymer is in the following range: about 80:20 to about 10:90, or about 70:30 to about 30:70, or about 60:40 to about 40:60; or about 70:30 to about 50 : 50, and the spun yarn further includes a second short fiber containing an olefin. In another embodiment, the first polymer includes poly(butylene terephthalate), and the weight ratio of poly(butylene terephthalate) to the second polymer is between about 90:10 and In the range of about 10:90, for example about 90:10 to about 80:20, the spun yarn further includes a second short fiber containing an olefin. As used herein, "olefin fibers" means man-made fibers other than amorphous (non-crystalline) polyolefins defined as rubber fibers in which the fiber-forming substance is composed of at least 85% by weight of ethylene, propylene or other Any long-chain synthetic polymer composed of olefin units. The olefin fibers may be present in an amount from about 5% to about 95% by weight, and the melt-spun staple fibers may be present in an amount from about 95% to about 5% by weight, based on the total weight of the spun yarn. For example, the spun yarn may contain about 5 wt. % olefin fibers and about 95 wt. % melt-spun staple fibers, or about 10 wt. % olefin fibers and about 90 wt. % melt-spun staple fibers, based on the total weight of the spun yarn. 15 wt% olefin fibers and about 85 wt% melt-spun staple fibers, or about 20 wt% olefin fibers and about 80 wt% melt-spun staple fibers, or about 25 wt% olefin fibers and about 75 wt% Melt spun staple fibers, or about 30 wt% olefin fibers and about 70 wt% melt spun staple fibers, or about 35 wt% olefin fibers and about 65 wt% melt spun staple fibers, or about 40 wt% olefins fiber 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 staple fibers, or about 55 wt. % olefin fibers and about 45 wt. % melt-spun staple fibers, or about 60 wt. % olefin fibers and about 40 wt. % melt-spun staple fibers, or about 65 wt. % olefin fibers and about 35 wt. % melt-spun staple fibers, or about 70 wt. % olefin fibers and about 30 wt. % melt-spun staple fibers, or about 75 wt. % olefin fibers and about 25 wt. % melt-spun staple fibers, or about 80 wt. of olefin fibers and about 20% by weight of melt-spun staple fibers, or about 85% by weight of olefin fibers and about 15% by weight of melt-spun staple fibers, or about 90% by weight of olefin fibers and about 10% by weight of melt-spun staple fibers fibers, or about 95% by weight olefin fibers and about 5% by weight melt-spun staple fibers. The relative amounts of olefin fibers and melt-spun staple fibers are selected to provide the desired properties for the spun yarns and fabrics made from the 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 first polymer is in contact with the second polymer. The weight ratio of the polymer is in the following range: about 80:20 to about 10:90, or about 70:30 to about 30:70, or about 60:40 to about 40:60; or about 70:30 to about 50 : 50, and the spun yarn further includes a second short fiber containing acetate. In another embodiment, the first polymer includes poly(butylene terephthalate), and the weight ratio of poly(butylene terephthalate) to the second polymer is between about 90:10 and In the range of about 10:90, for example about 90:10 to about 80:20, the spun yarn further includes a second short fiber containing acetate. As used herein, "acetate" refers to man-made fibers in which the fiber-forming material is cellulose acetate, and includes diacetate and triacetate. Diacetate is defined as cellulose acetate fibers in which greater than 74% and less than 92% of the hydroxyl groups are acetylated (degree of esterification greater than 2.22 and less than 2.76). Triacetate is defined as cellulose acetate fibers in which greater than 92% of the hydroxyl groups are acetylated (degree of esterification greater than 2.76 and less than 3.00). The acetate fibers may be present in an amount from about 5% to about 95% by weight, and the melt-spun staple fibers may be present in an amount from about 95% to about 5% by weight, based on the total weight of the spun yarn. For example, the spun yarn may contain about 5 wt. % acetate fibers and about 95 wt. % melt-spun staple fibers, or about 10 wt. % acetate fibers and about 90 wt. % melt-spun staple fibers, based on the total weight of the spun yarn. fiber, or about 15 wt% acetate fiber and about 85 wt% melt-spun staple fiber, or about 20 wt% acetate fiber and about 80 wt% melt-spun staple fiber, or about 25 wt% Acetate fiber and about 75 weight percent melt-spun staple fiber, or about 30 weight percent acetate fiber and about 70 weight percent melt-spun staple fiber, or about 35 weight percent acetate fiber and about 65 weight percent % melt-spun staple fibers, or about 40 wt% acetate fibers and about 60 wt% melt-spun staple fibers, or about 45 wt% acetate fibers and about 55 wt% melt-spun staple fibers, or About 50 wt% acetate fiber and about 50 wt% melt-spun staple fiber, or about 55 wt% acetate fiber and about 45 wt% melt-spun staple fiber, or about 60 wt% acetate fiber and about 40% by weight of melt-spun staple fibers, or about 65% by weight of acetate fiber and about 35% by weight of melt-spun staple fiber, or about 70% by weight of acetate fiber and about 30% by weight of melt-spun staple fiber. Spun staple fibers, or about 75 weight percent acetate fiber and about 25 weight percent melt-spun staple fiber, or about 80 weight percent acetate fiber and about 20 weight percent melt-spun staple fiber, or about 85 weight percent % acetate fiber and about 15 wt% melt-spun staple fiber, or about 90 wt% acetate fiber and about 10 wt% melt-spun staple fiber, or about 95 wt% acetate fiber and about 5% by weight of melt-spun staple fibers. The relative amounts of acetate fibers and melt-spun staple fibers are selected to provide the desired properties for the spun yarns and fabrics made from the 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 first polymer is in contact with the second polymer. The weight ratio of the polymer is in the following range: about 80:20 to about 10:90, or about 70:30 to about 30:70, or about 60:40 to about 40:60; or about 70:30 to about 50 : 50, and the spun yarn further includes a second short fiber, the second short fiber includes polyester, such as poly(ethylene terephthalate), poly(trimethylene terephthalate), or poly(terephthalate). butylene glycol ester). In another embodiment, the first polymer includes poly(butylene terephthalate), and the weight ratio of poly(butylene terephthalate) to the second polymer is between about 90:10 and In the range of about 10:90, such as about 90:10 to about 80:20, the spun yarn further includes a second short fiber containing polyester. The polyester may be present in an amount from about 5% to about 95% by weight, and the melt-spun staple fibers may be present in an amount from about 95% to about 5% by weight, based on the total weight of the spun yarn. For example, the spun yarn may contain about 5 wt. % polyester fiber and about 95 wt. % melt-spun staple fiber, or about 10 wt. % polyester fiber and about 90 wt. % melt-spun staple fiber, based on the total weight of the spun yarn. or about 15 wt% polyester fibers and about 85 wt% melt-spun staple fibers, or about 20 wt% polyester fibers and about 80 wt% melt-spun staple fibers, or about 25 wt% polyester fibers and about 75% by weight of melt-spun staple fibers, or about 30% by weight of polyester fibers and about 70% by weight of melt-spun staple fibers, or about 35% by weight of polyester fibers and about 65% by weight of melt-spun staple fibers, or about 40 wt% polyester fibers and about 60 wt% melt-spun staple fibers, or about 45 wt% polyester fibers and about 55 wt% melt-spun staple fibers, or about 50 wt% polyester fibers and about 50% by weight of melt-spun staple fibers, or about 55% by weight of polyester fibers and about 45% by weight of melt-spun staple fibers, or about 60% by weight of polyester fibers and about 40% by weight of melt-spun staple fibers, or about 65 wt% polyester fibers and about 35 wt% melt-spun staple fibers, or about 70 wt% polyester fibers and about 30 wt% melt-spun staple fibers, or about 75 wt% polyester fibers and about 25% by weight of melt-spun staple fibers, or about 80% by weight of polyester fibers and about 20% by weight of melt-spun staple fibers, or about 85% by weight of polyester fibers and about 15% by weight of melt-spun staple fibers, Or about 90 wt% polyester fiber and about 10 wt% melt-spun staple fiber, or about 95 wt% polyester fiber and about 5 wt% melt-spun staple fiber. The relative amounts of polyester fibers and melt-spun staple fibers are selected to provide the desired properties for the spun yarns and fabrics made from the yarns. The yarn count (Ne) of the spun yarn may be from about 4 to about 80, such as from about 10 to about 60, or from about 12 to about 40.

The melt-spun staple fibers are cut as needed into lengths for blending with secondary fibers and subsequent processing on cotton spinning or woolen spinning systems. For example, spun yarns containing melt-spun staple fibers and cotton, linen, polylactic, acrylic, nylon, olefin, acetate, polyester, or rayon fibers can typically be processed on a cotton spinning system. Spun yarns containing melt-spun staple fibers and wool, angora, mohair, or cashmere goat hair fibers can often be processed on wool spinning systems.

To form the spun yarn, melt-spun staple fibers and optionally at least one second staple fiber are first blended, such as by stack blending, a process in which fiber bundles are opened, mixed, and laid into layers. For example, in a blowroom, fiber bundles can be opened into smaller sized fiber tufts using a series of rough and then fine openers. The smaller fiber bundles are then carded to form continuous fiber strands, called slivers, in which nearly all of the fibers are oriented along the sliver axis. The slivers from the card can have very high quality/length variations, so usually multiple card slivers (i.e. 6) are combined and drafted simultaneously e.g. with a draw frame or other methods known in the art amount (i.e. 6 times) to further orient the fibers in the resulting slivers. The sliver output from the final draw frame has minimal mass/length changes but has a high linear density compared to the linear density desired in the final spun yarn, so the linear density of the sliver decreases during the drawing process. Typically, the drawing process operates in two steps, where partial drafting and twisting are performed to prepare the roving. The roving is converted into a spun yarn by further drafting on the final spinning machine using known methods such as ring spinning, open end spinning, air jet spinning, and vortex spinning. Spun yarn can be wound on small packages called packages in ring spinning; several packages can be connected and wound on a larger final package, called a package.

Woven and knitted fabrics can be made from the spun yarns disclosed herein. Examples of stretch fabrics include round, flat and warp knitted fabrics, as well as plain, twill and satin weaves. Articles such as clothing can be made from fabrics containing the spun yarns disclosed herein. Nonwoven fabrics can be made from the staple fibers disclosed herein and can be used in articles such as wipes, diapers, napkins, and personal care items. Nonwoven fabrics can also be used as base materials for coated fabrics and are used in a variety of other applications, such as apparel and home furnishings.

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

Fabrics containing spun yarns as disclosed herein may provide advantages over fabrics of the same construction composed of spun yarns of PET, cotton, rayon, PTT, or combinations thereof and lacking the melt-spun staple fibers disclosed herein. For example, compared to fabrics of PET, cotton, rayon, or combinations thereof, fabrics containing spun yarns containing melt-spun staple fibers as disclosed herein may have a softer hand (i.e., feel softer), as well as larger Bulk, as shown by greater fabric thickness. Fabrics containing the spun yarns disclosed herein may have better dyeability than fabrics of the same construction composed of PET, cotton, rayon, or combinations thereof. The fabrics disclosed herein can be dyed deeper, darker and at lower temperatures than PET fabrics of similar construction. When dyed at lower temperatures, the fabrics disclosed herein can have better dye absorption than PET fabrics, which reduces costs through energy savings. For example, when dyed simultaneously, fabrics containing the spun yarns disclosed herein can be dyed darker (i.e., have lower L* values when measured under a D65 light source) than PET fabrics, and even when dyed at 100°C and with It can also be dyed darker than PET fabric when compared to PET fabric dyed at 130°C. The properties of absorbing more dye, absorbing dye at lower temperatures, and dyeing deeper are referred to as the "better dyeability" of the fabric. The woven fabrics disclosed herein may also have improved drape, for example as evidenced by higher drape area and drape coefficient values, for example as determined by method BS 5058. Particularly desirable in fabrics is the combination of a softer hand and improved drape. Additionally, the fabrics disclosed herein exhibit less pilling (higher pilling, for example, as measured by the ASTM D4970 method) compared to fabrics of the same construction composed of PET, cotton, rayon, or combinations thereof. pilling rating), and better abrasion resistance. The fabrics disclosed herein may also have better tear strength in the warp and/or weft direction than fabrics of the same construction composed of PET, cotton, rayon, or combinations thereof. Knitted fabrics containing spun yarns as disclosed herein may have higher recovery rates than knitted fabrics of the same construction composed of polyethylene terephthalate, cotton, rayon, or combinations thereof.

