U.S. patent application number 17/251917 was filed with the patent office on 2021-06-03 for fabrics and spun yarns comprising polyester staple fiber.
The applicant listed for this patent is DUPONT INDUSTRIAL BIOSCIENCES USA, LLC. Invention is credited to Steven R. Ackerman, Akshay Kumar, Dennis Gerard Madeleine, Wayne E. Marsh, Kalika Ranjan Samant.
Application Number | 20210164131 17/251917 |
Document ID | / |
Family ID | 1000005417136 |
Filed Date | 2021-06-03 |
United States Patent
Application |
20210164131 |
Kind Code |
A1 |
Ackerman; Steven R. ; et
al. |
June 3, 2021 |
FABRICS AND SPUN YARNS COMPRISING POLYESTER STAPLE FIBER
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.
Inventors: |
Ackerman; Steven R.;
(PHILADELPHIA, PA) ; Kumar; Akshay; (GURUGRAM,
IN) ; Madeleine; Dennis Gerard; (WILMINGTON, DE)
; Marsh; Wayne E.; (BEAR, DE) ; Samant; Kalika
Ranjan; (HOCKESSIN, DE) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
DUPONT INDUSTRIAL BIOSCIENCES USA, LLC |
Wilmington |
DE |
US |
|
|
Family ID: |
1000005417136 |
Appl. No.: |
17/251917 |
Filed: |
June 26, 2019 |
PCT Filed: |
June 26, 2019 |
PCT NO: |
PCT/US2019/039183 |
371 Date: |
December 14, 2020 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
62691066 |
Jun 28, 2018 |
|
|
|
62747999 |
Oct 19, 2018 |
|
|
|
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
D01F 6/84 20130101; D10B
2331/04 20130101; D01F 8/14 20130101; D02G 3/04 20130101; D01F 6/92
20130101 |
International
Class: |
D01F 6/92 20060101
D01F006/92; D01F 6/84 20060101 D01F006/84; D01F 8/14 20060101
D01F008/14; D02G 3/04 20060101 D02G003/04 |
Claims
1. A spun yarn comprising: melt spun staple fiber comprising a
first polymer comprising poly(trimethylene terephthalate) or
poly(butylene terephthalate) and a second polymer comprising
poly(ethylene terephthalate) or Co-PET, wherein Co-PET is a
poly(ethylene terephthalate) copolymer comprising 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 first polymer comprises poly(butylene
terephthalate) and the weight ratio of the poly(butylene
terephthalate) to the second polymer is in the range of from about
90:10 to about 10:90.
2. The spun yarn of claim 1, wherein the first polymer comprises
poly(trimethylene terephthalate) and the second polymer comprises
poly(ethylene terephthalate).
3. The spun yarn of claim 1, wherein the first polymer comprises
poly(trimethylene terephthalate) and the second polymer comprises
Co-PET, and the Co-PET contains from about 0.5 mole percent to
about 10 mole percent isophthalic acid monomer, based on the total
copolymer composition.
4. The spun yarn of claim 1, wherein the first polymer comprises
poly(butylene terephthalate) and the second polymer comprises
poly(ethylene terephthalate).
5. The spun yarn of claim 1, wherein the first polymer comprises
poly(butylene terephthalate) and the second polymer comprises
Co-PET, and the Co-PET contains from about 0.5 mole percent to
about 10 mole percent isophthalic acid monomer, based on the total
copolymer composition.
6. The spun yarn of claim 3 or claim 5, wherein the spun yarn has a
boil off shrinkage of at least about 6% as determined according to
ASTM D2259.
8. The spun yarn of claim 1, wherein the weight ratio of the
poly(trimethylene terephthalate) or the poly(butylene
terephthalate) to the second polymer is in the range of 70:30 to
30:70.
9. The spun yarn of claim 1, further comprising a second staple
fiber in an amount from about 5 wt % to about 95 wt %, based on the
total weight of the spun yarn.
10. The spun yarn of claim 9, wherein the second staple fiber
comprises polylactic acid, acrylic, nylon, olefin, acetate, rayon,
polyester, cotton, linen, wool, angora, mohair, alpaca, cashmere,
or a mixture thereof.
11. The spun yarn of claim 10, wherein the second staple fiber
comprises cotton or wool.
12. A fabric comprising the spun yarn of claim 1.
13. The fabric of claim 12, wherein the first polymer comprises
poly(trimethylene terephthalate) and the second polymer comprises
poly(ethylene terephthalate).
14. The fabric of claim 12, wherein the first polymer comprises
poly(trimethylene terephthalate) and the second polymer comprises
Co-PET.
15. The fabric of claim 12, wherein the first polymer comprises
poly(butylene terephthalate) and the second polymer comprises
poly(ethylene terephthalate).
16. The fabric of claim 12, wherein the first polymer comprises
poly(butylene terephthalate) and the second polymer comprises
Co-PET.
17. The fabric of claim 12, wherein the fabric has at least one of:
i) better abrasion resistance as determined according to ASTM D4966
Standard Test Method; ii) higher pill rating values as determined
according to ASTM D4970 Standard Test Method; or iii) greater bulk
as determined according to ASTM D1777 Standard Test Method; than a
fabric of the same fabric construction consisting of polyethylene
terephthalate, cotton, rayon, or a combination thereof.
18. The fabric of claim 12, wherein the fabric is a woven fabric
having a warp and a weft, and the warp, the weft, or both the warp
and the weft each comprise the spun yarn of claim 1.
19. The fabric of claim 12, wherein the fabric is a knit
fabric.
20. The fabric of claim 19, wherein the fabric has higher recovery
as determined according to Method BS 4294 than a knit fabric of the
same fabric construction consisting of polyethylene terephthalate,
cotton, rayon, or a combination thereof.
21. An article comprising the fabric of claim 12.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to and the benefit of U.S.
provisional application No. 62/691066, titled "Fabrics and Spun
Yarns Comprising Polyester Staple Fiber," filed Jun. 28, 2018, and
U.S. provisional application No. 62/747999, also titled "Fabrics
and Spun Yarns Comprising Polyester Staple Fiber," filed Oct. 19,
2018 the disclosure of both of which is incorporated by reference
herein in their entirety.
FIELD OF THE DISCLOSURE
[0002] The present disclosure is directed towards spun yarn
comprising melt spun staple fiber comprising a first polymer and a
second polymer, and to fabrics comprising the spun yarn. 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.
BACKGROUND
[0003] Poly(trimethylene terephthalate) (PTT) is a commercial
fiber, offering desirable properties such as easy disperse
dyeability at atmospheric pressure, relatively low bending modulus,
and relatively high elastic recovery and resilience. Processes for
the production of PTT staple fibers are known, however consistent
processing of PTT into staple is often hampered by the shrinkage of
partially oriented tow during storage prior to drawing, crimping,
and cutting. Shrinkage is affected by storage time and storage
temperature, and uncontrolled shrinkage leads to denier
nonuniformity and draw breaks during the drawing process. As a
result, commercialization of PTT staple or blends of PTT staple
with natural fibers has been limited.
[0004] In certain textile end uses, staple fibers are preferred
over continuous filament. For example, staple spun yarns for
apparel fabrics require discontinuous fiber rather than continuous
to permit use of textile staple processing equipment. Staple fibers
additionally allow blending synthetic fibers with natural fibers,
such as wool, cotton, and cellulose. The manufacture of staple
fiber suitable for fabrics can present special problems,
particularly in conventional split spin/draw processes where the
drawing is carried out in a separate step and characteristics of
the undrawn fiber, for example dry heat shrinkage, can change as
the undrawn fiber ages during storage.
[0005] There is a continuing need for PTT-based staple of good
uniformity and tenacity, and economical processes to produce such
staple. There is a continuing need for spun yarns comprising
PTT-based staple fiber and having good tenacity and elongation at
break, and which can impart desired qualities to fabrics comprising
such spun yarns.
SUMMARY
[0006] Disclosed herein are melt spun staple fibers, spun yarns
comprising the melt spun staple fibers, and fabrics comprising the
spun yarns. In one embodiment, a spun yarn is disclosed, the spun
yarn comprising melt spun staple fiber comprising a first polymer
comprising poly(trimethylene terephthalate) or poly(butylene
terephthalate) and a second polymer comprising poly(ethylene
terephthalate) or Co-PET, wherein Co-PET is a poly(ethylene
terephthalate) copolymer comprising 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 first polymer comprises poly(butylene
terephthalate) and the weight ratio of the poly(butylene
terephthalate) to the second polymer is in the range of from about
90:10 to about 10:90. In another embodiment of the spun yarn, the
weight ratio of the poly(trimethylene terephthalate) or the
poly(butylene terephthalate) to the second polymer is in the range
of from about 70:30 to 30:70. In a further embodiment, the spun
yarn has a boil off shrinkage of at least about 6% as determined
according to ASTM D2259.
[0007] In one embodiment of the spun yarn, the melt spun staple
fiber comprises poly(trimethylene terephthalate) and poly(ethylene
terephthalate). In another embodiment of the spun yarn, the melt
spun staple fiber comprises poly(trimethylene terephthalate) and
Co-PET. In one embodiment of the spun yarn, the first polymer
comprises poly(trimethylene terephthalate) and the second polymer
comprises Co-PET, and the co-PET contains from about 0.5 mole
percent to about 10 mole percent isophthalic acid monomer, based on
the total copolymer composition. In an additional embodiment of the
spun yarn, the melt spun staple fiber comprises poly(butylene
terephthalate) and poly(ethylene terephthalate). In yet another
embodiment of the spun yarn, the melt spun staple fiber comprises
poly(butylene terephthalate) and Co-PET. In one embodiment of the
spun yarn, the first polymer comprises poly(butylene terephthalate)
and the second polymer comprises Co-PET, and the Co-PET contains
from about 0.5 mole percent to about 10 mole percent isophthalic
acid monomer, based on the total copolymer composition. In a
further embodiment of the spun yarn, the second polymer comprises
Co-PET, and the Co-PET contains from about 0.5 mole percent to
about 10 mole percent isophthalic acid monomer, based on the total
copolymer composition.
[0008] In one embodiment, the spun yarn further comprises a second
staple fiber in an amount from about 5 wt % to about 95 wt %, based
on the total weight of the spun yarn. In an additional embodiment,
the second staple fiber comprises polylactic acid, acrylic, nylon,
olefin, acetate, rayon, or polyester. In a further embodiment, the
second staple fiber comprises at least one natural fiber selected
from cotton, linen, wool, angora, mohair, alpaca, or cashmere. In
another embodiment, the second staple fiber comprises polylactic
acid, acrylic, nylon, olefin, acetate, rayon, polyester, cotton,
linen, wool, angora, mohair, alpaca, cashmere, or a mixture
thereof. In yet another embodiment, the second staple fiber
comprises cotton or wool.
[0009] In one embodiment, the second staple fiber comprises cotton.
In one embodiment, the spun yarn further comprises a second staple
fiber comprising cotton, and the cotton is present in an amount
from about 5 wt % to about 95 wt %, based on the total weight of
the spun yarn. In another embodiment, the spun yarn further
comprising cotton has a cotton count of about 4 Ne to about 80
Ne.
[0010] In another embodiment, the second staple fiber comprises
wool. In one embodiment, the spun yarn further comprises a second
staple fiber comprising wool, and the wool is present in an amount
from about 5 wt % to about 95 wt %, 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 from 7 Nm to
120 Nm.
[0011] In another embodiment, a fabric is disclosed, the fabric
comprising 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, cotton, or a combination thereof. In one embodiment,
the fabric has at least one of: i) better abrasion resistance as
determined according to ASTM D4966 Standard Test Method; ii) higher
pill rating values as determined according to ASTM D4970 Standard
Test Method,; or iii) greater bulk as determined according to ASTM
D1777 Standard Test Method; than a fabric of the same fabric
construction consisting of polyethylene terephthalate, cotton,
rayon, or a combination thereof. 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 a further embodiment, the
fabric has less pilling (higher pill rating values) than a fabric
of the same fabric construction consisting of polyethylene
terephthalate, cotton, rayon, or a combination thereof. In an
additional embodiment, the fabric has greater bulk than a fabric of
the same fabric construction consisting of polyethylene
terephthalate, cotton, rayon, or a combination thereof.
[0012] In one embodiment, the fabric is a woven fabric having a
warp and a weft. In one embodiment, the fabric is a woven fabric
having a warp and a weft, and the warp, the weft, or both the warp
and the weft each comprise a spun yarn as disclosed herein. In an
additional embodiment, the warp comprises a spun yarn as disclosed
herein. In another embodiment, the weft comprises a spun yarn as
disclosed herein. In yet a further embodiment, the warp and the
weft each comprise a spun yarn as disclosed herein. In another
embodiment, the fabric is a knit fabric. In one embodiment, the
knit fabric has higher recovery than a knit fabric of the same
fabric construction consisting of polyethylene terephthalate,
cotton, rayon, or a combination thereof. Also disclosed herein are
articles comprising a fabric as disclosed herein, for example a
garment.
[0013] In yet another embodiment, melt spun staple fiber is
disclosed, the fiber comprising a first polymer comprising
poly(trimethylene terephthalate) or poly(butylene terephthalate)
and a second polymer comprising poly(ethylene terephthalate) or
Co-PET, wherein Co-PET is a poly(ethylene terephthalate) copolymer
comprising isophthalic acid monomer, the staple fiber having a
weight ratio of the first polymer to the second polymer in the
range of about 70:30 to about 30:70, and a dry heat shrinkage of
less than 6% as determined by the Dry Heat Shrinkage Method. In one
embodiment, the melt spun staple fiber comprises poly(trimethylene
terephthalate) and poly(ethylene terephthalate). In another
embodiment, the melt spun staple fiber comprises poly(trimethylene
terephthalate) and Co-PET. In an additional embodiment, the melt
spun staple fiber comprises poly(butylene terephthalate) and
poly(ethylene terephthalate). In yet another embodiment, the melt
spun staple fiber comprises poly(butylene terephthalate) and Co-PET
In a further embodiment, the second polymer comprises Co-PET, and
the Co-PET contains from about 0.5 mole percent to about 10 mole
percent isophthalic acid monomer, based on the total copolymer
composition. In yet another embodiment of the melt spun staple
fiber, the weight ratio of the first polymer to the second polymer
is in the range of from about 70:30 to 50:50.