Non-limiting examples of implementations disclosed herein include:

1. A spun yarn, comprising: melt-spun staple fibers, the melt-spun staple fibers comprising a first polymer containing poly(trimethylene terephthalate) (PTT) or poly(butylene terephthalate) (PBT) and a second polymer containing poly(ethylene terephthalate) (PET) or Co-PET, wherein Co-PET is poly(ethylene terephthalate) containing isophthalic acid monomers. ) copolymer; and wherein the first polymer comprises poly(trimethylene terephthalate), and the weight ratio of the poly(trimethylene terephthalate) to the second polymer is from about 80:20 to about 10 : within the range of 90; or the first polymer includes poly(butylene terephthalate), and the weight ratio of the poly(butylene terephthalate) to the second polymer is about 90 :10 to approximately 10 :90.

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

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

6. The spun yarn of embodiments 1, 3, or 5, wherein the second polymer includes Co-PET, and the Co-PET contains about 0.5 mol% to about 10 mol% based on the total polymer composition. Isophthalic acid monomer.

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

8. The spun yarn of embodiment 1, 2, 3, 4, 5, or 6, wherein the weight ratio is in the range of about 60:40 to about 40:60.

9. The spun yarn of embodiment 1, 2, 3, 4, 5, or 6, wherein the weight ratio is in the range of about 70:30 to about 50:50.

10. The spun yarn of embodiment 1, 2, 3, 4, 5, 6, or 7, wherein the poly(trimethylene terephthalate) or the poly(butylene terephthalate) and the The weight ratio of the second polymer ranges from about 70:30 to about 30:70.

11. The spun yarn of embodiments 1, 2, 3, 4, 5, 6, 7, 8, 9, or 10, wherein the spun yarn has a boiling water shrinkage of at least about 6% as determined according to ASTM D2259 Rate.

12. The spun yarn of embodiment 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, or 11, the spun yarn further comprises a second short fiber, the amount of which is based on the total weight of the spun yarn from about 5% to about 95% by weight.

13. In the spun yarn of embodiment 12, wherein the second short fiber comprises polylactic acid, acrylic acid, nylon, olefin, acetate, rayon, polyester, cotton, linen, wool, angora goat hair, mohair, Alpaca, cashmere goat wool, or mixtures thereof.

14. The spun yarn of embodiment 12, wherein the second short fibers comprise cotton or wool.

15. The spun yarn of embodiments 12, 13, or 14, wherein the second short fibers comprise cotton.

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

17. The spun yarn of embodiments 12, 13, or 14, wherein the second short fibers comprise wool.

18. The spun yarn as described in embodiment 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, or 17, wherein the worsted count of the spun yarn is 7 Nm to 120 Nm range.

19. A fabric, the fabric comprising as described in embodiment 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, or 18 Fine yarn.

20. The fabric of embodiment 19, wherein the fabric has softer properties than a fabric having the same fabric construction composed of rayon, polyethylene terephthalate, ester, cotton, or a combination thereof. feel and better drape.

21. The fabric of embodiment 19 or 20, wherein the fabric has a better fabric construction than a fabric of the same fabric construction composed of polyethylene terephthalate, cotton, rayon, or a combination thereof. Good dyeability.

22. The fabric of embodiments 19, 20, or 21, wherein the fabric has the same fabric construction as compared to a fabric composed of polyethylene terephthalate, cotton, rayon, or a combination thereof. The fabric has better abrasion resistance as measured according to ASTM D4966 standard test method.

23. The fabric of embodiments 19, 20, 21, or 22, wherein compared with a fabric having the same fabric construction composed of polyethylene terephthalate, cotton, rayon, or a combination thereof , the fabric has less pilling (higher pilling rating value) as measured according to ASTM D4970 standard test method.

24. The fabric of embodiment 19, 20, 21, 22, or 23, wherein the fabric has the same fabric structure as a fabric composed of polyethylene terephthalate, cotton, rayon, or a combination thereof In comparison, the fabric has greater loft as determined according to ASTM D1777 standard test method.

25. The fabric of embodiments 19, 20, or 21, wherein the fabric has the same fabric construction as compared to a fabric composed of polyethylene terephthalate, cotton, rayon, or a combination thereof. The fabric has at least one of the following: i) Better abrasion resistance as determined according to ASTM D4966 standard test method; ii) A higher pilling rating as determined according to ASTM D4970 standard test method; or iii) Greater loft as determined according to ASTM D1777 standard test method.

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

27. The fabric of embodiment 26, wherein the warp yarns comprise the fabric of embodiments 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, or the spun yarn described in 18.

28. The fabric of embodiment 26 or 27, wherein the weft yarns comprise the fabric of embodiments 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, The spun yarn described in 16, 17, or 18.

29. The fabric of embodiments 26, 27, or 28, wherein both the warp yarns and the weft yarns each comprise the fabric of embodiments 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, The spun yarn described in 12, 13, 14, 15, 16, 17, or 18.

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

31. The fabric of embodiment 30, wherein compared with a knitted fabric having the same fabric construction composed of polyethylene terephthalate, cotton, rayon, or a combination thereof, the knitted fabric has the following properties: Higher recovery rate as determined according to method BS 4294.

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

33. The article of embodiment 32, wherein the article is clothing.

34. A melt-spun staple fiber comprising a first polymer containing poly(trimethylene terephthalate) or poly(butylene terephthalate) and a polymer containing poly(ethylene terephthalate) glycol ester) or a second polymer of Co-PET, wherein Co-PET is a poly(ethylene terephthalate) copolymer containing isophthalic acid monomer, and the short fiber has: a) A weight ratio of poly(trimethylene terephthalate) to the second polymer in the range of about 80:20 to about 10:90. or a weight ratio of poly(butylene terephthalate) to the second polymer in the range of about 90:10 to about 10:90; and b) A dry heat shrinkage rate of less than 6% as measured by the dry heat shrinkage method.

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

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

37. The melt-spun staple fiber of embodiments 34, 35, or 36, wherein the first polymer includes poly(trimethylene terephthalate), and the second polymer includes poly(ethylene terephthalate). glycol ester).

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

39. The melt-spun staple fiber of embodiments 34, 35, or 36, wherein the first polymer comprises poly(butylene terephthalate), and the second polymer comprises poly(terephthalate). Ethylene glycol formate).

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

41. The melt-spun staple fiber of embodiment 34, 35, 36, 38, or 40, wherein the second polymer includes Co-PET, and the Co-PET contains about 0.5 mol based on the total polymer composition. % to about 10 mol% of isophthalic acid monomer. Example

As used herein, "Comp.Ex." means comparative example; "Ex." means example; "rpm" means revolutions per minute; "wt%" means weight percent; "dL/g" means Deciliter/gram; "g" means grams; "mg" means milligrams; "°C" means degrees Celsius; "min" means minutes; "h" means hours; "s" means seconds; "lb" means pounds; ""kg" means kilograms; "mm" means millimeters; "m" means meters; "gpl" means grams/liter; "m/min" means meters/minute; "mol" means moles; "kg" means kilograms; "ppm" ” means parts per million; “Hz” means hertz; “cN” means centinewtons; “rpm” means revolutions per minute; “wt” means weight; “dpf” means denier/filament; “g/d” In grams per denier; "Ne" represents cotton yarn count (English) and is a measure of linear density, defined as the number of skeins (850 yards or 770 meters) of skein material weighing 1 pound (0.45 kg); "Nm" Represents the metric count and refers to the number of 1000-meter units in one 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; and “BS” means the British Standards Institution. Material

Unless otherwise noted, all materials are used as is.

Polytrimethylene terephthalate (PTT) containing 0.3% _TiO2 and having an intrinsic viscosity of 0.96 dL/g was obtained as Merged K2266 from DuPont, Wilmington, DE.

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 from South Carolina, USA. Nan Ya Plastics Corporation, America, P.O. Box 939, Lake City, S.C 29560, USA. Co-PET composition was determined by NMR analysis and is given based on the total polymer composition. Co-PET has an intrinsic viscosity of approximately 0.80 dL/g.

Fiber-grade post-consumer recycled Co-PET containing 1.1 mol% IPA monomer, 49.1 mol% TPA monomer and 49.9 mol% EG monomer from William Barnet & Sons, Spartanburg, South Carolina, USA & Son, LLC, POBox 171898, Spartanburg, SC29301, USA). Co-PET composition was determined by NMR analysis and is given based on the total polymer composition. Co-PET has an intrinsic viscosity of approximately 0.76 dL/g. method

"Co-PET" composition was determined by NMR analysis using the following procedure. Freeze the Co-PET pellets into powder form, then weigh approximately 18 mg into an NMR tube and add 5:1 _CDCl :TFA-D (5:1 deuterated chloroform/deuterated trifluoroacetic acid) solution was added to a total volume of 0.6 mL. Vortex the sample to dissolve the Co-PET. Proton NMR spectra were obtained within 30 minutes of dissolution.

Proton NMR spectra were acquired 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: loop delay 30 seconds, acquisition time 4 seconds, 90 degree pulse 8.0 seconds, spectral window 10000 Hz, 79998 points, acquisition and average of a total of 64 sweeps/transients. The spectrum was referenced to the chloroform-d residual proton signal at 7.24 ppm and processed with lb at 0.10 Hz and zero-filled to 512 k.

The Co-PET composition was calculated from the integration of the signals at approximately 8.7 ppm, 8.1 ppm, and 4.8 ppm corresponding to isophthalic acid, terephthalic acid, and ethylene glycol between the terephthalic acid groups. The isophthalic acid signal used represents 1 mole of protons, so its integration is already relative. The terephthalic acid integral represents 4 moles of terephthalic acid protons and includes 2 moles of isophthalic acid protons; determined by subtracting 2 times the relative integral of isophthalic acid and dividing the remainder by 4 Terephthalic acid relative integral. The integral relative to ethylene glycol corresponds to 4 moles of ethylene glycol protons, and the relative integral is determined by dividing the measured integral by 4. The three relative integrals are totaled, and the relative mol% value is calculated as each corresponding relative integral divided by the total and then multiplied by 100%.

The dry heat shrinkage of undrawn melt-spun fibers was determined using the following procedure, referred to herein as the dry heat shrinkage method. Prepare a 10-ring skein with a diameter of 50 cm and measure its length under a weight of 20 g. Two such rings were allowed to shrink by exposure to 40°C for 20 hours under zero applied tension. The ring was cooled to 21°C at 65% relative humidity, after which the length at 20 g weight was remeasured. Dry heat shrinkage (as a percentage) is calculated as follows: For melt-spun staple fibers, the following methods are used to determine fiber properties using the automated single fiber testing system FAVIMAT+. Denier is measured according to ASTM D1577, Standard Test Method for Linear Density of Textile Fibers. Tenacity and elongation at break were determined according to ASTM D3822 Tensile Properties of Single Textile Fibers.

The crimp characteristics of short fibers are characterized by shrinkage rate, crimp stability and crimp recovery rate. Shrinkage is the length difference between crimped fibers and de-crimped fibers. Measuring the curling length L0 under a low load of 0.001 cN/dtex and the decurling length L1 under a heavy load of 0.1 cN/dtex, the shrinkage rate can be calculated as [(L1-L0)/L1]*100.

Curl stability is a measure of the stability of the curl under a specific load. This can be measured by determining the recovery of short fiber length when the load is removed. Since L2 is the length of the short fiber (measured at 0.001 cN/dtex) 60 seconds after applying a heavier load of 0.1 cN/dtex for 10 seconds (to determine L1), the curl stability can be calculated as [(L1-L2/ (L1-L0)]*100.

The crimp recovery rate is the difference between the length L1 of the decurled fiber and the fiber length L2 after the curl removal force is released, expressed as the percentage of the decurled fiber: [(L1-L2)/L1]*100. Melt Spun Fiber Examples Comparative Example A Melt Spun PTT Fiber

Polytrimethylene terephthalate (PTT) containing 0.3% _TiO2 and having an intrinsic viscosity of 0.96 dL/g was dried in nitrogen in a vacuum oven at 120 °C for 16 h and spun using twin-screw extrusion The machine melts and extrudes 34-filament yarn bundles into circular cross-sections. The temperature of the melting zone of the extruder is maintained at 180°C-255°C. The polymer delivery rate was 14.06 g/min with a winding speed of 1250 m/m, resulting in a spinning denier/filament of 2.9.

The dry 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% _TiO2 and having an intrinsic viscosity of 0.96 dL/g was compared with polyethylene terephthalate (Co-PET) having an intrinsic viscosity of 0.80 dL/g (from South Asia Plastics Company) are melt-blended in a twin-screw extruder at a 50/50 weight ratio to form compounded pellets. The extruder throughput was 150 lb/h (68.04 kg/h, 0.0189 kg/s) and the melt temperature at the extruder exit was below 285°C, as measured by a handheld thermocouple.

The PTT:Co-PET compound pellets were dried in a vacuum oven under nitrogen cover at 120°C for 16 h and melt-extruded into 34-filament yarns of circular cross-section using a twin-screw extrusion spinning machine. bundle. The temperature of the melting zone of the extruder is maintained at 180°C-255°C. The polymer delivery rate is 14.06 g/min or 21.52 g/min. For each delivery amount, the winding speed was 750 m/m or 1250 m/m, resulting in a spinning denier/filament in the range of 3.3 to 7.7. The measured dry heat shrinkage of yarn bundles (tows) ranged from 1.2% to 3.1%. This amount of dry heat shrinkage in 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 dry heat shrinkage of tow Example 2 Undrawn melt-spun fibers containing PTT and Co-PET

Polytrimethylene terephthalate containing 0.3% _TiO2 and having an intrinsic viscosity of 0.96 dL/g was compared with fiber grade consumer products containing 1.1 mol% IPA monomer, 49.1 mol% TPA monomer, and 49.9 mol% EG monomer. Post-recycled Co-PET was melt-blended in a twin-screw extruder at a 50/50 weight ratio to form compounded pellets. Co-PET has an intrinsic viscosity of approximately 0.76 dL/g. The extruder throughput was 150 lb/h (0.0189 kg/s) and the melt temperature at the extruder exit was below 285°C, as measured by a handheld thermocouple.

The PTT:Co-PET compound pellets were dried in a vacuum oven under nitrogen cover at 120°C for 16 h and melt-extruded into 34-filament yarns of circular cross-section using a twin-screw extrusion spinning machine. bundle. The temperature of the melting zone of the extruder is maintained at 180°C-255°C. The polymer delivery rate is 14.06 g/min or 21.52 g/min. For each delivery amount, the winding speed was 750 m/m or 1250 m/m, resulting in spinning denier/filament between 3.3 and 7.7. The dry heat shrinkage of the yarn bundles was measured in the range of 1.2% to 2.5%. This amount of dry heat shrinkage in 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 dry heat shrinkage of tow Example 3 Melt-spun staple fibers containing PTT and Co-PET

Polytrimethylene terephthalate containing 0.3% _TiO2 and having an intrinsic viscosity of 0.96 dL/g was melt blended with Co-PET (from Nan Ya Plastics Company) in a 50/50 weight ratio in a twin-screw extruder , to form compounded pellets. The extruder throughput was 150 lb/h (0.0189 kg/s) and the melt temperature at the extruder exit was below 285°C, as measured by a handheld thermocouple. The compounded materials were maintained at 145°C for 20 hours.

6800 filaments of circular cross-section were spun using a single extrusion spinning machine with radial quenching. The temperature of the melting zone of the extruder is maintained at 252°C-274°C. The polymer delivery rate is 0.379 g/min/hole and the feed roller speed is 1100 m/m. The spinning dpf is 3.0. The spun fibers are collected in cans. Twenty-two cans, totaling 448,800 denier, feed the draw-crimp-cut/bale module. Melt-spun staple fibers are produced using a typical cotton yarn count staple fiber process utilizing multiple stages of drawing, crimping, annealing, and cutting. The tows were immersed in a finish bath (0.5% concentration, commercially available from Seilacher, Schill+Seilacher) at 22°C. The tows were first drawn at 80°C in a 0.5% concentration finish bath between a 22°C feed roll operating at 36 m/m and a heated draw roll operating at 75°C at 110.88 m/m. Stretching was carried out during the period to obtain a first-stage stretching ratio of 3.08. The drawn tow was pulled through a steam cabinet at 100°C by a downstream heated roll operating at 165°C and 110.88 m/m. The tow is passed through another set of rollers heated at 165°C and operating at 99.8 m/m. Finish was sprayed (6% concentration) and the tow was passed through a chilled drum roll running at 99.8 m/m at 25°C. The tow enters the steam box at 100°C and then enters the 50 mm crimping machine. The curling speed is 100 m/m. The temperature and pressure of the crimping roller are 65°C and 0.8 bar respectively. The crimped tow is annealed in a belt dryer at 100°C for 8 minutes and finally the crimped tow is cut to produce melt-spun staple fibers with the following properties: Denier/filament (dpf) = 1.2, variation Coefficient (CV) = 8.79% Tenacity = 4.89 g/d, CV = 8.79% Elongation = 45.97%, CV = 19.59% Short fiber length = 37-38 mm Number of crimps (full sine 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% _TiO2 and having an intrinsic viscosity of 0.96 dL/g was melt blended with Co-PET (from Nan Ya Plastics Company) in a 50/50 weight ratio in a twin-screw extruder , to form compounded pellets. The extruder throughput was 150 lb/h (0.0189 kg/s) and the melt temperature at the extruder exit was below 285°C, as measured by a handheld thermocouple. The compounded materials were maintained at 145°C for 20 hours.

6800 filaments of circular cross-section were spun using a single extrusion spinning machine with radial quenching. The temperature of the melting zone of the extruder is maintained at 252°C-274°C. The polymer delivery rate is 0.493 g/min/hole, and the feed roller speed is 600 m/m. The spinning dpf is 7.2. The spun fibers are collected in cans. Ten cans, totaling 489,600 denier, feed the draw-crimp-cut/bale module. Melt-spun staple fibers are produced using a typical wool count staple fiber process utilizing multiple stages of drawing, crimping, annealing, and cutting. The tows were immersed in a finish bath (0.5% concentration, commercially available from Seilacher, Schill+Seilacher) at 22°C. The tows were first drawn at 80°C in a 0.5% concentration finish bath between a 22°C feed roll operating at 30 m/m and a heated draw roll operating at 75°C at 109.3 m/m. Stretching was carried out during the period to obtain a first-stage stretching ratio of 3.64. The tow was drawn through a downstream heated roller operating at 165°C and 103.9 m/m. Finish was sprayed (6% concentration) and the tow was passed through a chilled roller running at 101.9 m/m at 25°C. The tow enters the steam box at 100°C and then enters the 50 mm crimping machine. The curling speed is 110.6 m/m. The temperature and pressure of the crimping roller are 65°C and 1.3 bar respectively. The crimped tow was annealed in a belt dryer at 100°C for 8 minutes, and finally the crimped tow was cut to produce short fibers with the following properties: dpf = 2.5, CV = 6.98% Tenacity = 3.83 g/ d, CV = 8.74% Elongation = 69.72%, CV = 25.26% Short fiber length = 82-125 mm, average multi-cut length 84 mm Number of crimps (full sine arc) = 14/inch Crimp stability = 91.19% , CV = 8.31% finishing agent on yarn = 0.21% commercially available spun yarn

Table 3 lists commercially available spun yarns and their abbreviations used in the table below. Some of these yarns were used to prepare the fabric of the comparative example. [Table 3]. Abbreviations of commercially available spun yarns. Examples of spun yarns produced on cotton spinning systems

The melt-spun staple fibers of Example 3 were used to prepare the spun yarns of Examples 5-10. Spun yarns and intermediate materials such as slivers obtained in the preparation of spun yarns are evaluated using the following methods: The toughness is measured at 5 m/min using a CRE type tensile testing equipment (such as a Uster Tensorapid-3) with a slot speed of 5 m/min and a sample length of 50 cm.

Elongation at Break % - Measured using a CRE type tensile testing equipment (such as USTER Rapid Tensometer-3) at a slot speed of 5 m/min and a sample length of 50 cm. Example 5 20s Ne yarn containing 100% melt spun fibers

Spun yarn is manufactured using cotton spinning system according to the following process.

The melt-spun staple fibers of Example 3 were removed from the bale and mixed manually. The average staple length is 40 mm and the denier is 1.2 D. The fibers are mixed and laid into layers in a stack mixing process and then acclimated for 24 hours at 65% relative humidity and 25°C. The fibrous material is removed from the stack by vertically withdrawing the material and feeding it to a blowroom line typically used for spinning synthetic fibers. During the process, the size of the fiber tufts is reduced from about 150 mg to about 30 mg. Use the following parameters: • Feed roller and agitator blade setting = 1.7 mm • Cotton roll linear density is about 400 g/m • All waste collection settings turned off to ‘0’ • Coarse fiberizer mixer speed = 400 rpm • Fine fiberizing mixer speed = 450 rpm

Next, the 30 mg fiber bundles were carded into individual fibers and arranged into continuous fiber strands (strips), with the fibers oriented along the length of the sliver. Use the following parameters: • Machine Type, Model: Carding Machine, L R C 1/3 • M/c production speed = 70m/min • Feed plate and licker-in size = 32 thou (thousandths of an inch) • Cover size = 14,14,14,12,12 thou • Horn size = 4.0 mm or larger • Yarn linear density = 4.5 g/m • Licker-in speed = 650 rpm • Cylinder speed = 350 rpm • Cover speed = 6 inches/minute • Final yarn linear density = 5.0 g/m

In the draw frame, the six carded slivers are twisted together and drafted simultaneously by the same amount (6 times) to further orient the fibers in the resulting slivers. The first step is called breaking stretching, and the second step is called finishing stretching. Use the following parameters: • Machine type and model: Draw frame, L R RSB 851 • Bottom roller specifications front/rear = 44/48 mm • Horn diameter = 3.8 mm • Yarn linear density = 4.5 g/m • Top rubber roller hardness = 83° degree • Breaking draft in breaking draw = 1.4, in finishing draw frame = 1.4 • Web tension draft = 1 • Creel Tension Draft = 1.02 • Output speed in I draw frame = 250 MPM, in II draw frame = 350 MPM • Twisting in both I draw frame and II draw frame = 6 times • Final yarn linear density = 5.00 g/m • Unevenness % in finishing sliver = 1.88

Next, rovings are prepared on a sanding machine from the sliver output from the final draw frame. Partial twisting is also provided in the roving machine to impart strength to the roving. Use the following parameters: • Machine type and model: Grit sand mill, LF 4200 • Spacer size = 5.5 mm • Spindle speed = 1000 rpm • Twist factor = 0.70 • Coarse grit number = 0.75s Ne • Roller size = 48/55/62 mm • Bracket = 36 mm

The Uster value (unevenness) of the roving was found to be 3.16%, and the Uster % (unevenness %) was 3.26.

The roving is further drafted on a ring spinning machine to produce a spun yarn with a yarn count of 20s Ne. Use the following parameters: • Machine type and model = ring spinning machine, LR G 5/1 • Roller size = 42.5/65 mm • Saddle size = 51/66 mm • Rubber roller hardness (front/rear F/B) = 68/83° • Draft at break = 1.22 • Twist factor/twist per inch = 3.6/16.09 • Traveler size: 1/0 M1HO • Spindle speed: 15500 rpm

The spun yarn is wound on small packages called zongzi on the ring spinning machine, each weighing about 50 g. Multiple cops (cops) are joined and any yarn defects removed, and finally wound into cops on a winding machine using the following parameters: • Speed =1000 m/min • Yarn tension = 5%-6% of yarn breaking load • Package hardness - min. • Cup weight = 1.0 kg or more

The tensile properties and unevenness % of the final spun yarn were evaluated on Uster Rapid Tensionometer-3 and Uster Unevenness Tester-3. The results are shown in Table 4.

The yarn wound in the final machine is crimped and may become tangled due to the twist produced during spinning. Since entanglement can lead to yarn breakage during fabric manufacturing, the yarn was structurally stabilized by conditioning the cups in an autoclave at a maximum temperature of 70°C for 50 minutes. Example 6 40s Ne spun yarn containing 100% melt spun fibers

According to the process of Example 5, the melt-spun short fiber of Example 3 was used to prepare spun yarn, with the following differences: The final yarn linear density is 4.75 g/m and the unevenness % is 1.75

Rovings were prepared as in Example 5, except that the number of roving skeins was 1.2 s Ne.

In the step of drafting the roving, the twist factor/twist per inch was 3.6/22.6, the traveler size was 4/0 M1HO, and the spindle speed was 16,500 rpm.

The spun yarn is wound onto the cup at 1500 m/min.

The properties of the spun yarns are given in Table 4. Example 7 20s Ne spun yarn containing 40/60 melt spun fiber / cotton (wt / wt)

Spun yarn was prepared using the melt-spun staple fibers of Example 3 and cotton (Shankar 6 variety Indian cotton obtained from northern India, such as Punjab and Haryana). The average length of cotton staple fibers measured using the airflow method was 31 mm, and the fineness (linear fiber density) was 4.1 micrograms/inch. Spun yarn was made according to the procedure of Example 5, with the following differences: In the manual mixing step, two layers of cotton slivers, taken from the 100% cotton yarn spinning process after the comber and broken into small tufts of size 25-30 mg, are laid on top of a layer of melt-spun short fibers.