DETAILED DESCRIPTION
[0014] All patents, patent applications, and publications cited
herein are incorporated herein by reference in their entirety.
[0015] As used herein, the term "embodiment" or "disclosure" is not
meant to be limiting, but applies generally to any of the
embodiments defined in the claims or described herein. These terms
are used interchangeably herein.
[0016] In this disclosure, a number of terms and abbreviations are
used. The following definitions apply unless specifically stated
otherwise.
[0017] The articles "a", "an", and "the" preceding an element or
component are intended to be nonrestrictive regarding the number of
instances (i.e. occurrences) of the element or component. There
"a", "an", and "the" should be read to include one or at least one,
and the singular word form of the element or component also
includes the plural unless the number is obviously meant to be
singular.
[0018] The term "comprising" means the presence of the stated
features, integers, steps, or components as referred to in the
claims, but that it does not preclude the presence or addition of
one or more other features, integers, steps, components, or groups
thereof. The term "comprising" is intended to include embodiments
encompassed by the terms "consisting essentially of" and
"consisting of". Similarly, the term "consisting essentially of" is
intended to include embodiments encompassed by the term "consisting
of".
[0019] Where present, all ranges are inclusive and combinable. For
example, when a range of "1 to 5" is recited, the recited range
should be construed as including ranges "1 to 4", "1 to 3", 1-2",
"1-2 and 4-5", "1-3 and 5", and the like.
[0020] As used herein in connection with a numerical value, the
term "about" refers to a range of +/-0.5 of the numerical value,
unless the term is otherwise specifically defined in context. For
instance, the phrase a "pH value of about 6" refers to pH values of
from 5.5 to 6.5, unless the pH value is specifically defined
otherwise.
[0021] It is intended that every maximum numerical limitation given
throughout this Specification includes 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.
[0022] The features and advantages of the present disclosure will
be more readily understood, by those of ordinary skill in the art
from reading the following detailed description. It is to be
appreciated that certain features of the disclosure, which are, for
clarity, described above and below in the context of separate
embodiments, may also be provided in combination in a single
element. Conversely, various features of the disclosure that are,
for brevity, described in the context of a single embodiment, may
also be provided separately or in any sub-combination.
[0023] The use of numerical values in the various ranges specified
in this application, unless expressly indicated otherwise, are
stated as approximations as though the minimum and maximum values
within the stated ranges were both proceeded by the word "about".
In this manner, slight variations above and below the stated ranges
can be used to achieve substantially the same results as values
within the ranges. Also, the disclosure of these ranges is intended
as a continuous range including each and every value between the
minimum and maximum values.
[0024] As used herein:
[0025] By "poly(trimethylene terephthalate)" or PTT is meant
polymer comprising repeat units derived from 1,3-propanediol and
terephthalic acid (or equivalent). As used herein, the term
"poly(trimethylene terephthalate) homopolymer" means polymer of
substantially only 1,3-propanediol and terephthalic acid (or
equivalent). As used herein, the term "poly(trimethylene
terephthalate)" also includes PTT copolymers, by which is meant
polymer comprising repeat units derived from 1,3-propanediol and
terephthalic acid (or equivalent) and also 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, a
copoly(trimethylene terephthalate) can be used in which the
comonomer used to make the copolyester is selected from the group
consisting of linear, cyclic, and branched aliphatic dicarboxylic
acids having 4-12 carbon atoms (for example butanedioic acid,
pentanedioic acid, hexanedioic acid, dodecanedioic acid, and
1,4-cyclo-hexanedicarboxylic acid); aromatic dicarboxylic acids
other than terephthalic acid and having 8-12 carbon atoms (for
example isophthalic acid and 2,6-naphthalenedicarboxylic acid);
linear, cyclic, and branched aliphatic diols having 2-8 carbon
atoms (other than 1,3-propanediol, for example, ethanediol,
1,2-propanediol, 1,4-butanediol, 3-methyl-1,5-pentanediol,
2,2-dimethyl-1,3-propanediol, 2-methyl-1,3-propanediol, and
1,4-cyclohexanediol); and aliphatic and aromatic ether glycols
having 4-10 carbon atoms (for example, hydroquinone
bis(2-hydroxyethyl) ether, or a poly(ethylene ether) glycol having
a molecular weight below about 460, including diethylene ether
glycol). The comonomer typically is present in the copolyester at a
level in the range of about 0.5 mole % to about 15 mole %, and can
be present in amounts up to about 30 mole %.
[0026] As used herein, the term "poly(butylene terephthalate)" or
PBT means polymer derived from substantially only 1,4-butanediol
and terephthalic acid, and is also referred to as poly(butylene
terephthalate) homopolymer. As used herein, the term "poly(butylene
terephthalate) copolymer refers to polymer comprising repeat units
derived from 1,4-butanediol and terephthalic acid and also
containing at least one additional unit derived from an additional
monomer, for example a comonomer for PTT copolymers as disclosed
herein.
[0027] As used herein, the term "poly(ethylene terephthalate)" or
PET means polymer derived from substantially only ethylene glycol
and terephthalic acid (or equivalent, such as dimethyl
terephthalate), and is also referred to as poly(ethylene
terephthalate) homopolymer. As used herein, the term "poly(ethylene
terephthalate) copolymer" refers to polymer comprising repeat units
derived from ethylene glycol and terephthalic acid (or equivalent)
and also containing at least one additional unit derived from an
additional monomer.
[0028] As used herein, the term "Co-PET" refers to poly(ethylene
terephthalate) copolymers in which the additional monomer is
isophthalic acid (or an ester equivalent). As such, Co-PET is a
poly(ethylene terephthalate) copolymer comprising ethylene
terephthalate and isophthalic acid monomers.
[0029] "Staple" refers to either natural fibers or cut lengths from
filaments. The term staple (fiber) is used in the textile industry
to distinguish natural or cut man-made fibers from filament.
Man-made fibers are cut to a specific length, for example, as long
as 8 inches or as short as 1.5 inches or less, so they can be
processed on cotton, woolen, or worsted yarn spinning systems, or
flocked.
[0030] The term "melt spun staple fiber" refers to staple fiber
obtained by melting a fiber-forming substance, extruding it through
a spinneret, then solidifying it directly by cooling; such melt
spun fiber is stored, combined with other batches of melt spun
fiber obtained similarly, and collectively drawn, crimped, heat
treated for stabilization, and cut to obtain staple fiber.
[0031] The term "spun yarn" refers to yarn produced by aligning cut
staple fibers in multiple steps wherein a tow of cut staple fibers
is successively drafted into a lower and lower denier continuous
strand and in which the staple fibers are bound together by
twist.
[0032] "Undrawn yarn" is a term customarily applied to fiber that
has not been drawn, and is not intended herein to include fibers
that have been drawn and processed into a yarn product, such as
those yarns used in knitting or weaving fabric. After melt
spinning, undrawn yarn is accumulated until an appropriate total
denier for the draw machine is produced. Accumulation can take up
to 24 hours or more including dormant or storage time between
steps. For example, making sufficient undrawn yarn for economic
drawing at the draw line generally takes 6 hours or more. Due to
production scheduling and other practical considerations, fiber may
be stored for several days. Fiber having been exposed to such
storage time is referred to as "aged" or "aged undrawn yarn".
[0033] "Draw ratio", or "draw down", is the amount by which
filaments are stretched following melt spinning. As used herein,
"draw ratio" refers to machine draw ratio, which is the ratio of
the surface speed of the pulling rolls to the forwarding rolls
(rolls that move the fiber). As a result of pulling, some
stretching occurs.
[0034] "Carding" is a process whereby staple fiber bunch is opened,
individualized, aligned and formed into a continuous untwisted
strand called sliver. The card machine consists of a series of
rolls whose surfaces are covered with many projecting metal teeth
or pins.
[0035] "Tow" means a large strand of continuous manufactured fiber
filaments without definite twist, collected in loose, rope-like
form before being cut into staple or formed into sliver.
[0036] A "sliver" is a continuous strand of loosely assembled
staple fibers without twist. Sliver is delivered by the card or
drawing frame. The production of sliver is the first step in the
textile operation that converts staple fiber into a form that can
be drawn and eventually twisted into a spun yarn.
[0037] The term "fabric" means a planar textile structure produced
by interlacing yarns, fibers, or filaments.
[0038] The term "woven fabric" means a fabric composed of warp
yarns and filling (weft) yarns which are interlaced. In a weaving
process, the lengthwise or longitudinal warp yarns are held
stationary in tension on a frame or loom while the transverse weft
(which can also be referred to as woof) is drawn through and
inserted over-and-under the warp.
[0039] The term "knit fabric" means a fabric produced by
interlooping one or more ends of yarn.
[0040] The term "fabric construction" means the details of the
structure of a fabric, including the style, width, type of weave or
knit, number of yarns per inch in the warp and weft, and the weight
of goods.
[0041] The term "decitex" (dtex) is a unit of measure for the
linear mass density of fiber or yarn, and is defined as the mass in
grams per 10,000 meters.
[0042] The term "sliver linear density" means the weight in grams
of a one meter length of sliver.
[0043] The term "sliver linear density" (after the carding step)
means the number of 840 yards cut length of sliver in one pound
weight, expressed in English count Ne, or weight of sliver in grams
in 1000 meter length expressed as g/meter.
[0044] The term "final sliver linear density" (after drawing step)
means the number of 840 yards cut length of sliver in one pound
weight expressed in English count Ne, or weight of sliver in grams
in one meter expressed as g/meter.
[0045] The term "unevenness %" means the average mean deviation in
weight of a 400 meter length of spun yarn, or in a 50 meter length
of roving or a 50 meter length of sliver, as measured by Uster
evenness tester-3 (UT3), expressed as a percentage. Measured by
industrial established method using UT-3 and 400 m length of yarn
or 25 m or 50 m length of sliver or roving.
[0046] The term "imperfections" with regard to spun yarn means the
numerical sum of the number of thick regions, the number of thin
regions, and the number of neps in a 1000 meter length of yarn, as
determined using a Uster evenness tester. As used herein, the term
"thick region" means a place on the spun yarn having mass greater
than or equal to +150% of the average mass of the yarn in a 8 mm
cut length. As used herein, the term "thin region" means a place on
the spun yarn having mass less than or equal to 50% of average mass
of the yarn in a 8 mm cut length. As used herein, the term "neps"
means a place on the spun yarn having mass greater than or equal to
200% of the average mass of the yarn in a 1 mm cut length.
[0047] The term "hairiness index" refers to the average of total
length of protruding fiber per 1 cm length of yarn measured in 400
m length of yarn, measured optically using a UT3 tester, expressed
as normalized units.
[0048] The present disclosure is directed to spun yarn comprising
melt spun staple fiber comprising a first polymer comprising
poly(trimethylene terephthalate) or poly(butylene terephthalate)
and a second polymer comprising poly(ethylene terephthalate) or
Co-PET, wherein Co-PET is a poly(ethylene terephthalate) copolymer
comprising 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 about 80:20 to about 10:90; or the first polymer
comprises poly(butylene terephthalate) and the weight ratio of the
poly(butylene terephthalate) to the second polymer is in the range
of from about 90:10 to about 10:90. The melt spun staple fiber
lacks any distinct interface between the first and second polymers.
The spun yarn has a boil off shrinkage of at least about 6%, as
determined according to ASTM D2259. Optionally, the spun yarn can
comprise a second staple fiber, for example cotton or wool. Fabrics
with desirable characteristics can be made from the spun yarns.
[0049] It has been found that the melt spun staple fiber disclosed
herein has improved tenacity, crimp, and stability in comparison to
PTT melt spun staple fiber, and the properties of the melt spun
staple fiber advantageously enable processing under conditions
typically used with PET during staple conversion into spun yarns.
Additionally, the spun yarns comprising the melt spun staple fiber
disclosed herein, whether further comprising a second staple fiber
or consisting essentially of the melt spun staple fiber alone,
enable production of woven, knitted, and nonwoven fabrics having
cotton-like aesthetics, good strength, and other desirable
attributes.
[0050] In one embodiment, the melt spun staple fiber of the spun
yarn comprises a first polymer comprising poly(trimethylene
terephthalate). Poly(trimethylene terephthalate) suitable for use
in the melt spun staple fiber is well known in the art and can be
prepared, for example, by polycondensation of 1,3-propane diol with
terephthalic acid or terephthalic acid equivalent. Optionally, the
1,3-propane diol may be obtained biochemically from a renewable
source ("biologically-derived" 1,3-propanediol). Poly(trimethylene
terephthalate)s are commercially available from E. I. du Pont de
Nemours and Company, Wilmington, Del. under the trademark
Sorona.RTM.. Optionally, PTT or its monomers could be obtained from
recycling post-industrial or post-consumer materials (i.e. fiber or
plastic waste).
[0051] By "terephthalic acid equivalent" is meant compounds that
perform substantially like terephthalic acids in reaction with
polymeric glycols and diols, as would be generally recognized by a
person of ordinary skill in the relevant art. Terephthalic acid
equivalents include, for example, esters (such as dimethyl
terephthalate), and ester-forming derivatives such as acid halides
(e.g., acid chlorides) and anhydrides. Terephthalic acid and
terephthalic acid esters, for example the dimethyl ester, are
suitable. Methods for preparation of poly(trimethylene
terephthalate) are disclosed, for example, in U.S. Pat. Nos.
6,277,947, 6,326,456, 6,657,044, 6,353,062, 6,538,076, and
7,531,617.
[0052] Preferably the 1,3-propanediol used as a reactant or as a
component of the reactant in making poly(trimethylene
terephthalate) has a purity of greater than about 99%, for example
greater than about 99.9%, by weight as determined by gas
chromatographic analysis. Purified 1,3-propanediols are disclosed
in U.S. Pat. No. 7,038,092, 7,098,368, 7,084,311, and
7,919,658.
[0053] Poly(trimethylene terephthalate) suitable for use in the
melt spun fibers can be poly(trimethylene terephthalate)
homopolymers (derived substantially from 1,3-propane diol and
terephthalic acid and/or equivalent) and copolymers. In one
embodiment, the poly(trimethylene terephthalate) contains about 70
mole % or more of repeat units derived from 1,3-propane diol and
terephthalic acid (and/or an equivalent thereof, such as dimethyl
terephthalate). The poly(trimethylene terephthalate) can contain at
least about 85 mole %, or at least about 90 mole %, or at least
about 95 mole %, or at least about 99 mole %, or about 100 mole %
of repeat units derived from 1,3-propane diol and terephthalic acid
(or equivalent).
[0054] The poly(trimethylene terephthalate) can contain minor
amounts of other comonomers, and such comonomers are usually
selected so that they do not have a significant adverse effect on
properties. Such other comonomers include
5-sodium-sulfoisophthalate, for example, at a level in the range of
about 0.2 to 5 mole %. Very small amounts of trifunctional
comonomers, for example trimellitic acid, can be incorporated for
viscosity control.
[0055] The poly(trimethylene terephthalate) can contain up to 30
mole % of repeat units made from other diols or diacids. Other
diacids include, for example, isophthalic acid, 1,4-cyclohexane
dicarboxylic acid, 2,6-naphthalene dicarboxylic acid,
1,3-cyclohexane dicarboxylic acid, succinic acid, glutaric acid,
adipic acid, sebacic acid, 1,12-dodecane dioic acid, and the
derivatives thereof such as the dimethyl, diethyl, or dipropyl
esters of these dicarboxylic acids. Other diols include ethylene
glycol, 1,4-butane diol, 1,2-propanediol, diethylene glycol,
triethylene glycol, 1,3-butane diol, 1,5-pentane diol, 1,6-hexane
diol, 1,2-, 1,3- and 1,4-cyclohexane dimethanol, and the longer
chain diols and polyols made by the reaction product of diols or
polyols with alkylene oxides.
[0056] The poly(trimethylene terephthalate) can also include
functional monomers, for example, up to about 5 mole % of sulfonate
compounds useful for imparting cationic dyeability. Specific
examples of preferred sulfonate compounds include 5-lithium
sulfoisophthalate, 5-sodium sulfoisophthalate, 5-potassium
sulfoisophthalate, 4-sodium sulfo-2,6-naphthalenedicarboxylate,
tetramethylphosphonium 3,5-dicarboxybenzene sulfonate,
tetrabutylphosphonium 3,5-dicarboxybenzene sulfonate,
tributyl-methylphosphonium 3,5-dicarboxybenzene sulfonate,
tetrabutylphosphonium 2,6-dicarboxynaphthalene-4-sulfonate,
tetramethylphosphonium 2,6-dicarboxynapthalene-4-sulfonate,
ammonium 3,5-dicarboxybenzene sulfonate, and ester derivatives
thereof, for example methyl or dimethyl esters.
[0057] Poly(trimethylene terephthalate) has an intrinsic viscosity
that typically is about 0.5 deciliters/gram (dl/g) or higher, and
typically is about 2 dl/g or less. In one embodiment, the
poly(trimethylene terephthalate) has an intrinsic viscosity that is
about 0.7 dl/g or higher, for example 0.8 dl/g or higher, or for
example 0.9 dl/g or higher, and typically it is about 1.5 dl/g or
less, for example 1.4 dl/g or less, and commercial products
presently available have intrinsic viscosities of 1.2 dl/g or
less.
[0058] In another embodiment, the melt spun staple fiber of the
spun yarn comprises a first polymer comprising poly(butylene
terephthalate). Poly(butylene terephthalate) suitable for use in
the melt spun staple fiber is also well known in the art and can be
prepared, for example, by polycondensation of 1,4-butanediol with
terephthalic acid. Poly(butylene terephthalate)s are commercially
available from E. I. du Pont de Nemours and Company, Wilmington,
Del. under the trademark Crastin.RTM..
[0059] Poly(butylene terephthalate) suitable for use in the melt
spun fibers can be homopolymers (derived substantially from
1,4-butanediol and terephthalic acid and/or equivalent) and
copolymers. In one embodiment, the poly(butylene terephthalate)
contains about 80 mole % or more of repeat units derived from
1,4-butanediol and terephthalic acid. In other embodiment, the
poly(butylene terephthalate) can contain at least about 85 mole %,
or at least about 90 mole %, or at least about 95 mole %, or at
least about 99 mole %, or about 100 mole % of repeat units derived
from 1,4-butanediol and terephthalic acid (or equivalent). The
poly(trimethylene terephthalate) can contain minor amounts of other
comonomers or functional monomers. Optionally, PBT or its monomers
could be obtained from recycling post-industrial or post-consumer
materials (i.e. fiber or plastic waste).
[0060] Polyethylene terephthalate (PET) is a polyester that may be
prepared by the condensation polymerization of ethylene glycol and
terephthalic acid (or dimethyl terephthalate or other terephthalate
ester). Processes for producing poly(ethylene terephthalate) are
known, for example as disclosed in U.S. Pat. No. 3,398,124 and U.S.
Pat. No. 3,487,049. Poly(ethylene terephthalate) suitable for use
in preparing the melt spun staple fiber disclosed herein is also
commercially available. In one embodiment, the poly(ethylene
terephthalate) is a homopolymer and is derived substantially from
ethylene glycol and terephthalic acid and/or equivalent.
Optionally, PET or its monomers could be obtained from recycling
post-industrial or post-consumer material (i.e. fiber or plastic
waste).
[0061] In many applications, it can be desirable to modify the
properties of poly(ethylene terephthalate) by adding a third
monomer. For example, a copolymer of polyethylene terephthalate can
be prepared from monomers of dimethyl terephthalate or terephthalic
acid in combination with cyclohexane dimethanol, or in combination
with cyclohexane dimethanol and ethylene glycol. In other cases,
isophthalic acid can be used to replace a portion of the
terephthalic acid monomer, which disrupts crystallinity and lowers
the melting point of the copolymer, which is referred to herein as
"Co-PET".
[0062] As used herein, "Co-PET" refers to poly(ethylene
terephthalate) copolymers that may be prepared by the condensation
polymerization of ethylene glycol, terephthalic acid (or dimethyl
terephthalate or other terephthalate ester) and isophthalic acid
(or dimethyl isophthalate or other terephthalate ester), as known
in the art. Co-PET can also be produced in a process in which
recycled poly(ethylene terephthalate) bottles are chopped, melted,
purified, and repelletized to produce fiber-grade post-consumer
recycled Co-PET. The isophthalic acid monomer is typically present
in Co-PET at a level in the range of about 0.5 mole % to about 15
mole %, and can be present in amounts up to about 30 mole %, based
on the total copolymer composition. 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 mole %,
of isophthalic acid monomer. In one embodiment, Co-PET useful in
the melt spun staple fibers disclosed herein contains from about 1
mole % to about 5 mole %, or up to about 10 mole %, or up to about
15 mole %, isophthalic acid monomer, based on the total copolymer
composition. In another embodiment, useful Co-PET contains from
about 0.5 mol % to about 3 mole % isophthalic acid monomer. The
amount of isophthalic acid monomer in Co-PET can be selected to
provide the desired properties to the Co-PET. It is thought that
the lower melting point of Co-PET can improve the compatibility of
Co-PET and poly(trimethylene terephthalate) during melt spinning.
Co-PET is commercially available.
[0063] In some embodiments, a polyethylene terephthalate copolymer
containing an additional monomer other than isophthalic acid may be
used. For example, a polyethylene terephthalate copolymer
comprising ethylene glycol, terephthalic acid (or equivalent), and
a dicarboxylic acid such as succinic acid, adipic acid, azelaic
acid, sebacic acid, glutaric acid, 1,10-decanedicarboxylic acid,
phthalic acid, dodecanedioic acid, sulfonated isophthalic acid,
oxalic acid, fumaric acid, maleic acid, itaconic acid,
1,4-cyclohexanedicarboxylic acid, 1,3-cyclohexanedicarboxylic acid,
1,2-cyclohexanedicarboxylic acid, and mixtures there of may be
useful in preparing a melt spun staple fiber. Alternatively, a
polyethylene terephthalate copolymer comprising ethylene glycol,
terephthalic acid (or equivalent), and a diol such as diethylene
glycol, polyethylene glycol, butylene glycol, 1,4-cyclohexane
dimethanol, 1,2-cyclohexanediol, 1,4-cyclohexanediol,
1,3-cyclohexanediol, 1,5-pentanediol, 1,6-hexanediol, and mixtures
thereof may be useful in preparing a melt spun staple fiber.
[0064] In one embodiment, Co-PET is a poly(ethylene terephthalate)
copolymer comprising ethylene terephthalate and isophthalic acid
monomers. In another embodiment, Co-PET is a poly(ethylene
terephthalate) copolymer consisting essentially of poly(ethylene
terephthalate) and isophthalic acid monomers. In a further
embodiment, Co-PET is a poly(ethylene terephthalate) copolymer
consisting of poly(ethylene terephthalate) and isophthalic acid
monomers.
[0065] The melt spun staple fiber comprises a first polymer
comprising poly(trimethylene terephthalate) or poly(butylene
terephthalate) and a second polymer comprising poly(ethylene
terephthalate) or Co-PET; 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 comprises
poly(butylene terephthalate) and the weight ratio of the
poly(butylene terephthalate) to the second polymer is in the range
of from about 90:10 to about 10:90. In one embodiment, the melt
spun staple fiber comprises poly(trimethylene terephthalate) (PTT)
and poly(ethylene terephthalate) (PET), and the melt spun staple
fiber comprises about 80 weight percent PTT and about 20 weight
percent PET. In one embodiment, the melt spun staple fiber
comprises about 75 weight percent PTT and about 25 weight percent
PET. In one embodiment, the melt spun staple fiber comprises about
70 weight percent PTT and about 30 weight percent PET. In another
embodiment, the staple fiber comprises about 65 weight percent PTT
and about 35 weight percent PET. In yet another embodiment, the
staple fiber comprises about 60 weight percent PTT and about 40
weight percent PET. In an additional embodiment, the staple fiber
comprises about 55 weight percent PTT and about 45 weight percent
PET. In a further embodiment, the staple fiber comprises about 50
weight percent PTT and about 50 weight percent PET. In another
embodiment, the staple fiber comprises about 45 weight percent PTT
and about 55 weight percent PET. In a separate embodiment, the
staple fiber comprises about 40 weight percent PTT and about 60
weight percent PET. In another embodiment, the staple fiber
comprises about 35 weight percent PTT and about 65 weight percent
PET. In yet another embodiment, the staple fiber comprises about 30
weight percent PTT and about 70 weight percent PET. In one
embodiment, the melt spun staple fiber comprises about 25 weight
percent PTT and about 75 weight percent PET. In one embodiment, the
melt spun staple fiber comprises about 20 weight percent PTT and
about 80 weight percent PET. In one embodiment, the melt spun
staple fiber comprises about 15 weight percent PTT and about 85
weight percent PET. In one embodiment, the melt spun staple fiber
comprises about 10 weight percent PTT and about 90 weight percent
PET.
[0066] In one embodiment, the melt spun staple fiber comprises
poly(trimethylene terephthalate (PTT) and a poly(ethylene
terephthalate) copolymer comprising 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 comprises about 80 weight percent PTT and about 20 weight
percent Co-PET. In an additional embodiment, the melt spun staple
fiber comprises about 75 weight percent PTT and about 25 weight
percent Co-PET. In one embodiment, the melt spun staple fiber
comprises about 70 weight percent PTT and about 30 weight percent
Co-PET. In another embodiment, the melt spun staple fiber comprises
about 65 weight percent PTT and about 35 weight percent Co-PET. In
yet another embodiment, the melt spun staple fiber comprises about
60 weight percent PTT and about 40 weight percent Co-PET. In an
additional embodiment, the melt spun staple fiber comprises about
55 weight percent PTT and about 45 weight percent Co-PET. In a
further embodiment, the melt spun staple fiber comprises about 50
weight percent PTT and about 50 weight percent Co-PET. In another
embodiment, the melt spun staple fiber comprises about 45 weight
percent PTT and about 55 weight percent Co-PET. In a separate
embodiment, the melt spun staple fiber comprises about 40 weight
percent PTT and about 60 weight percent Co-PET. In another
embodiment, the melt spun staple fiber comprises about 35 weight
percent PTT and about 65 weight percent Co-PET. In yet another
embodiment, the melt spun staple fiber comprises about 30 weight
percent PTT and about 70 weight percent Co-PET. In one embodiment,
the melt spun staple fiber comprises about 25 weight percent PTT
and about 75 weight percent Co-PET. In another embodiment, the melt
spun staple fiber comprises about 20 weight percent PTT and about
80 weight percent Co-PET. In yet another embodiment, the melt spun
staple fiber comprises about 15 weight percent PTT and about 85
weight percent Co-PET. In an additional embodiment, the melt spun
staple fiber comprises about 10 weight percent PTT and about 90
weight percent Co-PET.