The linear density of the final sliver from the carding step is 4.7 g/m.

The roving was prepared as in Example 5, except that the twist factor was 0.85 and the number of roving skeins was 0.7 s Ne.

The roving was further drafted as in Example 5, except that the twist per inch was 16.99.

The properties of the spun yarns are given in Table 4. Example 8 40s Ne spun yarn containing 40/60 melt spun fiber / cotton (wt / wt)

Spun yarn was prepared using the melt-spun staple fibers of Example 3 and cotton (Shankar 6 variety Indian cotton commercially available from North India). The average length of cotton staple fibers is 31 mm and the linear density is 4.1 micrograms/inch. Spun yarn was made according to the procedure of Example 5, with the following differences: In the manual mixing step, two layers of cotton slivers, taken from the 100% cotton yarn spinning process after the comber and broken into small tufts of size 25-30 mg, are laid on top of a layer of melt-spun short fibers.

The linear density of the final sliver from the carding step is 4.7 g/m.

After stretching, the final yarn linear density is 4.75 g/m.

The roving was prepared as in Example 5, except that the twist factor was 0.85 and the number of roving skeins was 1.2 s Ne.

The roving was further drafted as in Example 5, except that the twist per inch was 24.02, the traveler size was 4/0 M1HO, and the spindle speed was 16500 rpm.

The spun yarn is wound onto the cup at 1500 m/min.

The properties of the spun yarns are given in Table 4. Example 9 20s Ne spun yarn containing 40/60 melt spun fiber / Tencel

Spun yarns were prepared using the melt-spun staple fibers of Example 3 and commercially available Tencel® staple fibers (Lenzing). Tencel® staple fibers have an average length of 40 mm and a denier of 1.2 D. Spun yarn was made according to the procedure of Example 5, with the following differences: In a manual mixing step, two layers of Tencel® fibers (broken into small tufts of 25-30 mg in size) are laid on top of a layer of melt-spun staple fibers.

The linear density of the final sliver from the carding step is 4.7 g/m.

The roving was prepared as in Example 5 except that the twist factor was 0.85.

The roving was further drafted as in Example 5, except that the twist per inch was 16.99.

The properties of the spun yarns are given in Table 4. Example 10 40s Ne spun yarn containing 40/60 melt spun fiber / Tencel

Spun yarns were prepared using the melt-spun staple fibers of Example 3 and commercially available Tencel® staple fibers (Lensing). Tencel® staple fibers have an average length of 40 mm and a denier of 1.2 D. Spun yarn was made according to the procedure of Example 5, with the following differences: In a manual mixing step, two layers of Tencel® fibers (broken into small tufts of 25-30 mg in size) are laid on top of a layer of melt-spun staple fibers.

The linear density of the final sliver from the carding step is 4.7 g/m.

After stretching, the final yarn linear density is 4.75 g/m.

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

The spun yarn is wound onto the cup at 1500 m/min. The properties of the spun yarns are given in Table 4. [Table 4]. Characteristics of spun yarns of Examples 5 to 10 and commercially available comparative spun yarns

Notes: ¹ For abbreviations of commercially available spun yarns, see Table 3 ² At a speed of 5 m/min

The results in Table 4 show that spun yarns containing 100% melt-spun staple fibers alone or in combination with cotton or Tencel® have sufficient tenacity and elongation at break for use in weaving or knitting processes.

Spun yarns (Examples 5 and 6) consisting solely of the melt-spun staple fibers of Example 3, poly(ethylene terephthalate) staple fibers, or poly(trimethylene terephthalate) staple fibers were tested in accordance with ASTM D2259 Boiling water shrinkage test method. The length of the yarn skein (with indicated net weight) is measured before and after immersion in boiling water (100°C, autoclave 30 min, MLR 1 : 40, where "MLR" means material to liquor ratio), and the skein The difference in length divided by the skein length before boiling water is reported as % shrinkage in Table 5. PET spun yarn and PTT spun yarn were commercially available. [Table 5]. Boiling water shrinkage of spun yarn

* Abbreviations are defined in Table 3.

The highest boiling water shrinkage % was observed for the spun yarn of Example 6 containing only melt-spun staple fibers, the lowest boiling water shrinkage was observed for the spun yarn containing PET, and a moderate % shrinkage value was observed for the spun yarn containing PTT . This provides greater finished fabric loft, which is desirable for fabrics based on melt-spun staple fibers. Examples of woven fabrics

Use the following methods to evaluate fabrics: Fabric weight (blank and finished product) - ASTM D3776 Standard test method for mass (weight) of fabrics per unit area Dimensional stability (stability in both warp and weft directions after 3 launderings) - AATCC 135 Dimensional changes in fabrics after home laundering Wicking - AATCC 197 Wicking Height of Textiles Tear Strength (Tear Strength in Both Warp and Fill Directions) - ASTM D1424 Standard Test Method for Tear Strength of Fabrics by Drop Weight (Elmendorf Type) Apparatus Thickness - ASTM D1777 Standard Test Method for Thickness of Textile Materials Pilling Rating (1000 rounds) - ASTM D4970 Standard Test Method for Pilling Resistance and Other Related Surface Changes in Textiles: Martindale Tester Abrasion (5000 cycles) - ASTM D4966 Standard Test Method for Abrasion Resistance of Textile Fabrics (Martindale Abrasion Test Method) Drape - BS 5058 Method for assessing the drape of fabrics Color Fastness to Rubbing - AATCC 8 Color Fastness to Rubbing Color Fastness to Washing - AATCC 61-2A (49°C, 45 min, 1.5 gpl) Bursting Strength (Circular Knit Fabrics) - ASTM D3786 Standard Test Method for Bursting Strength of Textile Fabrics Stretch and recovery (circular knitted fabrics) - BS 4294 (5 kg) Test method for stretch and recovery properties of fabrics

Shrinkage % (in fabric, blank to finished product) is determined as follows. The blank fabric is permanently marked to indicate the 30 cm thread in the length of the fabric (warp) and the 30 cm thread in the width of the fabric (fill). The fabric is then dyed and finished, and the length of the permanent marker line is remeasured. For each of the length (warp) and width (fill) directions, calculate percent shrinkage by dividing the difference in thread length before and after dyeing and finishing by 30 and multiplying by 100. This method is referred to herein as the shrinkage percentage method.

Softness Assessment (also known as Subjective Hand Value) - Subjective Hand Value Assessment is tested by the field at the South India Textile Research Association (SITRA), Coimbatore, India. 12 experts evaluate the fabric's feel to finish. This is a method widely used in the textile industry to evaluate the softness of fabrics. Fabrics are coded as A and B, and fabric ratings are independently evaluated based on the perception of fabric softness. Each expert rated softer fabrics a '1' and less soft fabrics a '2'. This was done for 100% PET fabrics and the fabrics of Examples 11 and 14. The final rating is completed by averaging 12 readings. Fabrics with lower rating averages receive a final rating of 1 (softer), while fabrics with higher rating averages receive a rating of 2.

As shown in Table 6, the spun yarns of Examples 5 to 10 were used to produce woven fabrics. Fabrication of woven twill (3/1) bottom fabric and plain woven (1/1) shirting fabric using the spun yarns disclosed herein as warp and weft (fill); fabrication comparison using commercially available spun yarns in warp and weft Fabric. For every woven fabric, the same yarns are used in both the warp and weft. Fabric evaluation results are presented in Tables 7 and 8. Unless otherwise stated, results reported are for finished fabrics. Example 11

A bottom weave twill fabric was prepared using the spun yarns of Example 5 as warp and weft yarns. The warp yarns were sized prior to doubling with a CCI single-end sizing machine using Elvanol-T25 PVA sizing agent. Using a 350 m/min warper, a final beam was prepared with 2150 warp yarns, a width of 18 inches, and a warp length of 3.5 meters. Use the following reeding plan: Stretch: 4 axes Stretch Type (Linear Stretch (1, 2, 3, and 4) Reeding: 2 warp threads/reed teeth Reed count: 75 teeth/2 inches The 3/1 LHT twill fabric was woven on a CCI sample loom at a loom speed of 40 picks/minute. The weft value is set to 63 picks/inch. A blank fabric of 2 m length and 49.5 cm width was obtained.

The blank fabric was desized on the RBE laboratory jigger as follows. Load the fabric sample into the jigger with water (2 L), NaOH (2 gpl), and wetting agent; add Levocol CESR (wetting agent) (5 gpl) and increase the bath temperature to 90° C. Leave the fabric in the bath for 60 minutes, then drain the bath, refill it with fresh water, and increase the bath temperature to 85°C. Wash the fabric in hot water for 15 minutes and drain the bath. Fill the bath with water again and leave the fabric in it for 15 minutes (wash in cold water). The bath was drained, filled with water and neutralized by adding acetic acid (1 gpl); the fabric was left in the bath for 15 minutes. After this, drain the bath, refill it with fresh water and leave the fabric in a cold water bath for 15 minutes. The fabric is then removed from the jigger and dried under atmospheric conditions before being heat set in an RBE tenter at 160°C for 45 seconds.

The fabric is then dyed with a mixture of disperse dyes using the following time and temperature profile: heat to 70°C and hold for 10 minutes, then increase the temperature at 1.5°C/min to 130°C and hold for 30 minutes, then increase the temperature to 1.5°C/min to 70°C and drain. After dyeing, the fabric was reduced and washed with Hydros and NaOH (2 gpl each) at 90°C for 20 minutes. The fabric was then washed in cold water for 10 minutes, contacted with acetic acid (2 gpl) for 15 minutes, and then washed in cold water for 10 minutes. Pad-dyed fabrics are pad-dyed with a finish (softener) and then heat set in an RBE laboratory tenter at 160°C for 45 seconds.

Fabric construction is shown in Table 6. Wicking test result is 100%. The fabric of Example 11 was found to have a softer hand (i.e., better softness) compared to the fabric of Comparative Example B. Other fabric properties are presented in Tables 7 and 8. Comparative example B

Using commercially available 20s Ne 100% PET short fiber spun yarn ("P1") as warp and weft yarns, a comparative bottom woven 3/1 LHT twill fabric was made following the process of Example 11, except that the reed plan was used 4 warps/teeth and reed count is 50 dents/2 inches. The blank fabric was dyed, finished, and heat set as in Example 11.

Fabric construction is shown in Table 6. Wicking test result is 100%. Other fabric properties are presented in Tables 7 and 8. Example 12

A bottom woven twill fabric was prepared according to the procedure of Example 11, using the spun yarns of Example 7 as warp and weft yarns, but with the following differences. The blank fabric is desized and bleached in a jigger, heat set in a tenter and then dyed with a mixture of disperse dyes and then additionally with reactive dyes under cotton dyeing conditions.

Fabric construction is shown in Table 6. Wicking test result is 100%. Other fabric properties are presented in Tables 7 and 8. Comparative example C

A comparative bottom weave 3/1 LHT twill fabric was made as in Example 12, except that commercially available 20s Ne 40/60 PET/cotton staple spun yarn ("PC1") was used as the warp and weft yarns.

Fabric construction is shown in Table 6. Wicking test result is 100%. Other fabric properties are presented in Tables 7 and 8. Example 13

A bottom weave twill fabric was prepared according to the procedure of Example 12 using the spun yarns of Example 9 as warp and weft yarns, except that no peroxide killer was used at the end of the bleaching step.

Fabric construction is shown in Table 6. Wicking test result is 100%. Other fabric properties are presented in Tables 7 and 8. Comparative example D

A comparative bottom woven 3/1 LHT twill fabric was fabricated according to the procedure of Example 12, except that commercially available 20s Ne 40/60 PET/Tencel® staple yarn (“PT1”) was used as the warp and weft yarns. The blank fabric was dyed, finished, and heat set as in Example 12, except that the second dyeing step using reactive dyes was done under Tencel® dyeing conditions.

Fabric construction is shown in Table 6. Wicking test result is 100%. Other fabric properties are presented in Tables 7 and 8. Example 14

A plain woven shirting fabric was prepared using the spun yarns of Example 6 as warp and weft yarns. The process was as described in Example 11, with the following exceptions: After warping, the warp beam contained 1680 warp yarns and the reed count was 84 teeth/2 inches.

Fabric construction is shown in Table 6. Wicking test result is 100%. The fabric of Example 14 was found to have a better (softer) hand compared to the fabric of Comparative Example E. Other fabric properties are presented in Tables 7 and 8. Comparative example E

A comparative plain woven shirting fabric was made according to the process of Example 11 except that commercially available 40s Ne 100% PET short fiber spun yarn ("P2") was used as the warp and weft yarns. After warping, the warp beam contained 1680 warp yarns and the reed count was 84 teeth/2 inches. A blank fabric of 2 m length and 47.7 cm was obtained.