[0067] In one embodiment, the melt spun staple fiber comprises
poly(butylene terephthalate) (PBT) and poly(ethylene terephthalate)
(PET), and the melt spun staple fiber comprises about 90 weight
percent PBT and about 10 weight percent PET. In another embodiment,
the melt spun staple fiber comprises about 85 weight percent PBT
and about 15 weight percent PET. In one embodiment, the melt spun
staple fiber comprises about 80 weight percent PBT and about 20
weight percent PET. In one embodiment, the melt spun staple fiber
comprises about 75 weight percent PBT and about 25 weight percent
PET. In one embodiment, the melt spun staple fiber comprises about
70 weight percent PBT and about 30 weight percent PET. In another
embodiment, the staple fiber comprises about 65 weight percent PBT
and about 35 weight percent PET. In yet another embodiment, the
staple fiber comprises about 60 weight percent PBT and about 40
weight percent PET. In an additional embodiment, the staple fiber
comprises about 55 weight percent PBT and about 45 weight percent
PET. In a further embodiment, the staple fiber comprises about 50
weight percent PBT and about 50 weight percent PET. In another
embodiment, the staple fiber comprises about 45 weight percent PBT
and about 55 weight percent PET. In a separate embodiment, the
staple fiber comprises about 40 weight percent PBT and about 60
weight percent PET. In another embodiment, the staple fiber
comprises about 35 weight percent PBT and about 65 weight percent
PET. In yet another embodiment, the staple fiber comprises about 30
weight percent PBT and about 70 weight percent PET. In one
embodiment, the melt spun staple fiber comprises about 25 weight
percent PBT and about 75 weight percent PET. In one embodiment, the
melt spun staple fiber comprises about 20 weight percent PBT and
about 80 weight percent PET. In one embodiment, the melt spun
staple fiber comprises about 15 weight percent PBT and about 85
weight percent PET. In one embodiment, the melt spun staple fiber
comprises about 10 weight percent PBT and about 90 weight percent
PET.
[0068] In one embodiment, the melt spun staple fiber comprises
poly(butylene terephthalate (PBT) and a poly(ethylene
terephthalate) copolymer comprising isophthalic acid monomer
(Co-PET), and the weight ratio of PBT to Co-PET is in the range of
about 90:10 to about 10:90. In one embodiment, the melt spun staple
fiber comprises about 85 weight percent PBT and about 15 weight
percent Co-PET. In another embodiment, the melt spun staple fiber
comprises about 80 weight percent PBT and about 20 weight percent
Co-PET. In an additional embodiment, the melt spun staple fiber
comprises about 75 weight percent PBT and about 25 weight percent
Co-PET. In one embodiment, the melt spun staple fiber comprises
about 70 weight percent PBT and about 30 weight percent Co-PET. In
another embodiment, the melt spun staple fiber comprises about 65
weight percent PBT and about 35 weight percent Co-PET. In yet
another embodiment, the melt spun staple fiber comprises about 60
weight percent PBT and about 40 weight percent Co-PET. In an
additional embodiment, the melt spun staple fiber comprises about
55 weight percent PBT and about 45 weight percent Co-PET. In a
further embodiment, the melt spun staple fiber comprises about 50
weight percent PBT and about 50 weight percent Co-PET. In another
embodiment, the melt spun staple fiber comprises about 45 weight
percent PBT and about 55 weight percent Co-PET. In a separate
embodiment, the melt spun staple fiber comprises about 40 weight
percent PBT and about 60 weight percent Co-PET. In another
embodiment, the melt spun staple fiber comprises about 35 weight
percent PBT and about 65 weight percent Co-PET. In yet another
embodiment, the melt spun staple fiber comprises about 30 weight
percent PBT and about 70 weight percent Co-PET. In one embodiment,
the melt spun staple fiber comprises about 25 weight percent PBT
and about 75 weight percent Co-PET. In another embodiment, the melt
spun staple fiber comprises about 20 weight percent PBT and about
80 weight percent Co-PET. In yet another embodiment, the melt spun
staple fiber comprises about 15 weight percent PBT and about 85
weight percent Co-PET. In an additional embodiment, the melt spun
staple fiber comprises about 10 weight percent PBT and about 90
weight percent Co-PET.
[0069] The melt spun staple fiber can be formed in a two-stage
process. In the first stage, the polymers are combined, melted,
extruded to form filaments comprising the polymers, the filaments
are cooled, and collected as tow. In the second stage, the tow can
be processed through at least one stage of draw, crimped, annealed,
and cut to produce staple fiber. Processes to prepare polyester
staple fiber are known, for example as disclosed in U.S. Pat. No.
5,308,564.
[0070] The first polymer (PTT or PBT) and the second polymer (PET
or Co-PET), can be combined by any known technique. The polymers
can be combined in a variety of ways, for example they can be (a)
heated and mixed simultaneously, (b) pre-mixed in a separate
apparatus before heating, or (c) heated and then mixed. The mixing,
heating, and forming can be carried out by conventional equipment
designed for that purpose such as extruders. The temperature should
be above the melting points of each polymer but below the lowest
decomposition temperature. Suitable temperatures can be in the
range of about 140.degree. C. to about 240.degree. C., for example
at least about 200.degree. C. and up to about 230.degree. C. In one
embodiment, the melt temperature is below 280.degree. C.
[0071] In one embodiment, the polymers can be compounded, for
example in a compounding screw, in a desired ratio to form pellets
which are then fed to a spinning machine extruder. In another
embodiment, pellets can be made of each polymer separately, and
then the pellets are blended together as a salt-and-pepper mixture
using up to two feeders to a spinning machine extruder.
Alternatively, pellets can be made of each polymer separately, and
the pellets pre-mixed together before being fed to a spinning
machine 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 "pellets" is used generically herein, and is used
regardless of shape so that it includes products sometimes called
"chips" or "flakes".
[0072] If desired, additives can be added to the poly(trimethylene
terephthalate), to the poly(butylene terephthalate), to the
poly(ethylene terephthalate), to the Co-PET, or to the mixture of
polymers. Useful additives can include, for example, delusterants,
nucleating agents, heat stabilizers, viscosity boosters, optical
brighteners, antioxidants, antimicrobials, plasticizers,
anti-static agents, lubricants, processing aids, flame retardants,
dyes, TiO.sub.2, or pigments.
[0073] The combined first and second polymers (i.e., a PTT and PET
mixture, a PTT and Co-PET mixture, a PBT and PET mixture, or a PBT
and Co-PET mixture) are extruded through a spinneret at a
temperature of about 250.degree. C. to about 275.degree. C., for
example at least about 255.degree. C. and up to about 270.degree.
C. The spun filaments are extruded in bundles comprising at least
about 34 filaments per threadline, for example from about 175
filaments to about 6800 filaments, or even 6900 filaments or
higher. The undrawn filaments typically have a denier per filament
in the range of about 3 to about 8, or more. Spinneret orifices are
typically round for round fiber cross-sections, but variously
shaped orifices can be used as needed, for example for trilobal or
delta cross-sections. The spun filaments have a denier in the range
of from about 3 to about 8 dpf and are collected as bundles (tow).
Typically, the tow has a dry heat shrinkage of less than 6% as
determined by the Dry Heat Shrinkage Method disclosed herein in the
Examples.
[0074] In the second stage of the process to prepare staple fiber,
tow is fed from a set of cans or a creel containing undrawn melt
spun yarns. Finish may be applied to facilitate processing
downstream. Tow is then then drawn while immersed in a heated
dilute finish water bath. In general feed roll is kept at room
temperature while the draw roll may be heated. Drawn tow is
stabilized by passing it through a saturated steam chamber and can
be optionally further drawn and annealed over a number of heated
draw roll modules before passing it over a room temperature roll
module. Various simplifications of the draw zone are possible with
less or more heater or room temperature draw module to optimally
draw and stabilize yarn in preparation for crimping. Crimping
module typically uses a steam box that reduces yarn modulus in
preparation for crimping, Typically, the crimper is a mechanical
stuffer box type crimper with a flapper gate, acted upon by
pneumatic pressure. Yarn tow is pulled into the crimper box by a
set of driven rolls; yarn buckles and forms crimp as the flow out
of the box is controlled by back pressure on the flapper. Crimped
tow passes through an annealer section prior to being cut into
staple.
[0075] The final denier per filament of the melt spun staple fiber
may range from 1-2 for cotton system processing and from 2-3 for
wool system processing.
[0076] The melt spun staple fibers disclosed herein offer
processing advantages. For example, the staple fiber can be
processed with good productivity through opening, carding, and
drawing steps in making spun yarns. The melt spun staple fibers
disclosed herein may be run on a staple spinning process using
conditions typical for PET staple spinning.
[0077] The drawn fiber can be cut into staple of any desired
length. If the staple fiber is too short, it can be difficult to
card. If it is too long, it can be difficult to spin on cotton or
woolen system equipment. For use in the cotton system, the staple
fiber typically has a length in the range of from about 32 mm to
about 51 mm, for example in the range of from about 38 to 40 mm.
For use in the worsted system, the staple fiber typically has
multiple cut lengths with an average cut length in the range of
from about 70 mm to about 100 mm, for example in the range of from
about 80 mm to about 90 mm. The staple fiber can be crimped to have
full sinus arc from about 10 to about 18, for example about 11 to
about 15, crimps per inch. For cotton system, the melt spun staple
fiber typically has 1-2 denier per filament, a tenacity greater
than 4 g/denier, and a break elongation of 20-60%, as determined
using methods disclosed in the Examples herein below. For worsted
system, melt spun staple fiber typically has 2-4 denier per
filament, a tenacity greater than 4 g/denier, and a break
elongation of 30-90%.
[0078] The melt spun staple fiber disclosed herein can be used to
make spun yarn. In one embodiment, the spun yarn consists
essentially of the melt spun staple fiber, and does not contain any
other type of staple fiber. In another embodiment, the spun yarn
comprises the melt spun staple fiber disclosed herein. In a further
embodiment, the spun yarn further comprises a second staple fiber
in an amount from about 5 weight percent to about 95 weight
percent, based on the total weight of the spun yarn. In one
embodiment, the second staple fiber can comprise at least one
natural fiber. In a further embodiment, the second staple fiber
comprises at least one natural fiber selected from cotton, linen,
wool, angora, mohair, alpaca, or cashmere. In another embodiment,
the second staple can comprise at least one synthetic fiber. In a
further embodiment, the second staple fiber comprises polylactic
acid, acrylic, nylon, olefin, acetate, rayon, or polyester. In yet
another embodiment, the second staple fiber can comprise at least
one regenerated cellulose fiber. As used herein, the term
"regenerated cellulose fiber" means a textile fiber made from
regenerated cellulose, also referred to as rayon, and includes
lyocell, viscose, Modal.RTM., and Tencel.RTM. fibers. As used
herein, "lyocell" means a form of rayon which consists of cellulose
fiber made from dissolving bleached wood pulp using dry jet-wet
spinning. As used herein, "viscose" means a regenerated
manufactured fiber made from cellulose and obtained by the viscose
process. As used herein, "Modal.RTM." means fiber made from wood
pulp from beech trees. As used herein, "Tencel.RTM." means fiber
made from eucalyptus trees.
[0079] In one embodiment, the spun yarn comprises melt spun staple
fiber comprising a first polymer comprising PTT or PBT and a second
polymer comprising PET or Co-PET, wherein the weight ratio of the
first polymer to the second polymer is in the range of from about
80:20 to about 10:90, or about 70:30 to about 30:70, or about 60:40
to about 40:60; or about 70:30 to about 50:50, and the spun yarn
further comprises a second staple fiber comprising cotton. In a
further embodiment, 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 from about
90:10 to about 10:90, for example from about 90:10 to about 80:20,
and the spun yarn further comprises a second staple fiber
comprising cotton. The cotton can be present in the spun yarn in an
amount from about 5 wt % to about 95 wt %, and the melt spun staple
fiber can be present in the spun yarn in an amount from about 95 wt
% to about 5 wt %, based on the total weight of the spun yarn. For
example, the spun yarn can contain about 5 wt % cotton and about 95
wt % melt spun staple fiber, or about 10 wt % cotton and about 90
wt % melt spun staple fiber, or about 15 wt % cotton and about 85
wt % melt spun staple fiber, or about 20 wt % cotton and about 80
wt % melt spun staple fiber, or about 25 wt % cotton and about 75
wt % melt spun staple fiber, or about 30 wt % cotton and about 70
wt % melt spun staple fiber, or about 35 wt % cotton and about 65
wt % melt spun staple fiber, or about 40 wt % cotton and about 60
wt % melt spun staple fiber, or about 45 wt % cotton and about 55
wt % melt spun staple fiber, or about 50 wt % cotton and about 50
wt % melt spun staple fiber, or about 55 wt % cotton and about 45
wt % melt spun staple fiber, or about 60 wt % cotton and about 40
wt % melt spun staple fiber, or about 65 wt % cotton and about 35
wt % melt spun staple fiber, or about 70 wt % cotton and about 30
wt % melt spun staple fiber, or about 75 wt % cotton and about 25
wt % melt spun staple fiber, or about 80 wt % cotton and about 20
wt % melt spun staple fiber, based on the total weight of the spun
yarn. In another embodiment, the spun yarn can comprise the melt
spun staple fiber at greater than 95 wt % and the second staple
fiber comprising cotton at less than 5 wt %. The relative amounts
of cotton and melt spun staple fiber are selected to provide
desired characteristics to the spun yarn and fabrics made from the
yarn. The spun yarn can have a cotton count (Ne) of about 4 to
about 70, for example from about 4 to about 60, or from about 4 to
about 50, or from about 10 to about 60, or from about 20 to about
60. The spun yarn comprising cotton can have a tenacity at break of
at least 10 cN/tex. In some embodiments the spun yarn comprising
cotton can have a tenacity at break of at least 10 cN/tex. The spun
yarn comprising cotton can have an elongation at break of at least
4%. Methods to determine tenacity and elongation at break are
provided in the Examples herein below.