Fabric construction is shown in Table 6. Wicking test result is 100%. Other fabric properties are presented in Tables 7 and 8. Example 15

A plain woven shirting fabric was prepared using the spun yarns of Example 8 as warp and weft yarns. The procedure was as described in Example 12 except that no peroxide killer was used at the end of the bleaching step.

Fabric construction is shown in Table 6. Wicking test result is 100%. Other fabric properties are presented in Tables 7 and 8. Comparative example F

A comparative plain woven shirting fabric was made according to the process of Example 11, except that commercially available 40s Ne 40/60 PET/cotton short fiber spun yarn ("PC2") was used as the warp and weft yarns and in the process had the following Additional differences: After warping, the warp beam contains 1748 warp yarns and the reed count is 92 teeth/2 inches. A blank fabric 2 m long and 48.7 cm wide was obtained and dyed as described in Example 12.

Fabric construction is shown in Table 6. Wicking test result is 100%. Other fabric properties are presented in Tables 7 and 8. Example 16

A plain woven shirting fabric was prepared using the spun yarns of Example 10 as warp and weft yarns. The process is as described in Example Wfab-1, except that after warping, the warp beam contains 1748 warp yarns, the reed count is 92 teeth/2 inches, and the weft value is set to 62 picks/inch. A blank fabric 2 m long and 48.7 cm wide was obtained and dyed as described in Example 12.

Fabric construction is shown in Table 6. Wicking test result is 100%. Other fabric properties are presented in Tables 7 and 8. Comparative example G

A comparative shirt fabric was made according to the process of Example 11, except that commercially available 40s Ne 40/60 PET/Tencel® staple yarn ("PT2") was used as the warp and weft yarns and had the following additional features in the process Difference: After warping, the warp beam contains 1748 warp threads, the reed count is 92 teeth/2 inches, and the weft value is set to 62 picks/inch. A blank fabric 2 m long and 48.7 cm wide was obtained and dyed as described in Example 12.

Fabric construction is shown in Table 6. Wicking test result is 100%. Other fabric properties are presented in Tables 7 and 8. [Table 6]. Woven fabric structure [Table 7]. Woven fabric evaluation results (upper half) [Table 8]. Woven fabric evaluation results (lower half)

The results in the foregoing table indicate that fabrics containing the spun yarns disclosed herein provide a number of advantages over the fabrics of the comparative examples. Woven fabrics containing the spun yarns disclosed herein can have greater loft than comparative example fabrics of similar construction, as shown by the greater thickness of the example fabrics. The woven fabrics of the Examples also exhibit less pilling (higher roughness ratings), better abrasion resistance (lower % weight loss), and better drape (lower % weight loss) relative to the fabrics of the Comparative Examples. higher drape coefficient value). Additionally, the example fabric can also be dyed more deeply (with the lower L* value of the D65 light source). The combination of improved hand (softer hand) and better drape is particularly ideal for fabric lines. Examples of circular knitted fabrics

The spun yarns of Examples 5 to 10 were used as knitting yarns to make endless knitted fabrics as shown in Table 9; commercially available spun yarns were used to make comparative fabrics. For all circular knitted fabrics made with 20s Ne count yarn, the machine gauge is 20”. For all circular knitted fabrics made with 40s Ne count yarn, the machine gauge is 24”. Fabric evaluation results are presented in Tables 9 and 10. Unless otherwise stated, results reported are for finished fabrics. Example 17

An endless knitted fabric was prepared on a Mesdan laboratory knitting machine using the spun yarn of Example 5. The blank fabric was heat set in an RBE tenter at 160°C for 45 seconds and then scrubbed in a HTHP Beaker dyer using the following process. Scrub the fabric with NaOH (2 gpl) at 90°C for 60 minutes and add the wetting agent Levocol CESR (5 gpl). The fabric was washed at 85°C for 15 min, then in cold water for 15 min, then in a neutralizing solution containing acetic acid (1 gpl) for 15 min, then in cold water for 15 min.

The scrubbed fabric is then dyed with a mixture of disperse dyes in the same machine using the following time and temperature profile: heat to 70°C and hold for 10 minutes, then increase the temperature to 130°C at 1.5°C/min and hold for 30 minutes, then reduce the temperature to 70°C at 1.5°C/minute and drain. After dyeing, the fabric was reduced and washed with Hydros and NaOH (2 gpl each) at 90°C for 20 minutes. The fabric is then washed in cold water for 10 minutes, neutralized with acetic acid (2 gpl) for 15 minutes and washed again in cold water for 10 minutes. Pad-dyed fabrics are pad-dyed with a finish (softener) and then heat set in a laboratory tenter at 160°C for 45 seconds.

Fabric construction is shown in Table 9. Wicking test result is 100%. The fabric of Example 17 was found to have a softer hand (i.e., better softness) compared to the fabric of Comparative Example H. Other fabric properties are presented in Tables 9 and 10. Comparative example H

A comparative knitted fabric was made following the procedure of Example 17, except that commercially available 20s Ne 100% PET short fiber spun yarn ("P1") was used.

Fabric construction is shown in Table 9. Wicking test result is 100%. Other fabric properties are presented in Tables 9 and 10. Example 18

The spun yarn of Example 7 was used to prepare a circular knitted fabric on a Mesdan laboratory knitting machine following the procedure of Example 17, except that after dyeing with disperse dyes, the fabric was dyed with salt (60 gpl) using the following time and temperature profile. ) are dyed in the same machine with a mixture of reactive dyes: heat to 60 ° C and hold for 30 minutes, then add soda ash (15 gpl) and hold for 30 minutes, then drain. The fabric was then washed with cold water for 10 minutes, with acetic acid (1 gpl) for 15 minutes and then with hot soaping with Albatex AD (2 gpl), during which the temperature was raised to 90°C and held for 15 minutes. The fabric is then washed in hot water (85°C) for 15 minutes, then cold water for 10 minutes. Fix the dye with Levocol HCF (0.5 gpl), during which time the temperature is increased to 50 °C and held for 20 min. Pad-dyed fabrics were pad-dyed with a finish and then heat set in a laboratory tenter at 160°C for 45 seconds.

Fabric construction is shown in Table 9. Wicking test result is 100%. Other fabric properties are presented in Tables 9 and 10. Comparative Example I

A comparative knitted fabric was made following the procedure of Example 18 except that commercially available 20s Ne 40/60 PET/cotton staple yarn ("PC1") was used.

Fabric construction is shown in Table 9. Wicking test result is 100%. Other fabric properties are presented in Tables 9 and 10. Example 19

An endless knitted fabric was prepared on a Mesdan laboratory knitting machine following the procedure of Example 18 using the spun yarn of Example 9.

Fabric construction is shown in Table 9. Wicking test result is 100%. Other fabric properties are presented in Tables 9 and 10. Comparative Example J

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

Fabric construction is shown in Table 9. Wicking test result is 100%. Other fabric properties are presented in Tables 9 and 10. Example 20

The spun yarn of Example 6 was used to prepare an annular knitted fabric on a Mesdan laboratory knitting machine following the procedure of Example 1 except that a different mixture of disperse dyes was used.

Fabric construction is shown in Table 9. Wicking test result is 100%. The fabric of Example 20 was found to have a better hand (i.e., better softness) compared to the fabric of Comparative Example K. Other fabric properties are presented in Tables 9 and 10. Comparative example K

A comparative knitted fabric was made following the procedure of Example 17, except that a commercially available 40s Ne 100% PET staple fiber spun yarn ("P2") and a different blend of disperse dyes were used.

Fabric construction is shown in Table 9. Wicking test result is 100%. Other fabric properties are presented in Tables 9 and 10. Example 21

The spun yarn of Example 8 was used to prepare an endless knitted fabric on a Mesdan laboratory knitting machine following the procedure of Example 18 except that a different mixture of disperse dyes was used.

Fabric construction is shown in Table 9. Wicking test result is 100%. Other fabric properties are presented in Tables 9 and 10. Comparative example L

A comparative knitted fabric was made following the procedure of Example 18, except using commercially available 40s Ne 40/60 PET/cotton staple yarn ("PC2"), a mixture of different disperse dyes, and a different mixture of reactive dyes. mixture.

Fabric construction is shown in Table 9. Wicking test result is 100%. Other fabric properties are presented in Tables 9 and 10. Example 22

The spun yarn of Example 10 was used to prepare an annular knitted fabric on a Mesdan laboratory knitting machine following the procedure of Example 18 except that a different mixture of disperse dyes and a different mixture of reactive dyes were used.

Fabric construction is shown in Table 9. Wicking test result is 100%. Other fabric properties are presented in Tables 9 and 10. Comparative example M

A comparative knitted fabric was made following the procedure of Example 18, except using commercially available 40s Ne 40/60 PET/Tencel® staple yarn ("PT2"), a different mixture of disperse dyes, and a different reactive dye .

Fabric construction is shown in Table 9. Wicking test result is 100%. Other fabric properties are presented in Tables 9 and 10. [Table 9]. Circular knit (CK) fabric construction and evaluation results [Table 10]. Circular knitted (CK) fabric evaluation results continued

The results in Tables 9 and 10 indicate that the endless knitted fabrics of the Examples provide advantages over the fabrics of the Comparative Examples. For example, an annular knitted fabric containing spun yarns containing melt-spun staple fibers disclosed herein has greater loft, as indicated by the greater thickness of the fabric, compared to the fabric of the Comparative Example. The example annular knit fabrics also exhibited less pilling (higher pilling rating values) and better abrasion resistance (lower % weight loss). In addition, the fabrics of the examples have better stretch recovery than the fabrics of the comparative examples, both having shorter and longer recovery times. Example 23 2/64s Nm spun yarn containing 70/30 wool / melt spun staple fiber

Spun yarn is manufactured using the worsted spinning system according to the following process.

The spun yarn of Example 23 was prepared using the melt spun staple fibers of Example 4. According to the conventional carding process normally used in spinning mills, melt-spun short fibers of 2.5 denier and an average length of 84 mm are taken and converted into sliver in a cotton card spinning system. The yarn was blended with top (20.5 micron Australian Merino sheep, average length 68 mm) and spun in a worsted spinning system at a 70/30 (weight/weight) wool/melt-spun short fiber blend ratio. spinning. The nominal spinning count of fine yarn is 2/64s Nm. Example 24

A bottom twill fabric was prepared using the spun yarn of Example 23 as warp and weft yarns. The warp yarns were sized prior to doubling with a CCI single-end sizing machine using Elvanol-T25 PVA sizing agent and softener. Using a 350 m/min warper, a final beam was prepared with 1770 warp yarns, a width of 18 inches, and a warp length of 3.5 meters. Use the following reeding plan: Stretch: 3 axes Stretch Type (Linear Stretch (1, 2, and 3)) Reeding: 3 warp threads/reed teeth Reed count: 60 teeth/2 inches The 2/1 RHT twill fabric was woven on a CCI sample loom at a loom speed of 40 picks/minute. The weft value is set to 63 picks/inch. A blank fabric of 2 m length and 50 cm width is obtained.

The blank fabric was desized in the jigger using a process similar to Example 11, except that Albatex AD was used in combination with Levocol CESR. The fabric was then washed in hot water (85°C, 15 minutes), in cold water (15 minutes), in a neutralization step with acetic acid (15 minutes), and again in cold water (15 minutes). Allow the fabric to dry flat under atmospheric conditions, then heat set at 170°C for 45 seconds.

The fabric is then dyed with a mixture of disperse dyes using the following time and temperature profile: heat to 70°C and hold for 10 minutes, then increase the temperature at 1.5°C/min to 130°C and hold for 30 minutes, then increase the temperature to 1.5°C/min to 70°C and drain. Fabrics were reduced with Hydros and NaOH (1 gpl each) for 20 minutes at 90°C. The fabric was then washed in cold water for 10 minutes, contacted with acetic acid (2 gpl) for 15 minutes, and then washed in cold water for 10 minutes.

The fabric is then dyed with a mixture of acid dyes using the following time and temperature profile: heat to 70°C and hold for 10 minutes, then increase the temperature at 1.5°C/min to 98°C and hold for 45 minutes, then increase the temperature to 1.5°C/min to 70°C and drain. Fabric was washed in cold water (10 min), treated with acetic acid (1 gpl, 15 min), hot soaped with Albatex AD (90°C, 15 min), washed in hot water (85°C, 15 min) , washed with cold water (10 min) and then contacted with Levocol HCF (0.5 gpl) for 20 min at 50°C to fix the dye.

The fabric was cooked in an autoclave (130°C, 3 min) and then padded with a finish before being heat set in a laboratory tenter at 160°C for 45 seconds and evaporated again in the autoclave (130 °C, 3 minutes).