[0080] In another embodiment, the spun yarn comprises melt spun
staple fiber comprising a first polymer comprising PTT or PBT and a
second polymer comprising PET or Co-PET, wherein the weight ratio
of the first polymer to the second polymer is in the range of from
about 80:20 to about 10:90, or about 70:30 to about 30:70, or about
60:40 to about 40:60; or about 70:30 to about 50:50, and the spun
yarn further comprises a second staple fiber comprising wool. In a
further embodiment, 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 from about
90:10 to about 10:90, for example from about 90:10 to about 80:20,
and the spun yarn further comprises a second staple fiber
comprising wool. The term "wool" refers to the fiber from fleece of
sheep or lamb. The wool can be present in an amount from about 5 wt
% to about 95 wt %, and the melt spun staple fiber can be present
in an amount from about 95 wt % to about 5 wt %, based on the total
weight of the spun yarn. For example, the spun yarn can contain
about 5 wt % wool and about 95 wt % melt spun staple fiber, or
about 10 wt % wool and about 90 wt % melt spun staple fiber, or
about 15 wt % wool and about 85 wt % melt spun staple fiber, or
about 20 wt % wool and about 80 wt % melt spun staple fiber, or
about 25 wt % wool and about 75 wt % melt spun staple fiber, or
about 30 wt % wool and about 70 wt % melt spun staple fiber, or
about 35 wt % wool and about 65 wt % melt spun staple fiber, or
about 40 wt % wool and about 60 wt % melt spun staple fiber, or
about 45 wt % wool and about 55 wt % melt spun staple fiber, or
about 50 wt % wool and about 50 wt % melt spun staple fiber, or
about 55 wt % wool and about 45 wt % melt spun staple fiber, or
about 60 wt % wool and about 40 wt % melt spun staple fiber, or
about 65 wt % wool and about 35 wt % melt spun staple fiber, or
about 70 wt % wool and about 30 wt % melt spun staple fiber, or
about 75 wt % wool and about 25 wt % melt spun staple fiber, or
about 80 wt % wool and about 20 wt % melt spun staple fiber, or
about 85 wt % wool and about 15 wt % melt spun staple fiber, or
about 90 wt % wool and about 10 wt % melt staple fiber, or about 95
wt % wool and about 5 wt % melt spun staple fiber, based on the
total weight of the spun yarn. The relative amounts of wool and
melt spun staple fiber are selected to provide desired
characteristics to the spun yarn and fabrics made from the yarn.
The spun yarn can have a worsted count (Nm) of about 7 to about
120, for example from about 7 to about 110, or from about 7 to
about 100, or from about 10 to about 120, or from about 10 to about
100, or from about 10 to about 75.
[0081] In another embodiment, the spun yarn comprises melt spun
staple fiber comprising a first polymer comprising PTT or PBT and a
second polymer comprising PET or Co-PET, wherein the weight ratio
of the first polymer to the second polymer is in the range of from
about 80:20 to about 10:90, or about 70:30 to about 30:70, or about
60:40 to about 40:60; or about 70:30 to about 50:50, and the spun
yarn further comprises a second staple fiber comprising rayon. In a
further embodiment, 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 from about
90:10 to about 10:90, for example from about 90:10 to about 80:20,
and the spun yarn further comprises a second staple fiber
comprising rayon. As used herein, "rayon" means textile fiber made
from regenerated cellulose and includes lyocell, viscose,
Modal.RTM., and Tencel.RTM. fibers. In the spun yarn, the rayon can
be present in an amount from about 5 wt % to about 95 wt %, and the
melt spun staple fiber can be present in an amount from about 95 wt
% to about 5 wt %, based on the total weight of the spun yarn. For
example, the spun yarn can contain about 5 wt % rayon and about 95
wt % melt spun staple fiber, or about 10 wt % rayon and about 90 wt
% melt spun staple fiber, or about 15 wt % rayon and about 85 wt %
melt spun staple fiber, or about 20 wt % rayon and about 80 wt %
melt spun staple fiber, or about 25 wt % rayon and about 75 wt %
melt spun staple fiber, or about 30 wt % rayon and about 70 wt %
melt spun staple fiber, or about 35 wt % rayon and about 65 wt %
melt spun staple fiber, or about 40 wt % rayon and about 60 wt %
melt spun staple fiber, or about 45 wt % rayon and about 55 wt %
melt spun staple fiber, or about 50 wt % rayon and about 50 wt %
melt spun staple fiber, or about 55 wt % rayon and about 45 wt %
melt spun staple fiber, or about 60 wt % rayon and about 40 wt %
melt spun staple fiber, or about 65 wt % rayon and about 35 wt %
melt spun staple fiber, or about 70 wt % rayon and about 30 wt %
melt spun staple fiber, or about 75 wt % rayon and about 25 wt %
melt spun staple fiber, or about 80 wt % rayon and about 20 wt %
melt spun staple fiber, or about 85 wt % rayon and about 15 wt %
melt spun staple fiber, or about 90 wt % rayon and about 10 wt %
melt staple fiber, or about 95 wt % rayon and about 5 wt % melt
spun staple fiber, based on the total weight of the spun yarn. The
relative amounts of rayon and melt spun staple fiber are selected
to provide desired characteristics to the spun yarn and fabrics
made from the yarn. The spun yarn can have a cotton count (Ne) of
about 4 to about 80,for example from about 10 to about 60, or from
about 12 to about 40.
[0082] In another embodiment, the spun yarn comprises melt spun
staple fiber comprising a first polymer comprising PTT or PBT and a
second polymer comprising PET or Co-PET, wherein the weight ratio
of the first polymer to the second polymer is in the range of from
about 80:20 to about 10:90, or about 70:30 to about 30:70, or about
60:40 to about 40:60; or about 70:30 to about 50:50, and the spun
yarn further comprises a second staple fiber comprising acrylic. In
a further embodiment, 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 from about
90:10 to about 10:90, for example from about 90:10 to about 80:20,
and the spun yarn further comprises a second staple fiber
comprising acrylic. As used herein, "acrylic fiber" means synthetic
fibers made from a polyacrylonitrile having an average molecular
weight of -100,000, about 1900 monomer units. The acrylic fiber can
be present in an amount from about 5 wt % to about 95 wt %, and the
melt spun staple fiber can be present in an amount from about 95 wt
% to about 5 wt %, based on the total weight of the spun yarn. For
example, the spun yarn can contain about 5 wt % acrylic fiber and
about 95 wt % melt spun staple fiber, or about 10 wt % acrylic
fiber and about 90 wt % melt spun staple fiber, or about 15 wt %
acrylic fiber and about 85 wt % melt spun staple fiber, or about 20
wt % acrylic fiber and about 80 wt % melt spun staple fiber, or
about 25 wt % acrylic fiber and about 75 wt % melt spun staple
fiber, or about 30 wt % acrylic fiber and about 70 wt % melt spun
staple fiber, or about 35 wt % acrylic fiber and about 65 wt % melt
spun staple fiber, or about 40 wt % acrylic fiber and about 60 wt %
melt spun staple fiber, or about 45 wt % acrylic fiber and about 55
wt % melt spun staple fiber, or about 50 wt % acrylic fiber and
about 50 wt % melt spun staple fiber, or about 55 wt % acrylic
fiber and about 45 wt % melt spun staple fiber, or about 60 wt %
acrylic fiber and about 40 wt % melt spun staple fiber, or about 65
wt % acrylic fiber and about 35 wt % melt spun staple fiber, or
about 70 wt % acrylic fiber and about 30 wt % melt spun staple
fiber, or about 75 wt % acrylic fiber and about 25 wt % melt spun
staple fiber, or about 80 wt % acrylic fiber and about 20 wt % melt
spun staple fiber, or about 85 wt % acrylic fiber and about 15 wt %
melt spun staple fiber, or about 90 wt % acrylic fiber and about 10
wt % melt staple fiber, or about 95 wt % acrylic fiber and about 5
wt % melt spun staple fiber, based on the total weight of the spun
yarn. The relative amounts of acrylic fiber and melt spun staple
fiber are selected to provide desired characteristics to the spun
yarn and fabrics made from the yarn. The spun yarn can have a
cotton count (Ne) of about 4 to about 80, for example from about 10
to about 60, or from about 12 to about 40.
[0083] In another embodiment, the spun yarn comprises melt spun
staple fiber comprising a first polymer comprising PTT or PBT and a
second polymer comprising PET or Co-PET, wherein the weight ratio
of the first polymer to the second polymer is in the range of from
about 80:20 to about 10:90, or about 70:30 to about 30:70, or about
60:40 to about 40:60; or about 70:30 to about 50:50, and the spun
yarn further comprises a second staple fiber comprising polylactic
acid (PLA). In a further embodiment, 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 from about 90:10 to about 10:90, for example from about 90:10 to
about 80:20, and the spun yarn further comprises a second staple
fiber comprising PLA. As used herein, "polylactic fiber" means a
manufactured fiber in which the fiber-forming substance is composed
of at least 85% by weight of lactic acid ester units derived from
naturally occurring sugars. The PLA can be present in an amount
from about 5 wt % to about 95 wt %, and the melt spun staple fiber
can be present in an amount from about 95 wt % to about 5 wt %,
based on the total weight of the spun yarn. For example, the spun
yarn can contain about 5 wt % PLA and about 95 wt % melt spun
staple fiber, or about 10 wt % PLA and about 90 wt % melt spun
staple fiber, or about 15 wt % PLA and about 85 wt % melt spun
staple fiber, or about 20 wt % PLA and about 80 wt % melt spun
staple fiber, or about 25 wt % PLA and about 75 wt % melt spun
staple fiber, or about 30 wt % PLA and about 70 wt % melt spun
staple fiber, or about 35 wt % PLA and about 65 wt % melt spun
staple fiber, or about 40 wt % PLA and about 60 wt % melt spun
staple fiber, or about 45 wt % PLA and about 55 wt % melt spun
staple fiber, or about 50 wt % PLA and about 50 wt % melt spun
staple fiber, or about 55 wt % PLA and about 45 wt % melt spun
staple fiber, or about 60 wt % PLA and about 40 wt % melt spun
staple fiber, or about 65 wt % PLA and about 35 wt % melt spun
staple fiber, or about 70 wt % PLA and about 30 wt % melt spun
staple fiber, or about 75 wt % PLA and about 25 wt % melt spun
staple fiber, or about 80 wt % PLA and about 20 wt % melt spun
staple fiber, or about 85 wt % PLA and about 15 wt % melt spun
staple fiber, or about 90 wt % PLA and about 10 wt % melt staple
fiber, or about 95 wt % PLA and about 5 wt % melt spun staple
fiber, based on the total weight of the spun yarn. The relative
amounts of PLA and melt spun staple fiber are selected to provide
desired characteristics to the spun yarn and fabrics made from the
yarn.
[0084] In another embodiment, the spun yarn comprises melt spun
staple fiber comprising a first polymer comprising PTT or PBT and a
second polymer comprising PET or Co-PET, wherein the weight ratio
of the first polymer to the second polymer is in the range of from
about 80:20 to about 10:90, or about 70:30 to about 30:70, or about
60:40 to about 40:60; or about 70:30 to about 50:50, and the spun
yarn further comprises a second staple fiber comprising nylon. In a
further embodiment, 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 from about
90:10 to about 10:90, for example from about 90:10 to about 80:20,
and the spun yarn further comprises a second staple fiber
comprising nylon. As used herein, "nylon fiber" means a
manufactured fiber in which the fiber-forming substance is a long
chain synthetic polyamide in which less than 85% of the amide
linkages are attached directly to two aliphatic groups. The nylon
can be present in an amount from about 5 wt % to about 95 wt %, and
the melt spun staple fiber can be present in an amount from about
95 wt % to about 5 wt %, based on the total weight of the spun
yarn. For example, the spun yarn can contain about 5 wt % nylon and
about 95 wt % melt spun staple fiber, or about 10 wt % nylon and
about 90 wt % melt spun staple fiber, or about 15 wt % nylon and
about 85 wt % melt spun staple fiber, or about 20 wt % nylon and
about 80 wt % melt spun staple fiber, or about 25 wt % nylon and
about 75 wt % melt spun staple fiber, or about 30 wt % nylon and
about 70 wt % melt spun staple fiber, or about 35 wt % nylon and
about 65 wt % melt spun staple fiber, or about 40 wt % nylon and
about 60 wt % melt spun staple fiber, or about 45 wt % nylon and
about 55 wt % melt spun staple fiber, or about 50 wt % nylon and
about 50 wt % melt spun staple fiber, or about 55 wt % nylon and
about 45 wt % melt spun staple fiber, or about 60 wt % nylon and
about 40 wt % melt spun staple fiber, or about 65 wt % nylon and
about 35 wt % melt spun staple fiber, or about 70 wt % nylon and
about 30 wt % melt spun staple fiber, or about 75 wt % nylon and
about 25 wt % melt spun staple fiber, or about 80 wt % nylon and
about 20 wt % melt spun staple fiber, or about 85 wt % nylon and
about 15 wt % melt spun staple fiber, or about 90 wt % nylon and
about 10 wt % melt staple fiber, or about 95 wt % nylon and about 5
wt % melt spun staple fiber, based on the total weight of the spun
yarn. The relative amounts of nylon and melt spun staple fiber are
selected to provide desired characteristics to the spun yarn and
fabrics made from the yarn.
[0085] In another embodiment, the spun yarn comprises melt spun
staple fiber comprising a first polymer comprising PTT or PBT and a
second polymer comprising PET or Co-PET, wherein the weight ratio
of the first polymer to the second polymer is in the range of from
about 80:20 to about 10:90, or about 70:30 to about 30:70, or about
60:40 to about 40:60; or about 70:30 to about 50:50, and the spun
yarn further comprises a second staple fiber comprising olefin. In
a further embodiment, 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 from about
90:10 to about 10:90, for example from about 90:10 to about 80:20,
and the spun yarn further comprises a second staple fiber
comprising olefin. As used herein, "olefin fiber" means a
manufactured fiber in which the fiber-forming substance is any long
chain synthetic polymer composed of at least 85% by weight of
ethylene, propylene, or other olefin units, except amorphous
(noncrystalline) polyolefins qualifying as a rubber fiber. The
olefin fiber can be present in an amount from about 5 wt % to about
95 wt %, and the melt spun staple fiber can be present in an amount
from about 95 wt % to about 5 wt %, based on the total weight of
the spun yarn. For example, the spun yarn can contain about 5 wt %
olefin fiber and about 95 wt % melt spun staple fiber, or about 10
wt % olefin fiber and about 90 wt % melt spun staple fiber, or
about 15 wt % olefin fiber and about 85 wt % melt spun staple
fiber, or about 20 wt % olefin fiber and about 80 wt % melt spun
staple fiber, or about 25 wt % olefin fiber and about 75 wt % melt
spun staple fiber, or about 30 wt % olefin fiber and about 70 wt %
melt spun staple fiber, or about 35 wt % olefin fiber and about 65
wt % melt spun staple fiber, or about 40 wt % olefin fiber and
about 60 wt % melt spun staple fiber, or about 45 wt % olefin fiber
and about 55 wt % melt spun staple fiber, or about 50 wt % olefin
fiber and about 50 wt % melt spun staple fiber, or about 55 wt %
olefin fiber and about 45 wt % melt spun staple fiber, or about 60
wt % olefin fiber and about 40 wt % melt spun staple fiber, or
about 65 wt % olefin fiber and about 35 wt % melt spun staple
fiber, or about 70 wt % olefin fiber and about 30 wt % melt spun
staple fiber, or about 75 wt % olefin fiber and about 25 wt % melt
spun staple fiber, or about 80 wt % olefin fiber and about 20 wt %
melt spun staple fiber, or about 85 wt % olefin fiber and about 15
wt % melt spun staple fiber, or about 90 wt % olefin fiber and
about 10 wt % melt staple fiber, or about 95 wt % olefin fiber and
about 5 wt % melt spun staple fiber, based on the total weight of
the spun yarn. The relative amounts of olefin fiber and melt spun
staple fiber are selected to provide desired characteristics to the
spun yarn and fabrics made from the yarn.
[0086] In another embodiment, the spun yarn comprises melt spun
staple fiber comprising a first polymer comprising PTT or PBT and a
second polymer comprising PET or Co-PET, wherein the weight ratio
of the first polymer to the second polymer is in the range of from
about 80:20 to about 10:90, or about 70:30 to about 30:70, or about
60:40 to about 40:60; or about 70:30 to about 50:50, and the spun
yarn further comprises a second staple fiber comprising acetate. In
a further embodiment, 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 from about
90:10 to about 10:90, for example from about 90:10 to about 80:20,
and the spun yarn further comprises a second staple fiber
comprising acetate. As used herein, "acetate fiber" means a
manufactured fiber in which the fiber-forming substance is
cellulose acetate, and includes diacetate and triacetate. Diacetate
is defined as cellulose acetate fiber for which more than 74% and
less than 92% of the hydroxyl groups has been acetylated (degree of
esterification above 2.22 and below 2.76). Triacetate is defined as
cellulose acetate fiber for which more than 92% of the hydroxyl
groups has been acetylated (degree of esterification above 2.76 and
below 3.00). The acetate fiber can be present in an amount from
about 5 wt % to about 95 wt %, and the melt spun staple fiber can
be present in an amount from about 95 wt % to about 5 wt %, based
on the total weight of the spun yarn. For example, the spun yarn
can contain about 5 wt % acetate fiber and about 95 wt % melt spun
staple fiber, or about 10 wt % acetate fiber and about 90 wt % melt
spun staple 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 wt % melt spun staple fiber, or about 30 wt % acetate
fiber and about 70 wt % melt spun staple fiber, or about 35 wt %
acetate fiber and about 65 wt % melt spun staple fiber, or about 40
wt % acetate fiber and about 60 wt % melt spun staple fiber, or
about 45 wt % acetate fiber and about 55 wt % melt spun staple
fiber, 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 wt %
melt spun staple fiber, or about 65 wt % acetate fiber and about 35
wt % melt spun staple fiber, or about 70 wt % acetate fiber and
about 30 wt % melt spun staple fiber, or about 75 wt % acetate
fiber and about 25 wt % melt spun staple fiber, or about 80 wt %
acetate fiber and about 20 wt % melt spun staple fiber, or about 85
wt % acetate fiber and about 15 wt % melt spun staple fiber, or
about 90 wt % acetate fiber and about 10 wt % melt staple fiber, or
about 95 wt % acetate fiber and about 5 wt % melt spun staple
fiber, based on the total weight of the spun yarn. The relative
amounts of acetate fiber and melt spun staple fiber are selected to
provide desired characteristics to the spun yarn and fabrics made
from the yarn.
[0087] In another embodiment, the spun yarn comprises melt spun
staple fiber comprising a first polymer comprising PTT or PBT and a
second polymer comprising PET or Co-PET, wherein the weight ratio
of the first polymer to the second polymer is in the range of from
about 80:20 to about 10:90, or about 70:30 to about 30:70, or about
60:40 to about 40:60; or about 70:30 to about 50:50, and the spun
yarn further comprises a second staple fiber comprising a
polyester, for example poly(ethylene terephthalate),
poly(trimethylene terephthalate), or poly (butylene terephthalate).
In a further embodiment, the first polymer comprises poly(butylene
terephthalate) and the weight ratio of the poly(butylene
terephthalate) to the second polymer is in the range of from about
90:10 to about 10:90, for example from about 90:10 to about 80:20,
and the spun yarn further comprises a second staple fiber
comprising a polyester. The polyester can be present in an amount
from about 5 wt % to about 95 wt %, and the melt spun staple fiber
can be present in an amount from about 95 wt % to about 5 wt %,
based on the total weight of the spun yarn. For example, the spun
yarn can 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, or about 15 wt % polyester fiber
and about 85 wt % melt spun staple fiber, or about 20 wt %
polyester fiber and about 80 wt % melt spun staple fiber, or about
25 wt % polyester fiber and about 75 wt % melt spun staple fiber,
or about 30 wt % polyester fiber and about 70 wt % melt spun staple
fiber, or about 35 wt % polyester fiber and about 65 wt % melt spun
staple fiber, or about 40 wt % polyester fiber and about 60 wt %
melt spun staple fiber, or about 45 wt % polyester fiber and about
55 wt % melt spun staple fiber, or about 50 wt % polyester fiber
and about 50 wt % melt spun staple fiber, or about 55 wt %
polyester fiber and about 45 wt % melt spun staple fiber, or about
60 wt % polyester fiber and about 40 wt % melt spun staple fiber,
or about 65 wt % polyester fiber and about 35 wt % melt spun staple
fiber, or about 70 wt % polyester fiber and about 30 wt % melt spun
staple fiber, or about 75 wt % polyester fiber and about 25 wt %
melt spun staple fiber, or about 80 wt % polyester fiber and about
20 wt % melt spun staple fiber, or about 85 wt % polyester fiber
and about 15 wt % melt spun staple fiber, or about 90 wt %
polyester fiber and about 10 wt % melt staple fiber, or about 95 wt
% polyester fiber and about 5 wt % melt spun staple fiber, based on
the total weight of the spun yarn. The relative amounts of
polyester fiber and melt spun staple fiber are selected to provide
desired characteristics to the spun yarn and fabrics made from the
yarn. The spun yarn can have a cotton count (Ne) of about 4 to
about 80, for example from about 10 to about 60, or from about 12
to about 40.
[0088] The melt spun staple fibers are cut to lengths as desired
for blending with a second fiber and subsequent processing on the
cotton or woolen system. For example, spun yarns comprising the
melt spun staple fiber and cotton, linen, polylactic acid, acrylic,
nylon, olefin, acetate, polyester, or rayon fiber typically can be
processed on the cotton system. Spun yarns comprising the melt spun
staple fiber and wool, angora, mohair, or cashmere fiber typically
can be processed on the woolen system.
[0089] To form the spun yarns, the melt spun staple fibers, and
optionally at least one second staple fiber, are first blended, for
example by stack mixing, a process in which fiber bales are opened,
mixed, and laid in layers. Fiber bundles can be opened to smaller
sized fiber tufts, for example in a blow room using a sequence of
coarse opening machines followed by fine opening machines. The
smaller fiber bundles are then carded to form a continuous fiber
strand, referred to as sliver, where almost all the fibers are
oriented along the sliver axis. Sliver from a carding machine can
have very high mass/length variation, so typically a number of
carding slivers (i.e. 6) are combined and simultaneously drafted by
the same amount (i.e., 6X) to further orient the fibers in the
resultant sliver, for example with a draw frame machine or other
methods known in the art. The sliver delivered from the final draw
frame has minimal mass/length variation but high linear density
compared to the linear density desired in the final spun yarn, so
the linear density of the sliver is reduced in a drawing process.
Typically the drawing process is operated in two steps, in which
partial drafting and twisting are performed to prepare the roving.
The roving is converted to spun yarn by drafting it further on a
final spinning machine using known processes such as ring, open
end, air jet, and vortex spinning. The spun yarn can be wound onto
a small package referred to as a cop in ring spinning; several cops
can be joined and wound onto a larger final package referred to as
a cone.
[0090] Woven and knitted fabrics can be made from the spun yarns
disclosed herein. Stretch fabric examples include circular, flat,
and warp knits, and plain, twill, and satin wovens. Articles such
as garments can be made from fabrics comprising the spun yarns
disclosed herein. Nonwoven fabrics can be made from the staple
fibers disclosed herein, and can be useful in articles such as
wipes, diapers, napkins, and personal care items. Nonwoven fabrics
can also be used as the base material for coated fabrics and in a
variety of other applications, such as apparel and home
furnishings.
[0091] The spun yarns disclosed herein are useful in making
fabrics, such as woven or knit fabrics. In one embodiment, a fabric
comprising a spun yarn as disclosed herein is a woven fabric having
a warp and a weft. In one embodiment, the warp comprises a spun
yarn as disclosed herein. In another embodiment, the weft comprises
a spun yarn as disclosed herein. In an additional embodiment, the
warp and the weft each comprise a spun yarn as disclosed herein.
The woven fabric can further comprise additional yarns or
continuous filament, for example in the warp, in the weft, or in
both the warp and the weft. In another embodiment, spun yarn as
disclosed herein is used in the warp, and a spun yarn comprising a
natural fiber is used in the weft. In another embodiment, spun yarn
as disclosed herein is used in the warp, and a spun yarn comprising
a synthetic fiber is used in the weft. In yet another embodiment, a
spun yarn comprising a natural fiber is used in the warp and a spun
yarn as disclosed herein is used in the weft. In a further
embodiment, a spun yarn comprising a synthetic fiber is used in the
warp and a spun yarn as disclosed herein is used in the weft. In
still another embodiment, spun yarn as disclosed herein is used in
the warp and also in the weft. Knit fabrics can be made using only
the spun yarns disclosed herein, or in conjunction with a spun yarn
comprising a natural or a synthetic fiber. Woven fabrics comprising
spun yarns as disclosed herein can have a fabric weight in the
range of about 80 g/m.sup.2 to about 600 g/m.sup.2, for
example.
[0092] Fabrics comprising spun yarns as disclosed herein can offer
advantages over fabrics of the same construction consisting of spun
yarns of PET, cotton, rayon, PTT, or a combination thereof, and
lacking the melt spun staple fibers disclosed herein. For example,
fabrics comprising spun yarns comprising melt spun staple fibers as
disclosed herein can have softer hand (i.e. feel softer) than
fabrics of PET, cotton, rayon, or a combination thereof, as well as
greater bulk, as indicated by greater fabric thickness. Fabrics
comprising the spun yarns disclosed herein can have better
dyeability than a fabric of the same construction consisting of
PET, cotton, rayon, or a combination thereof. Compared to PET
fabrics of similar construction, the fabrics disclosed herein can
dye more deeply, darker, and at lower temperatures. The fabrics
disclosed herein can have better dye pickup than PET fabrics when
dyed at a lower temperature, which offers reduced cost through
energy savings. For example, fabrics containing the spun yarns
disclosed herein can dye darker (i.e. have lower L* values when
measured under a D65 light source) than PET fabrics when dyed
simultaneously, and can dye darker than PET fabric even when dyed
at 100.degree. C. and with comparison PET fabrics dyed at
130.degree. C. The properties of picking up more dye, picking up
dye at lower temperature, and dyeing more deeply can be referred to
as "better dyeability" of a fabric. The woven fabrics disclosed
herein can also have improved drape, for example as demonstrated by
higher area of drape and drape coefficient values, for example as
determined by method BS 5058. Especially desirable in a fabric is
the combination of softer hand and improved drape. Additionally,
the fabrics disclosed herein demonstrated less pilling (higher pill
rating values) than fabrics of the same construction consisting of
PET, cotton, rayon, or a combination thereof, for example as
determined by the ASTM D4970 method, and better abrasion
resistance. The fabrics disclosed herein can also have better tear
strength in the warp and/or weft direction than fabrics of the same
construction consisting of PET, cotton, rayon, or a combination
thereof. Knit fabrics comprising spun yarns as disclosed herein can
have higher recovery than a knit fabric of the same construction
consisting of polyethylene terephthalate, cotton, rayon, or a
combination thereof.