Evaluate raw and finished fabrics. The results are as follows: Base fabric structure: 96*54 (warp/inch* weft/inch) Finished fabric structure: 114*63 (warp/inch* weft/inch) Base fabric weight: 198 g/m ² Finished fabric Weight: 249 g/ ^m2 Dimensional stability (%): Length - 2.8%; Width - 1.7% Wicking test: 100% Tear strength: Warp 1984 g, weft 896 g Stretch % 42.7 Recovery rate at 1 minute, % : 83.1 Recovery rate at 30 minutes, %: 90.9 Recovery rate at 60 minutes, %: 93.51 Example 25 Undrawn melt-spun fiber containing PTT and Co-PET

Pellets of polytrimethylene terephthalate (PTT) containing 0.3% _TiO2 and having an intrinsic viscosity of 0.96 dL/g were co-mixed with polyethylene terephthalate having an intrinsic viscosity of 0.80 dL/g. Pellets of ethylene glycol phthalate (Co-PET) (from Nan Ya Plastics Company) were dried separately in a vacuum oven under nitrogen blanket at 120 °C for 16 h. Dry PTT pellets and dry Co-PET pellets were blended together in a small drum at the ratios given in Table 11 by manual shaking and rolling action of the drum. Each of the resulting salt-and-pepper blends was melt-extruded into circular cross-section, 34-filament yarn bundles using a twin-screw extrusion spinning machine. The temperature of the melting zone of the extruder is maintained at 180°C-265°C. Polymer delivery, winding speed, spin denier/filament, and dry heat shrinkage of yarn bundles (tows) are provided in Table 11. [Table 11]. Example 25 spinning conditions and dry heat shrinkage of tow Example 26 Undrawn melt-spun fibers containing Co-PET and PBT

Polyethylene terephthalate co-isophthalate (Co-PET) pellets (from Nanya Plastics) with an intrinsic viscosity of 0.80 dL/g and 1.15 dL/g were used. Pellets of viscosity CRASTIN® 6130C NC010 polybutylene terephthalate (PBT) were separately dried in a vacuum oven under nitrogen blanket at 120°C for 16 hours. The dry PTT and PBT pellets were blended together in a small tumbler at the ratios given in Table 12 by manual shaking and rolling action of the tumbler. Each of the resulting salt-and-pepper blends was melt-extruded into circular cross-section, 34-filament yarn bundles using a twin-screw extrusion spinning machine. The temperature of the melting zone of the extruder is maintained at 180°C-265°C. Polymer delivery, winding speed, spin denier/filament, and dry heat shrinkage of yarn bundles (tows) are provided in Table 12. [Table 12].Example 26 spinning conditions and dry heat shrinkage of tow Example 27 Melt spun staple fibers containing a salt and pepper blend of 20 wt % PTT and 80 wt % Co-PET

Polytrimethylene terephthalate and co-PET (from Nanya Plastics) were co-fed through a 7590-hole spinneret using a single-screw extruder at a weight ratio of 20:80. Polytrimethylene terephthalate contains 0.3% TiO ₂ and has an intrinsic viscosity of 0.96 dL/g. Circular cross-section filaments were spun using radial quenching at an extruder throughput of 100 kg/h. The temperature of the melting zone of the extruder is maintained at 252°C-263°C. The polymer delivery rate is 0.220 g/min/hole and the feed roller speed is 650 m/m. The spinning dpf is nominally 3.4. The spun fibers are collected in cans.

Sixteen (16) cans, totaling 412,896 denier, feed the draw-crimp-cut/bale module. Melt-spun staple fibers are produced using a typical cotton yarn count staple fiber process utilizing multiple stages of drawing, crimping, annealing, and cutting. The tows were immersed in a bath of finish (0.5% concentration, commercially available Duron 3176 from CHT Corporation) at 22°C. The tows were first drawn at 75°C in a 0.5% concentration finish bath between an 18°C feed roll operating at 30 m/m and a heated draw roll operating at 80°C at 84 m/m. Stretching was carried out during the period to obtain a first-stage stretching ratio of 2.8. The drawn tow was pulled through the steam cabinet at 100°C by a downstream heated roll operating at 165°C and 88.20 m/m. The tow is passed through another set of rollers heated at 165°C and operating at 88.20 m/m. Finish was sprayed (2% concentration, 30/70 active substances Duron 14 + Duron 1105 PE, both from the company CHT) and the tow was passed through a cooling drum roller running at 86.44 m/m at 25°C. The tow enters the steam box at 100°C and then enters the 40 mm crimping machine. The curling speed is 90.76 m/m. The temperature and pressure of the crimping roller are 65°C and 0.8 bar respectively. The crimped tow was annealed in a belt dryer at 100°C for 4 minutes, and finally the crimped tow was cut to produce melt-spun staple fibers with the following properties (determined using the method disclosed above): Denier/ Filament (dpf) = 1.28, coefficient of variation (CV) = 15.47% Tenacity = 5.24 g/d, CV = 13.05% Elongation = 53.37%, CV = 39.14% Short fiber length = 38 mm Crimp number (full sinusoidal arc ) = 12.9/inch Curl Stability = 64.08%, CV = 17.67% Finish on Yarn = 0.26% Example 28 Melt Spun Shortage of Salt and Pepper Blend Containing 50 wt % PTT and 50 wt % Co-PET fiber

Poly(trimethylene terephthalate) and co-PET (from Nanya Plastics) were co-fed through a 7590-hole spinneret using a single-screw extruder at a weight ratio of 50:50. Polytrimethylene terephthalate contains 0.3% TiO ₂ and has an intrinsic viscosity of 0.96 dL/g. Circular cross-section filaments were spun using radial quenching at an extruder throughput of 122.2 kg/h. The temperature of the melting zone of the extruder is maintained at 252°C-263°C. The polymer delivery rate is 0.268 g/min/hole and the feed roller speed is 792 m/m. The spinning dpf is nominally 3.4. The spun fibers are collected in cans.

Sixteen (16) cans, totaling 412,896 denier, feed the draw-crimp-cut/bale module. Melt-spun staple fibers are produced using a typical cotton yarn count staple fiber process utilizing multiple stages of drawing, crimping, annealing, and cutting. The tows were immersed in a bath of finish (0.5% concentration, commercially available Duron 3176 from CHT Corporation) at 22°C. The tows were first drawn at 75°C in a 0.5% concentration finish bath between an 18°C feed roll operating at 30 m/m and a heated draw roll operating at 80°C at 87 m/m. Stretching was carried out during the period to obtain a first-stage stretching ratio of 2.9. The drawn tow was pulled through the steam cabinet at 100°C by a downstream heated roll operating at 165°C and 92.22 m/m. The tow is passed through another set of rollers heated at 165°C and operating at 90.38 m/m. Finish was sprayed (2% concentration, 30/70 active substances Duron 14 + Duron 1105 PE, both from the company CHT) and the tow was passed through a cooling drum roller running at 90.38 m/m at 25°C. The tow enters the steam box at 100°C and then enters the 40 mm crimping machine. The curling speed is 94.89 m/m. The temperature and pressure of the crimping roller are 65°C and 0.8 bar respectively. The crimped tow was annealed in a belt dryer at 100°C for 4 minutes, and finally the crimped tow was cut to produce melt-spun staple fibers with the following properties (determined using the method disclosed above): Denier/ Filament (dpf) = 1.31, coefficient of variation (CV) = 10.13% Tenacity = 4.66 g/d, CV = 9.72% Elongation = 53.86%, CV = 25.47% Short fiber length = 38 mm Crimp number (full sinusoidal arc ) = 13.1/inch Curl Stability = 79.51%, CV = 9.45% Finish on Yarn = 0.20% Example 29 Melt Spun Shortage of Salt and Pepper Blend Containing 50 wt % PTT and 50 wt % Co-PET fiber

Poly(trimethylene terephthalate) and co-PET (from Nanya Plastics) were co-fed through a 7590-hole spinneret using a single-screw extruder at a weight ratio of 50:50. Polytrimethylene terephthalate contains 0.3% TiO ₂ and has an intrinsic viscosity of 0.96 dL/g. Circular cross-section filaments were spun using radial quenching at an extruder throughput of 122.2 kg/h. The temperature of the melting zone of the extruder is maintained at 252°C-263°C. The polymer delivery rate is 0.268 g/min/hole, and the feed roller speed is 400 m/m. The spinning dpf is nominally 6.4. The spun fibers are collected in cans.

Eight (8) cans, totaling 388,608 denier, feed the draw-crimp-cut/bale module. Melt-spun staple fibers are produced using a typical worsted count staple fiber process utilizing multiple stages of drawing, crimping, annealing, and cutting. The tows were immersed in a bath of finish (0.5% concentration, commercially available Duron 3176 from CHT Corporation) at 22°C. The tows were first drawn at 75°C in a 0.5% concentration finish bath between an 18°C feed roll operating at 30 m/m and a heated draw roll operating at 80°C at 114 m/m. Stretching was carried out during the period to obtain a first-stage stretching ratio of 3.8. The drawn tow was pulled through a steam cabinet at 100°C by a downstream heated roll operating at 165°C and 108.3 m/m. The tow is passed through another set of rollers heated at 165°C and running at 106.1 m/m. Finish was sprayed (2% concentration, 30/70 active substances Duron 14 + Duron 1105 PE, both from CHT) and the tow was passed through a cooling drum roller running at 107.2 m/m at 25°C. The tow enters the steam box at 100°C and then enters the 40 mm crimping machine. The curling speed is 112.56 m/m. The temperature and pressure of the crimping roller are 65°C and 0.8 bar respectively. The crimped tow was annealed in a belt dryer at 100°C for 4 minutes, and finally the crimped tow was cut to produce multiple cut lengths of melt-spun staple fibers with the following properties (determined using the method disclosed above ): Denier/filament (dpf) = 2.08, coefficient of variation (CV) = 7.47% Tenacity = 4.31 g/d, CV = 15.67% Elongation = 67.77%, CV = 24.33% Short fiber length = multiple cuts Length, 59.5/79.3/119 mm Crimp count (full sinusoidal arc) = 12/inch Crimp stability = 72.11%, CV = 12.8% Finish on yarn = 0.09% Example 30 contains 20 wt % PBT and 80 wt% Melt-spun short fibers of salt and pepper blends of % Co-PET

CRASTIN® 6130C NC010 polybutylene terephthalate (PBT) and co-PET with an intrinsic viscosity of 1.15 dL/g were co-fed through a 7590-hole spinneret using a single-screw extruder at a weight ratio of 20:80 (from Nanya Plastics). Circular cross-section filaments were spun using radial quenching at an extruder throughput of 100 kg/h. The temperature of the melting zone of the extruder is maintained at 252°C-263°C. The polymer delivery rate is 0.220 g/min/hole and the feed roller speed is 650 m/m. The spinning dpf is nominally 3.18. The spun fibers are collected in cans.

Sixteen (16) cans, totaling 386,179 denier, feed the draw-crimp-cut/bale module. Melt-spun staple fibers are produced using a typical cotton yarn count staple fiber process utilizing multiple stages of drawing, crimping, annealing, and cutting. The tows were immersed in a bath of finish (0.5% concentration, commercially available Duron 3176 from CHT Corporation) at 22°C. The tows were first drawn at 75°C in a 0.5% concentration finish bath between an 18°C feed roll operating at 30 m/m and a heated draw roll operating at 80°C at 88.2 m/m. Stretching was carried out during the period to obtain a first-stage stretching ratio of 2.94. The drawn tow was pulled through the steam cabinet at 100°C by a downstream heated roll operating at 165°C and 92.61 m/m. The tow is passed through another set of rollers heated at 165°C and operating at 92.61 m/m. Finish was sprayed (2% concentration, 30/70 active substances Duron 14 + Duron 1105 PE, both from CHT) and the tow was passed through a cooling drum roller running at 90.76 m/m at 25°C. The tow enters the steam box at 100°C and then enters the 40 mm crimping machine. The curling speed is 95.30 m/m. The temperature and pressure of the crimping roller are 65°C and 0.8 bar respectively. The crimped tow was annealed in a belt dryer at 100°C for 4 minutes, and finally the crimped tow was cut to produce melt-spun staple fibers with the following properties (determined using the method disclosed above): Denier/ Filament (dpf) = 1.24, coefficient of variation (CV) = 13.51% Tenacity = 5.36 g/d, CV = 11.77% Elongation = 47.07%, CV = 39.30% Short fiber length = 40 mm Crimp number (full sinusoidal arc ) = 10.4/inch Curl Stability = 56.2%, CV = 13.9% Finish on Yarn = 0.31% Example 31 Melt spun yarn of salt and pepper blend containing 50 wt % PBT and 50 wt % Co-PET fiber

CRASTIN® 6130C NC010 polybutylene terephthalate (PBT) and co-PET with an intrinsic viscosity of 1.15 dL/g were co-fed through a 7590-hole spinneret using a single-screw extruder at a 50:50 weight ratio. (from Nanya Plastics). Circular cross-section filaments were spun using radial quenching at an extruder throughput of 122.2 kg/h. The temperature of the melting zone of the extruder is maintained at 252°C-263°C. The polymer delivery rate is 0.268 g/min/hole and the feed roller speed is 792 m/m. The spinning dpf is nominally 3.42. The spun fibers are collected in cans.