[0093] Non-limiting examples of the embodiments disclosed herein
include: [0094] 1. A spun yarn comprising: melt spun staple fiber
comprising a first polymer comprising poly(trimethylene
terephthalate) (PTT) or poly(butylene terephthalate) (PBT) and a
second polymer comprising poly(ethylene terephthalate) (PET) or
Co-PET, 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 first polymer
comprises poly(butylene terephthalate) and the weight ratio of the
poly(butylene terephthalate) to the second polymer is in the range
of from about 90:10 to about 10:90. [0095] 2. The spun yarn of
embodiment 1, wherein the first polymer comprises poly(trimethylene
terephthalate) and the second polymer comprises poly(ethylene
terephthalate). [0096] 3. The spun yarn of embodiment 1 or 2,
wherein the first polymer comprises poly(trimethylene
terephthalate) and the second polymer comprises Co-PET. [0097] 4.
The spun yarn of embodiment 1, wherein the first polymer comprises
poly(butylene terephthalate) and the second polymer comprises
poly(ethylene terephthalate). [0098] 5. The spun yarn of embodiment
1 or 4, wherein the first polymer comprises poly(butylene
terephthalate) and the second polymer comprises Co-PET. [0099] 6.
The spun yarn of embodiment 1, 3, or 5, wherein the second polymer
comprises Co-PET, and the Co-PET contains from about 0.5 mole
percent to about 10 mole percent isophthalic acid monomer, based on
the total copolymer composition. [0100] 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. [0101] 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. [0102] 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. [0103] 10. The spun yarn of
spun yarn of embodiment 1, 2, 3, 4, 5, 6, or 7, wherein the weight
ratio of the poly(trimethylene terephthalate) or the poly(butylene
terephthalate) to the second polymer is in the range of about 70:30
to about 30:70. [0104] 11. The spun yarn of embodiment 1, 2, 3, 4,
5, 6, 7, 8, 9, or 10, wherein the spun yarn has a boil off
shrinkage of at least about 6% as determined according to ASTM
D2259. [0105] 12. The spun yarn of embodiment 1, 2, 3, 4, 5, 6, 7,
8, 9, 10, or 11 further comprising a second staple fiber in an
amount from about 5 wt % to about 95 wt %, based on the total
weight of the spun yarn. [0106] 13. The spun yarn of embodiment 12,
wherein the second staple fiber comprises polylactic acid, acrylic,
nylon, olefin, acetate, rayon, polyester, cotton, linen, wool,
angora, mohair, alpaca, cashmere, or a mixture thereof. [0107] 14.
The spun yarn of embodiment 12, wherein the second staple fiber
comprises cotton or wool. [0108] 15. The spun yarn of embodiment
12, 13, or 14, wherein the second staple fiber comprises cotton.
[0109] 16. The spun yarn of embodiment 1, 2, 3, 4, 5, 6, 7, 8, 9,
10, 11, 12, 13, 14, or 15, wherein the spun yarn has a cotton count
of about 4 Ne to about 80 Ne. [0110] 17. The spun yarn of
embodiment 12, 13, or 14, wherein the second staple fiber comprises
wool. [0111] 18. The spun yarn of embodiment 1, 2, 3, 4, 5, 6, 7,
8, 9, 10, 11, 12, 13, 14, or 17, wherein the spun yarn has a
worsted count in the range of from 7 Nm to 120 Nm. [0112] 19. A
fabric comprising a spun yarn of embodiment 1, 2, 3, 4, 5, 6, 7, 8,
9, 10, 11, 12, 13, 14, 15, 16, 17, or 18. [0113] 20. A fabric of
embodiment 19, wherein the fabric has a softer hand and better
drape than a fabric of the same fabric construction consisting of
rayon, polyethylene terephthalate, cotton, or a combination
thereof. [0114] 21. A fabric of embodiment 19 or 20, wherein the
fabric has better dyeability than a fabric of the same fabric
construction consisting of polyethylene terephthalate, cotton,
rayon, or a combination thereof. [0115] 22. A fabric of embodiment
19, 20, or 21, wherein the fabric has better abrasion resistance as
determined according to ASTM D4966 Standard Test Method than a
fabric of the same fabric construction consisting of polyethylene
terephthalate, cotton, rayon, or a combination thereof. [0116] 23.
A fabric of embodiment 19, 20, 21, or 22, wherein the fabric has
less pilling (higher pill rating values) as determined according to
ASTM D4970 Standard Test Method than a fabric of the same fabric
construction consisting of polyethylene terephthalate, cotton,
rayon, or a combination thereof. [0117] 24. A fabric of embodiment
19, 20, 21, 22, or 23, wherein the fabric has greater bulk as
determined according to ASTM D1777 Standard Test Method than a
fabric of the same fabric construction consisting of polyethylene
terephthalate, cotton, rayon, or a combination thereof. [0118] 25.
A fabric of embodiment 19, 20, or 21, wherein the fabric has at
least one of: [0119] i) better abrasion resistance as determined
according to ASTM D4966 Standard Test Method; [0120] ii) higher
pill rating values as determined according to ASTM D4970 Standard
Test Method; or [0121] iii) greater bulk as determined according to
ASTM D1777 Standard Test Method; than a fabric of the same fabric
construction consisting of polyethylene terephthalate, cotton,
rayon, or a combination thereof. [0122] 26. A fabric of embodiment
19, 20, 21, 22, 23, 24, or 25, wherein the fabric is a woven fabric
having a warp and a weft. [0123] 27. A fabric of embodiment 26,
wherein the warp comprises a spun yarn of embodiment 1, 2, 3, 4, 5,
6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, or 18. [0124] 28. A
fabric of embodiment 26 or 27, wherein the weft comprises a spun
yarn of embodiment 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14,
15, 16, 17, or 18. [0125] 29. A fabric of embodiment 26, 27, or 28,
wherein both the warp and the weft each comprise a spun yarn of
embodiment 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16,
17, or 18. [0126] 30. A fabric of embodiment 19, 20, 21, 22, 23,
24, or 25, wherein the fabric is a knit fabric. [0127] 31. A fabric
of embodiment 30, wherein the knit fabric has higher recovery as
determined according to Method BS 4294 than a knit fabric of the
same fabric construction consisting of polyethylene terephthalate,
cotton, rayon, or a combination thereof. [0128] 32. An article
comprising a fabric of embodiment 19, 20, 21, 22, 23, 24, 25, 26,
27, 28, 29, 30, or 31. [0129] 33. An article of embodiment 32,
wherein the article is a garment. [0130] 34. Melt spun staple fiber
comprising a first polymer comprising poly(trimethylene
terephthalate) or poly(butylene terephthalate) and a second polymer
comprising poly(ethylene terephthalate) or Co-PET, wherein Co-PET
is a poly(ethylene terephthalate) copolymer comprising isophthalic
acid monomer, the staple fiber having: [0131] a) a weight ratio of
poly(trimethylene terephthalate) to the second polymer in the range
of from about 80:20 to about 10:90; or [0132] a weight ratio of
poly(butylene terephthalate) to the second polymer in the range of
from about 90:10 to about 10:90; and [0133] b) a dry heat shrinkage
of less than 6% as determined by the Dry Heat Shrinkage Method.
[0134] 35. 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 in the range
of about 70:30 to about 30:70. [0135] 36. 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 in the range of about 70:30 to about 50:50. [0136] 37.
Melt spun staple fiber of embodiment 34, 35, or 36, wherein the
first polymer comprises poly(trimethylene terephthalate) and the
second polymer comprises poly(ethylene terephthalate). [0137] 38.
Melt spun staple fiber of embodiment 34, 35, or 36, wherein the
first polymer comprises poly(trimethylene terephthalate) and the
second polymer comprises Co-PET. [0138] 39. Melt spun staple fiber
of embodiment 34, 35, or 36, wherein the first polymer comprises
poly(butylene terephthalate) and the second polymer comprises
poly(ethylene terephthalate). [0139] 40. Melt spun staple fiber of
embodiment 34, 35, or 36, wherein the first polymer comprises
poly(butylene terephthalate) and the second polymer comprises
Co-PET. [0140] 41. Melt spun staple fiber of embodiment 34, 35, 36,
38, or 40, wherein the second polymer comprises Co-PET, and the
Co-PET contains from about 0.5 mole percent to about 10 mole
percent isophthalic acid monomer, based on the total copolymer
composition.
EXAMPLES
[0141] As used herein, "Comp. Ex." Means Comparative Example; "Ex."
means Example; "rpm" means revolutions per minute; "wt %" means
weight percent; "dL/g" is deciliters per gram; "g" is gram(s); "mg"
is millligram(s); ".degree. C." means degrees Celsius; "min" is
minute(s); "h" is hour(s); "s" is second(s); "lb" is pound(s); "kg"
is kilogram(s); "mm" is millimeter(s); "m" is meter(s); "gpl" is
grams per liter; "m/min" is meters per minute; "mol" is mole; "kg"
is kilogram(s); "ppm" is parts per million; "Hz" is hertz; "cN" is
centiNewton(s); "rpm" is revolutions per minute; "wt" is weight;
"dpf" is denier per filament; "g/d" is grams per denier; "Ne" means
cotton count (English) and is a measure of linear density defined
as the number hanks (850 yards or 770 meters) of skein material
that weight 1 pound (0.45 kg); "Nm" means metric count and refers
to the number of 1000 meter units in a kilogram of yarn; "dtex"
means decitex; "AATCC" means American Association of Textile
Chemists and Colorists; "ASTM" means American Society for Testing
and Materials; and "BS" means British Standards Institution.
Materials
[0142] Unless otherwise noted, all materials were used as
received.
[0143] Polytrimethylene terephthalate (PTT) containing 0.3%
TiO.sub.2 and having an intrinsic viscosity of 0.96 dL/g was
obtained from E.I. du Pont de Nemours and Company (Wilmington,
Del.) as merge K2266.
[0144] Co-PET containing 1.7 mol % of isophthalic acid (IPA)
monomer, 48.4 mol % of terephthalic acid (TPA) monomer, and 49.9
mol % of ethylene glycol (EG) monomer was obtained from Nan Ya
Plastics Corporation, America, P.O. Box 939, Lake City, S.C 29560,
USA. The Co-PET composition was determined by NMR analysis and is
given based on the total copolymer composition. The Co-PET had an
intrinsic viscosity of 0.80 dL/g.
[0145] Fiber-grade post-consumer recycled Co-PET, containing 1.1
mol % IPA monomer, 49.1 mol % TPA monomer, and 49.9 mol % of EG
monomer was obtained from William Barnet & Son, LLC, P.O. Box
171898, Spartanburg, S.C. 29301, USA. The Co-PET composition was
determined by NMR analysis and is given based on the total
copolymer composition. The Co-PET had an intrinsic viscosity of
0.76 dL/g.
Methods
[0146] "Co-PET" composition was determined by NMR analysis using
the following procedure. The Co-PET pellets were cryoground into a
powder-like form, then .about.18 mg were weighed into an NMR tube
and a solution of 5:1 CDCI3:TFA-D (5:1 deuterated
chloroform/deuterated trifluoroacetic acid) added to 0.6 mL total
volume. The sample was vortexed to dissolve the Co-PET. A proton
NMR spectrum was obtained within 30 minutes of dissolution.
[0147] Proton NMR spectra were acquired on a 500 MHz Bruker Avance
III HD NMR equipped with 5 mm CPQCI (indirect) cryoprobe at
30.degree. C. The following parameters were used for acquisition:
recycle delay of 30 seconds, acquisition time of 4 sec, 90 degree
pulse of 8.0 seconds, spectral window of 10000 Hz, 79998 points, a
total of 64 scans/transients collected and averaged. The spectrum
is referenced to chloroform-d residual proton signal at 7.24 ppm,
and processed with lb of 0.10 Hz and zero-filled out to 512 k.
[0148] Co-PET composition was calculated from integrals for the
signals at approximately 8.7 ppm, 8.1 ppm, and 4.8 ppm
corresponding to isophthalic acid, terephthalic acid, and ethylene
glycol between terephthalic acid groups, respectively. The
isophthalic acid signal used represents 1 mole of protons, so its
integral was already relative. The terephthalic acid integral
represents 4 moles of terephthalic acid protons and includes 2
moles of isophthalic acid protons; the terephthalic acid relative
integral was determined by subtracting 2.times. the isophthalic
acid relative integral, then dividing the remainder by 4. The
ethylene glycol-related integral corresponds to 4 moles of ethylene
glycol protons, and the relative integral was determined by
dividing the measured integral by 4. The three relative integrals
were totaled, and the relative mol % values were calculated as each
corresponding relative integral divided by the total, then
multiplied by 100%.
[0149] Dry Heat Shrinkage of undrawn melt spun fiber was determined
using the following procedure, which is referred to herein as Dry
Heat Shrinkage Method. A 50-cm diameter, 10-loop skein was prepared
and its length was measured under a 20 g weight. Two such loops
were allowed to shrink by exposure to 40.degree. C. for 20 hours
under zero imposed tension. Loops were cooled to 21.degree. C. at
65% relative humidity prior to remeasuring the length under 20 g
weight. Dry Heat Shrinkage, as a percentage, was calculated as
follows:
% Dry heat shrinkage=(Initial length-length after
heating)*100/Initial length
For melt spun staple fiber, an Automatic Single-Fiber Test System
FAVIMAT+ was used to determine fiber properties, using the
following methods. Denier was determined according to ASTM D1577
Standard Test Methods for Linear Density of Textile Fibers.