Sixteen (16) cans, totaling 415,324 denier, feed the draw-crimp-cut/bale module. Melt-spun staple fibers are produced using a typical cotton yarn count staple fiber process utilizing multiple stages of drawing, crimping, annealing, and cutting. The tows were immersed in a bath of finish (0.5% concentration, commercially available Duron 3176 from CHT Corporation) at 22°C. The tows were first drawn at 75°C in a 0.5% concentration finish bath between an 18°C feed roll operating at 30 m/m and a heated draw roll operating at 87.90 m/m at 80°C. Stretching was carried out during the period to obtain a first-stage stretching ratio of 2.93. The drawn tow was pulled through a steam cabinet at 100°C by a downstream heated roll operating at 165°C and 94.93 m/m. The tow is passed through another set of rollers heated at 165°C and operating at 94.93 m/m. Finish was sprayed (2% concentration, 30/70 active substances Duron 14 + Duron 1105 PE, both from the company CHT) and the tow was passed through a cooling drum roller running at 93.03 m/m at 25°C. The tow enters the steam box at 100°C and then enters the 40 mm crimping machine. The curling speed is 97.69 m/m. The temperature and pressure of the crimping roller are 65°C and 0.8 bar respectively. The crimped tow was annealed in a belt dryer at 100°C for 4 minutes, and finally the crimped tow was cut to produce melt-spun staple fibers with the following properties (determined using the method disclosed above): Denier/ Filament (dpf) = 1.17, coefficient of variation (CV) = 13.6% Tenacity = 5.48 g/d, CV = 12.38% Elongation = 39.74%, CV = 27.57% Short fiber length = 40 mm Crimp number (full sinusoidal arc ) = 11.8/inch Crimp Stability = 60.23%, CV = 8.30% Finish on Yarn = 0.24% Example 32 40s Ne Spun Yarn Containing 100 % Melt Spun Fibers

According to the process of Example 5, the melt-spun staple fiber of Example 28 was used to prepare spun yarn, with the following differences: The linear density of the final sliver was 4.75 g/m and the unevenness % was 1.75.

The number of coarse sand twists is 1.2s Ne.

In the step of drafting the roving, the twist factor/twist per inch was 3.6/22.6, the traveler size was 4/0 M1HO, and the spindle speed was 16,500 rpm.

The spun yarn is wound onto the cup at 1500 m/min. The properties of the spun yarns are given in Table 13. The properties of the spun yarns of this and the following examples were determined using the methods disclosed above. Example 33 40s Ne spun yarn containing 100% melt spun fibers

Spun yarn was prepared using the melt-spun staple fibers of Example 27 according to the procedure of Example 32. The properties of the spun yarns are given in Table 13. Example 34 40s Ne spun yarn containing 100% melt spun fibers

Spun yarn was prepared using the melt-spun staple fibers of Example 31 according to the procedure of Example 32. The properties of the spun yarns are given in Table 13. Example 35 40s Ne spun yarn containing 100% melt spun fibers

Spun yarn was prepared using the melt-spun staple fibers of Example 30 according to the procedure of Example 32. The properties of the spun yarns are given in Table 13. Example 36 40s Ne spun yarn containing 40/60 (weight / weight) melt spun fiber / cotton

Spun yarn was prepared using the melt-spun staple fibers of Example 28 and cotton (Shankar 6 variety Indian cotton commercially available from northern India). Cotton staple fibers have an average length of 31 mm and a linear density of 4.1 μg/in (1.6 μg/cm). Spun yarns were made according to the procedure of Example 32. The properties of the spun yarns are given in Table 13. Example 37 40s Ne spun yarn containing 40/60 (wt / wt) melt spun fiber / cotton

Spun yarn was prepared using the melt-spun staple fibers of Example 27 and cotton (Shankar 6 variety Indian cotton commercially available from northern India). Cotton staple fibers have an average length of 31 mm and a linear density of 4.1 μg/in (1.6 μg/cm). Spun yarns were produced according to the procedure of Example 8. The properties of the spun yarns are given in Table 13. Example 38 40s Ne spun yarn containing 40/60 (weight / weight) melt spun fiber / cotton

Spun yarn was prepared using the melt-spun staple fibers of Example 31 and cotton (Shankar 6 variety Indian cotton commercially available from northern India). Cotton staple fibers have an average length of 31 mm and a linear density of 4.1 μg/in (1.6 μg/cm). Spun yarns were produced according to the procedure of Example 8. The properties of the spun yarns are given in Table 13. Example 39 40s Ne spun yarn containing 40/60 (wt / wt) melt spun fiber / cotton

Spun yarn was prepared using the melt-spun staple fibers of Example 30 and cotton (Shankar 6 variety Indian cotton commercially available from northern India). Cotton staple fibers have an average length of 31 mm and a linear density of 4.1 μg/in (1.6 μg/cm). Spun yarns were produced according to the procedure of Example 8. The properties of the spun yarns are given in Table 13. Example 40 40s Ne spun yarn containing 40/60 melt spun fiber / Tencel

Spun yarns were prepared using the melt-spun staple fibers of Example 28 and commercially available Tencel® staple fibers (Lensing). Tencel® staple fibers have an average length of 40 mm and a denier of 1.2 D. Spun yarns were made according to the procedure of Example 10. The properties of the spun yarns are given in Table 13. Example 41 40s Ne spun yarn containing 40/60 melt spun fiber / Tencel

Spun yarns were prepared using the melt-spun staple fibers of Example 27 and commercially available Tencel® staple fibers (Lensing). Tencel® staple fibers have an average length of 40 mm and a denier of 1.2 D. Spun yarns were made according to the procedure of Example 10. The properties of the spun yarns are given in Table 13. Example 42 40s Ne spun yarn containing 40/60 melt spun fiber / Tencel

Spun yarns were prepared using the melt-spun staple fibers of Example 31 and commercially available Tencel® staple fibers (Lensing). Tencel® staple fibers have an average length of 40 mm and a denier of 1.2 D. Spun yarns were made according to the procedure of Example 10. The properties of the spun yarns are given in Table 13. Example 43 40s Ne spun yarn containing 40/60 melt spun fiber / Tencel

Spun yarns were prepared using the melt-spun staple fibers of Example 30 and commercially available Tencel® staple fibers (Lensing). Tencel® staple fibers have an average length of 40 mm and a denier of 1.2 D. Spun yarns were made according to the procedure of Example 10. The properties of the spun yarns are given in Table 13. Example 44 2/68s Nm spun yarn containing 45/55 wool / melt spun staple fiber

Spun yarn is manufactured using the worsted spinning system according to the following process.

The spun yarn of Example 44 was prepared using the melt spun staple fibers of Example 29. According to the conventional carding process normally used in spinning mills, melt-spun short fibers of 2.5 denier and an average length of 84 mm are taken and converted into sliver in a cotton card spinning system. The yarn was blended with top (20.5 micron Australian Merino sheep, average length 68 mm) and spun in a worsted spinning system at a 45/55 (weight/weight) wool/melt-spun short fiber blend ratio. spinning. The nominal spinning count of fine yarn is 2/68s Nm.

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

[Table 13]. Characteristics of spun yarns of Examples 32 to 44

Compared with the results in Tables 4 and 5, the results in Table 13 indicate that the tenacity of spun yarns incorporating salt-and-pepper blended PET/PTT 50:50 melt-spun short fibers is comparable to that of blended PET/PTT 50:50. The tenacity of the spun yarns of 50 melt-spun short fibers is similar. The boiling water shrinkage of the spun yarn incorporating salt-and-pepper PET/PTT 50:50 melt-spun short fiber was higher than that of the spun yarn containing compounded PET/PTT 50:50 melt-spun short fiber. All other properties were found to be similar. Examples of woven fabrics

As shown in Table 14, the spun yarns of Examples 32 to 44 were used to make woven fabrics. Plain weave (1/1) shirting fabric is made using the spun yarns disclosed herein as warp and weft (filler) yarns. For every woven fabric, the same yarns are used in both the warp and weft. Fabric evaluation results are presented in Tables 15 and 16. Unless otherwise stated, results reported are for finished fabrics. The fabric properties of this and the following examples were determined using the methods disclosed above. Example 45

A plain weave (1/1) shirting fabric was prepared using the spun yarns of Example 32 as warp and weft yarns. The warp yarns were sized prior to doubling with a CCI single-end sizing machine using Elvanol-T25 PVA sizing agent. Using a 350 m/min warper, a final beam was prepared with 1680 warp yarns, a width of 18 inches, and a warp length of 3.5 meters. Use the following reeding plan: Stretch: 4 axes Stretch Type (Linear Stretch (1, 2, 3, and 4) Reeding: 2 warp threads/reed teeth Reed count: 84 teeth/2 inches 1/1 plain weave fabric was woven on a CCI sample loom at a loom speed of 40 picks/minute. The weft value is set to 49 picks/inch.

The blank fabric was desized on the RBE laboratory jigger as follows. Load the fabric sample into the jigger with water (2 L), NaOH (2 gpl), and wetting agent; add Levocol CESR (wetting agent) (5 gpl) and increase the bath temperature to 90° C. Leave the fabric in the bath for 60 minutes, then drain the bath, refill it with fresh water, and increase the bath temperature to 85°C. Wash the fabric in hot water for 15 minutes and drain the bath. Fill the bath with water again and leave the fabric in it for 15 minutes (wash in cold water). The bath was drained, filled with water and neutralized by adding acetic acid (1 gpl); the fabric was left in the bath for 15 minutes. After this, drain the bath, refill it with fresh water and leave the fabric in a cold water bath for 15 minutes. The fabric is then removed from the jigger and dried under atmospheric conditions before being heat set in an RBE tenter at 160°C for 45 seconds.

The fabric is then dyed with a mixture of disperse dyes using the following time and temperature profile: heat to 70°C and hold for 10 minutes, then increase the temperature at 1.5°C/min to 130°C and hold for 30 minutes, then increase the temperature to 1.5°C/min to 70°C and drain. After dyeing, the fabric was reduced and washed with Hydros and NaOH (2 gpl each) at 90°C for 20 minutes. The fabric was then washed in cold water for 10 minutes, contacted with acetic acid (2 gpl) for 15 minutes, and then washed in cold water for 10 minutes. Pad-dyed fabrics are pad-dyed with a finish (softener) and then heat set in an RBE laboratory tenter at 160°C for 45 seconds.

Fabric construction is shown in Table 14. Wicking test result is 100%. Other fabric properties are presented in Tables 15 and 16. Example 46

A plain woven shirting fabric was prepared according to the procedure given in Example 45 using the spun yarns of Example 33 as warp and weft yarns. Fabric construction is shown in Table 14. Wicking test result is 100%. Other fabric properties are presented in Tables 15 and 16. Example 47

A plain woven shirting fabric was prepared according to the procedure given in Example 45 using the spun yarns of Example 34 as warp and weft yarns. The fabric construction is shown in Table 14. Wicking test result is 100%. Other fabric properties are presented in Tables 15 and 16. Example 48

A plain woven shirting fabric was prepared according to the procedure given in Example 45 using the spun yarns of Example 35 as warp and weft yarns. Fabric construction is shown in Table 14. Wicking test result is 100%. Other fabric properties are presented in Tables 15 and 16. Example 49

A plain woven shirting fabric was prepared according to the procedure of Example 45, using the spun yarns of Example 36 as warp and weft yarns, but with the following differences. The pick number on the loom is set to 58 picks/inch. The blank fabric is desized and bleached in a jigger, heat set in a tenter and then dyed with a mixture of disperse dyes and then additionally dyed with reactive dyes under cotton dyeing conditions. Fabric construction is shown in Table 14. Wicking test result is 100%. Other fabric properties are presented in Tables 15 and 16. Example 50

A plain woven shirting fabric was prepared according to the procedure of Example 49, using the spun yarns of Example 37 as warp and weft yarns, but with the following differences. The blank fabric is desized and bleached in a jigger, heat set in a tenter and then dyed with a mixture of disperse dyes and then additionally dyed with reactive dyes under cotton dyeing conditions. Fabric construction is shown in Table 14. Wicking test result is 100%. Other fabric properties are presented in Tables 15 and 16. Example 51

A plain woven shirting fabric was prepared according to the procedure of Example 49, using the spun yarns of Example 38 as warp and weft yarns, but with the following differences. The blank fabric is desized and bleached in a jigger, heat set in a tenter and then dyed with a mixture of disperse dyes and then additionally dyed with reactive dyes under cotton dyeing conditions. Fabric construction is shown in Table 14. Wicking test result is 100%. Other fabric properties are presented in Tables 15 and 16. Example 52

A plain woven shirting fabric was prepared according to the procedure of Example 49, using the spun yarns of Example 39 as warp and weft yarns, but with the following differences. The blank fabric is desized and bleached in a jigger, heat set in a tenter and then dyed with a mixture of disperse dyes and then additionally with reactive dyes under cotton dyeing conditions.

Fabric construction is shown in Table 14. Wicking test result is 100%. Other fabric properties are presented in Tables 15 and 16. Example 53

A plain woven shirting fabric was prepared according to the procedure of Example 49 using the spun yarns of Example 40 as warp and weft yarns, except that no peroxide killer was used at the end of the bleaching step. The pick value on the loom is set to 65 picks/inch.

Fabric construction is shown in Table 14. Wicking test result is 100%. Other fabric properties are presented in Tables 15 and 16. Example 54

A plain woven shirting fabric was prepared according to the procedure of Example 53 using the spun yarns of Example 41 as warp and weft yarns. Fabric construction is shown in Table 14. Wicking test result is 100%. Other fabric properties are presented in Tables 15 and 16. Example 55

A plain woven shirting fabric was prepared according to the procedure of Example 53 using the spun yarns of Example 42 as warp and weft yarns. The fabric construction is shown in Table 14. Wicking test result is 100%. Other fabric properties are presented in Tables 15 and 16. Example 56

A plain woven shirting fabric was prepared according to the procedure of Example 53 using the spun yarns of Example 42 as warp and weft yarns. The fabric construction is shown in Table 14. Wicking test result is 100%. Other fabric properties are presented in Tables 15 and 16. Example 57

A suiting fabric of 2/1 twill construction was prepared using the spun yarns of Example 34 as warp and weft yarns. The warp yarns were sized prior to doubling with a CCI single-end sizing machine using Elvanol-T25 PVA sizing agent and softener. Using a 350 m/min warper, a final beam was prepared with 1518 warp yarns, a width of 18 inches, and a warp length of 3.5 meters. Use the following reeding plan: Stretch: 3 axes Stretch Type (Linear Stretch (1, 2, and 3) Reeding: 3 warp threads/reed teeth Reed count: 51.5 teeth/2 inches The 2/1 RHT twill fabric was woven on a CCI sample loom at a loom speed of 40 picks/minute. The weft value is set to 53 picks/inch. A blank fabric of 2 m length and 48.3 cm width was obtained.

The blank fabric was desized in the jigger using a process similar to Example 49, except that Albatex AD was used in combination with Levocol CESR. The fabric was then washed in hot water (85°C, 15 minutes), in cold water (15 minutes), in a neutralization step with acetic acid (15 minutes), and again in cold water (15 minutes). Allow the fabric to dry flat under atmospheric conditions, then heat set at 170°C for 45 seconds.

The fabric is then dyed with a mixture of disperse dyes using the following time and temperature profile: heat to 70°C and hold for 10 minutes, then increase the temperature at 1.5°C/min to 130°C and hold for 30 minutes, then increase the temperature to 1.5°C/min to 70°C and drain. Fabrics were reduced with Hydros and NaOH (1 gpl each) for 20 minutes at 90°C. The fabric was then washed in cold water for 10 minutes, contacted with acetic acid (2 gpl) for 15 minutes, and then washed in cold water for 10 minutes.

The fabric is then dyed with a mixture of acid dyes using the following time and temperature profile: heat to 70°C and hold for 10 minutes, then increase the temperature at 1.5°C/min to 98°C and hold for 45 minutes, then increase the temperature to 1.5°C/min to 70°C and drain. Fabric was washed in cold water (10 min), treated with acetic acid (1 gpl, 15 min), hot soaped with Albatex AD (90°C, 15 min), washed in hot water (85°C, 15 min) , washed with cold water (10 min) and then contacted with Levocol HCF (0.5 gpl) for 20 min at 50°C to fix the dye.

The fabric was cooked in an autoclave (130°C, 3 min) and then padded with the finishing agents Levofin HYP-5gpl Levocol PNLI-10gpl before being heat set in a laboratory tenter at 160°C for 45 seconds and then Evaporate again in autoclave (130°C, 3 min).

Evaluate raw and finished fabrics. Fabric construction and test results are given in Tables 14, 15 and 16. Wicking test result is 100%.

[Table 14]. Woven fabric construction of fabric examples 45-57 [Table 15]. Woven fabric evaluation results of fabric examples 45-57 (upper half) [Table 16]. Woven fabric evaluation results of fabric examples 45-57 (lower half)

The results shown in Tables 14, 15, and 16, as well as the preceding Tables 6, 7, and 8, indicate that the spun yarns disclosed herein can be used to make woven fabrics with desirable properties. Examples of circular knitted fabrics

The spun yarns of Examples 32 to 44 were used as knitting yarns to make circular knitted fabrics as shown in Table 17; for all circular knitted fabrics made using 40s Ne count yarn, the machine specification was 24”. Fabric evaluation results are presented In Table 18. Unless otherwise noted, results are reported for finished fabrics. Examples 58 , 59 , 60 , and 61

Circular knitted fabrics were prepared on a Mesdan laboratory knitting machine using the spun yarns of Examples 32, 33, 34, and 35, respectively. The blank fabric was heat set in an RBE tenter at 160°C for 45 seconds and then scrubbed in a HTHP Beaker dyer using the following process. Scrub the fabric with NaOH (2 gpl) at 90°C for 60 minutes and add the wetting agent Levocol CESR (5 gpl). The fabric was washed at 85°C for 15 min, then in cold water for 15 min, then in a neutralizing solution containing acetic acid (1 gpl) for 15 min, then in cold water for 15 min.

The scrubbed fabric is then dyed with a mixture of disperse dyes in the same machine using the following time and temperature profile: heat to 70°C and hold for 10 minutes, then increase the temperature to 130°C at 1.5°C/min and hold for 30 minutes, then reduce the temperature to 70°C at 1.5°C/minute and drain. After dyeing, the fabric was reduced and washed with Hydros and NaOH (2 gpl each) at 90°C for 20 minutes. The fabric is then washed in cold water for 10 minutes, neutralized with acetic acid (2 gpl) for 15 minutes and washed again in cold water for 10 minutes. Pad-dyed fabrics are pad-dyed with a finish (softener) and then heat set in a laboratory tenter at 160°C for 45 seconds. Fabric construction and test results are presented in Tables 17 and 18. Wicking test results for all fabrics were 100% Examples 62 , 63 , 64 , and 65

According to the procedure of Example 58, the spun yarns of Examples 36, 37, 38, and 39 were used to prepare circular knitted fabrics on a Mesdan laboratory knitting machine, except that after dyeing with disperse dyes, the following time and temperature profiles were used to The fabric is dyed in the same machine with a mixture of reactive dyes to which salt (60 gpl) is added: it is heated to 60 ° C and held for 30 minutes, then soda ash (15 gpl) is added and held for 30 minutes and then drained. The fabric was then washed with cold water for 10 minutes, with acetic acid (1 gpl) for 15 minutes and then with hot soaping with Albatex AD (2 gpl), during which the temperature was raised to 90°C and held for 15 minutes. The fabric is then washed in hot water (85°C) for 15 minutes, then cold water for 10 minutes. Fix the dye with Levocol HCF (0.5 gpl), during which time the temperature is increased to 50 °C and held for 20 min. Pad-dyed fabrics were pad-dyed with a finish and then heat set in a laboratory tenter at 160°C for 45 seconds. Fabric construction and test results are presented in Tables 17 and 18. Wicking test results for all fabrics were 100% Examples 66 , 67 , 68 , and 69

According to the procedure of Example 18, the spun yarns of Examples 40, 41, 42, and 43 were used to prepare circular knitted fabrics on a Mesdan laboratory knitting machine, except that different mixtures of disperse dyes and different reactive dyes were used. mixture and do not use a peroxide killer at the end of the bleaching step. Fabric construction and test results are presented in Tables 17 and 18. Wicking test results for all fabrics are 100% Example 70

An endless knit fabric was prepared on a Mesdan laboratory knitting machine following the procedure of Example 14 using the spun yarn of Example 44. Dye and finish the fabric as per Example 57. Fabric construction and test results are presented in Tables 17 and 18. Wicking test results for all fabrics were 100% [Table 17]. Circular knit (CK) fabric construction and evaluation results for Examples 58 to 70 [Table 18]. Evaluation results of circular knitted (CK) fabrics of Examples 58 to 70 continued

The results shown in Tables 17 and 18, as well as the preceding Tables 9 and 10, indicate that the spun yarns disclosed herein can be used to make endless knitted fabrics with desirable properties.

without

Claims (19)

A spun yarn comprising: melt-spun staple fibers comprising a combined first polymer and a second polymer, wherein the first polymer comprises poly(trimethylene terephthalate), the second The polymer includes poly(ethylene terephthalate) or Co-PET, wherein Co-PET is a poly(ethylene terephthalate) copolymer including isophthalic acid monomer; and the first The weight ratio of polymer to the second polymer ranges from 70:30 to 30:70. The spun yarn described in item 1 of the patent application, wherein the weight ratio of the first polymer to the second polymer is in the range of 60:40 to 40:60. The spun yarn of claim 1, wherein the first polymer includes poly(trimethylene terephthalate), and the second polymer includes poly(ethylene terephthalate). The spun yarn as described in item 1 of the patent application, wherein the first polymer includes poly(trimethylene terephthalate), and the second polymer includes Co-PET, and the Co-PET contains poly(trimethylene terephthalate) based on the total The composition consists of 0.5 mol% to 10 mol% isophthalic acid monomer. The spun yarn of claim 3, wherein the spun yarn has a boiling water shrinkage of at least 6% as measured according to ASTM D2259. The spun yarn described in item 1 of the patent application, wherein the melt-spun short fiber has a dry heat shrinkage rate of less than 6%, and the dry heat shrinkage rate is measured by a dry heat shrinkage method. The spun yarn as described in any one of items 1 to 5 of the patent application, wherein the spun yarn has: a cotton yarn count of 4 Ne to 80 Ne; or a worsted count in the range of 7 Nm to 120 Nm. As for the spun yarn described in item 1 of the patent application, the spun yarn further includes a second short fiber, and the amount of the second short fiber is 5% to 95% by weight based on the total weight of the spun yarn. The spun yarn described in item 8 of the patent application, wherein the second short fiber includes polylactic acid, acrylic acid, nylon, olefin, acetate, rayon, polyester, cotton, linen, wool, Angora goat hair, mohair , alpaca, cashmere goat hair, or mixtures thereof. The spun yarn described in item 9 of the patent application, wherein the second short fiber contains cotton or wool. A fabric comprising the spun yarn described in item 1 of the patent application. The fabric of claim 11, wherein the first polymer includes poly(trimethylene terephthalate), and the second polymer includes poly(ethylene terephthalate). The fabric of claim 11, wherein the first polymer includes poly(trimethylene terephthalate), and the second polymer includes Co-PET. The fabric described in item 11 of the patent application, wherein, compared with a fabric having the same fabric structure composed of polyethylene terephthalate, cotton, rayon, or a combination thereof, the fabric has the following properties: At least one of: i) better abrasion resistance as determined according to ASTM D4966 standard test method; ii) higher pilling rating value as determined according to ASTM D4970 standard test method; or iii) as determined according to ASTM D4970 standard test method Greater loft as determined by Standard Test Method D1777. The fabric as described in Item 11 of the patent application, wherein the fabric is a woven fabric having warp yarns and weft yarns, and the warp yarn, the weft yarn or both the warp yarn and the weft yarn each include as described in Item 1 of the patent application. of fine yarn. The fabric described in item 11 of the patent application, wherein the fabric is a knitted fabric. The fabric described in item 16 of the patent application, wherein compared with a knitted fabric having the same fabric structure composed of polyethylene terephthalate, cotton, rayon, or a combination thereof, the fabric has the following properties: Higher recovery rate as determined according to method BS 4294. An article comprising the fabric described in item 11 of the patent application. The product described in item 18 of the patent application, wherein the product is clothing.