Tenacity and elongation at break were determined according to ASTM
D3822 Tensile Properties of Single Textile Fibers.
[0150] Crimp properties of staple fibers are characterized by crimp
contraction, crimp stability, and crimp recovery. Crimp contraction
is the difference in length of a crimped versus de-crimped fiber.
Measuring crimped length, L0, under a low load of 0.001 cN/dtex and
de-crimped length, L1, under a heavy load of 0.1 cN/dtex allows one
to calculate crimp contraction as [(L1-L0)/L1]*100.
[0151] Crimp stability is a measure of stability of crimp under a
specified load. It can be measured by determining recovery in
staple length when a load is removed. With L2 as the length of
staple fiber (measured under 0.001 cN/dtex) 60 sec after a heavier
load of 0.1 cN/dtex is applied for 10 sec (to determine L1), crimp
stability can be calculated as [(L1-L241-L0)]*100.
[0152] Crimp recovery is the difference in length of a de-crimped
fiber, L1, and the fiber length after releasing the crimp removal
force, L2, expressed as a percentage of de-crimped fiber:
[(L1-L2)/L1]*100.
Melt Spun Fiber Examples
Comparative Example A
Melt Spun PTT Fiber
[0153] Polytrimethylene terephthalate (PTT) containing 0.3%
TiO.sub.2 and having an intrinsic viscosity of 0.96 dL/g was dried
at 120.degree. C. under nitrogen blanket in a vacuum oven for 16
hours and melt-extruded into round cross-section, 34-filament yarn
bundle using a twin-screw extruder spinning machine. Extruder melt
zone temperatures were maintained from 180-255.degree. C. Polymer
throughput was 14.06 g/min with a winder speed of 1250 m/m giving a
spun denier per filament of 2.9.
[0154] Dry heat shrinkage of yarn bundle was determined to be
47%.
Example 1
Undrawn Melt Spun Fiber Containing PTT and Co-PET
[0155] Polytrimethylene terephthalate containing 0.3% TiO.sub.2 and
having an intrinsic viscosity of 0.96 dL/g was melt blended with
polyethylene terephthalate co-ethylene isophthalate (Co-PET) (from
Nan Ya Plastics) having an intrinsic viscosity of 0.80 dL/g in a
twin-screw extruder in a 50/50 weight ratio to form compounded
pellets. Extruder throughput was 150 lb/h (68.04 kg/h, 0.0189 kg/s)
and melt temperature at extruder exit was under 285.degree. C. as
measured by a hand-held thermocouple.
[0156] PTT:Co-PET compounded pellets were dried at 120.degree. C.
under nitrogen blanket in a vacuum oven for 16 hours and
melt-extruded into round cross-section, 34-filament yarn bundle
using a twin-screw extruder spinning machine.
[0157] Extruder melt zone temperatures were maintained from
180-255.degree. C. Polymer throughput was either 14.06 g/min or
21.52 g/min. For each throughput, winder speed was either 750 m/m
or 1250 m/m giving a spun denier per filament in the range of from
3.3 to 7.7. Dry heat shrinkage of yarn bundles (tow) was measured
to be in the range of 1.2% to 3.1%. This amount of dry heat
shrinkage in undrawn fiber is very low and indicates stability of
the material during storage. Results are shown in the following
Table.
TABLE-US-00001 TABLE 1 Example 1 Spinning Conditions and Dry Heat
Shrinkage of Tow Throughput, g/min Winder Speed, m/m Dry Heat
Shrinkage, % 14.06 750 1.4 14.06 1250 3.1 21.52 750 1.2 21.52 1250
2.3
Example 2
Undrawn Melt Spun Fiber Containing PTT and Co-PET
[0158] Polytrimethylene terephthalate containing 0.3% TiO.sub.2 and
having an intrinsic viscosity of 0.96 dL/g was melt blended with
fiber-grade post-consumer recycled Co-PET containing 1.1 mol % IPA
monomer, 49.1 mol % TPA monomer, and 49.9 mol % of EG monomer in a
twin-screw extruder in a 50/50 weight ratio to form compounded
pellets. The Co-PET had an intrinsic viscosity of 0.76 dL/g.
Extruder throughput was 150 lb/h (0.0189 kg/s) and melt temperature
at extruder exit was under 285.degree. C. as measured by a
hand-held thermocouple.
[0159] PTT:Co-PET compounded pellets were dried at 120.degree. C.
under nitrogen blanket in a vacuum oven for 16 hours and
melt-extruded into round cross-section, 34-filament yarn bundle
using a twin-screw extruder spinning machine. Extruder melt zone
temperatures were maintained from 180-255.degree. C. Polymer
throughput was either 14.06 g/min or 21.52 g/min. For each
throughput, winder speed was either 750 m/m or 1250 m/m giving a
spun denier per filament from 3.3 to 7.7. Dry heat shrinkage of
yarn bundles was measured to be in the range of 1.2% to 2.5%. This
amount of dry heat shrinkage in undrawn fiber is very low and
indicates stability of the material during storage. Results are
shown in the following Table.
TABLE-US-00002 TABLE 2 Example 2 Spinning Conditions and Dry Heat
Shrinkage of Tow Throughput, g/min Winder Speed, m/m Dry Heat
Shrinkage, % 21.52 750 1.2 21.52 1250 3 14.06 750 1.2 14.06 1250
2.5
Example 3
Melt Spun Staple Fiber Containing PTT and Co-PET
[0160] Polytrimethylene terephthalate containing 0.3% TiO.sub.2 and
having an intrinsic viscosity of 0.96 dL/g was melt blended with
Co-PET (from Nan Ya Plastics) in a twin-screw extruder in a 50/50
weight ratio to form compounded pellets. Extruder throughput was
150 lb/h (0.0189 kg/s) and melt temperature at extruder exit was
under 285.degree. C. as measured by a hand-held thermocouple.
Compounded material was at 145.degree. C. for 20 hours.
[0161] 6800 Round cross-section filaments were spun using a
single-extruder spinning machine with radial quench. Extruder melt
zone temperatures were maintained from 252-274.degree. C. Polymer
throughput was 0.379 g/min/hole and feed roll speed was 1100 m/m.
Spun dpf was 3.0. Spun fibers were collected in cans. Twenty-two
cans, totaling 448,800 denier, fed draw-crimp-cut/bale module. A
typical cotton count staple process utilizing multi-stage draw,
crimper, annealer, and cutter was used to produce staple melt spun
fiber. Tow was dipped in a finish bath (0.5% concentration,
commercially available, Seilacher from Schill+Seilacher) at
22.degree. C. Tow was first drawn, in a 0.5% concentration finish
bath at 80.degree. C. between a 22.degree. C. feed roll running at
36 m/m and heated draw rolls at 75.degree. C. running at 110.88 m/m
giving a first stage draw ratio of 3.08. Drawn tow was pulled
through a steam chest at 100.degree. C. by a downstream heated roll
at 165.degree. C. and running at 110.88 m/m. Tow was passed over
another set of rolls heated at 165.degree. C. running at 99.8 m/m.
Finish (6% concentration) was sprayed and tow was passed over
cooling drum rolls at 25.degree. C., running at 99.8 m/m. Tow
entered a steam box at 100.degree. C. prior to entering a 50-mm
crimper. Crimper speed was 100 m/m. Crimper roller temperature and
pressure was 65.degree. C. and 0.8 bar, respectively. Crimped tow
was annealed for 8 min at 100.degree. C. in a plate belt drier,
Crimped tow was finally cut to produce staple melt spun fiber
having the following properties:
[0162] Denier per filament (dpf)=1.2, Coefficient of variation
(CV)=8.79%
[0163] Tenacity=4.89 g/d, CV=8.79%
[0164] Elongation=45.97%, CV=19.59%
[0165] Staple length=37-38 mm
[0166] Number of crimp (full-sinus arc)=12/inch
[0167] Crimp stability=67.09%, CV=22.1%
[0168] Finish on yarn=0.26%
Example 4
Melt Spun Fiber Containing PTT and Co-PET
[0169] 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) in a twin-screw extruder in a 50/50
weight ratio to form compounded pellets. Extruder throughput was
150 lb/h (0.0189 kg/s) and melt temperature at extruder exit was
under 285.degree. C. as measured by a hand-held thermocouple.
Compounded material was at 145.degree. C. for 20 hours.
[0170] 6800 Round cross-section filaments were spun using a
single-extruder spinning machine with radial quench. Extruder melt
zone temperatures were maintained from 252-274.degree. C. Polymer
throughput was 0.493 g/min/hole and feed roll speed was 600 m/m.
Spun dpf was 7.2. Spun fibers were collected in cans. Ten cans,
totaling 489,600 denier, fed draw-crimp-cut/bale module. A typical
wool count staple process utilizing multi-stage draw, crimper,
annealer and cutter was used to produce melt spun staple fiber. Tow
was dipped in a finish bath (0.5% concentration, commercially
available, Seilacher from Schill+Seilacher) at 22.degree. C. Tow
was first drawn in a 0.5% concentration finish bath at 80.degree.
C. between a 22.degree. C. feed roll running at 30 m/m and heated
draw rolls at 75.degree. C. running at 109.3 m/m giving a first
stage draw ratio of 3.64. Tow was pulled by a downstream heated
roll at 165.degree. C. and running at 103.9 m/m. Finish (6%
concentration) was sprayed and tow was passed over cooling drum
rolls at 25.degree. C., running at 101.9 m/m. Tow entered a steam
box at 100.degree. C. prior to entering a 50-mm crimper. Crimper
speed was 110.6 m/m. Crimper roller temperature and pressure was
65.degree. C. and 1.3 bar, respectively. Crimped tow was annealed
for 8 min at 100.degree. C. in a plate belt drier, Crimped tow was
finally cut to produce staple having the following properties:
[0171] dpf=2.5, CV=6.98%
[0172] Tenacity=3.83 g/d, CV=8.74%
[0173] Elongation=69.72%, CV=25.26%
[0174] Staple length=82-125 mm multi-cut length with an average of
84 mm
[0175] Number of crimp (full-sinus arc)=14/inch
[0176] Crimp stability=91.19%, CV=8.31%
[0177] Finish on yarn=0.21%
Commercially Obtained Spun Yarns
[0178] Table 3 lists commercially obtained spun yarns and the
abbreviations used for them in the Tables which follow. Some of
these yarns were used to prepare the fabrics of the Comparative
Examples.
TABLE-US-00003 TABLE 3 Abbreviations for Spun Yarns Obtained
Commercially. Cotton Count and Yarn Composition Abbreviation 20 s
Ne 100% PET staple P1 40 s Ne 100% PET staple P2 20 s Ne 40/60
blended PET/cotton staple PC1 40 s Ne 40/60 blended PET/cotton
staple PC2 20 s Ne 40/60 blended PET/Tencel .RTM. staple PT1 40 s
Ne 40/60 blended PET/Tencel .RTM. staple PT2 20 s Ne 100% PTT
staple P3 40 s Ne 100% PTT staple P4 20 s Ne 40/60 blended
PTT/cotton staple PC3 40 s Ne 40/60 blended PTT/cotton staple PC4
20 s 40/60 blended PTT/Tencel .RTM. staple PT3 40 s 40/60 blended
PTT/Tencel .RTM. staple PT4
Spun Yarn Examples Made on Cotton System
[0179] Melt spun staple fiber from Example 3 was used to prepare
the spun yarns of Examples 5-10. The spun yarns, and the
intermediate materials such as sliver obtained in the preparation
of the spun yarns, were evaluated using the following methods:
[0180] Tenacity was measured at 5 m/min using CRE type tensile
testing equipment (such as Uster Tensorapid -3) at jaw speed of 5
m/min and specimen length of 50 cm.
[0181] Breaking elongation %--measured using CRE type tensile
testing equipment (such as Uster Tensorapid -3) at jaw speed of 5
m/min and specimen length of 50 cm.
Example 5
20s Ne Spun Yarn Containing 100% Melt Spun Fiber
[0182] Spun yarn was made using the cotton spinning system,
according to the following procedure.
[0183] Melt spun staple fiber from Example 3 was taken from bales
and hand mixed. The average staple fiber length was 40 mm and the
denier was 1.2 D. The fibers were mixed and laid in layers in a
stack mixing process, then conditioned at 65% relative humidity and
25.degree. C. for 24 hours. Fiber mass was taken from the stack by
vertically withdrawing material and feeding it to a blow room line
as typically used to spin synthetic fibers. In this process, the
size of a fiber tuft was broken down from about 150 mg to about 30
mg. The following parameters were used: [0184] Feed rollers and
beaters blades setting=1.7 mm [0185] Lap linear density .about.400
g/meter [0186] All waste collection setting is closed to `0` [0187]
Coarse opening beater speed=400 rpm [0188] Fine opening beater
speed=450 rpm
[0189] Next, the 30 mg fiber bunches were carded to single fibers
and arranged into a continuous fiber strand (sliver) where fibers
were oriented along the length of the sliver. The following
parameters were used: [0190] Machine type, Model : card frame, L R
C 1/3 [0191] M/c Production speed=70 meter/min [0192] Feed Plate
and Licker in gauge=32 thou (thousandths of an inch) [0193] Flat
gauge=14,14,14,12,12 thou [0194] Trumpet size=4.0 mm or above
[0195] Sliver linear density=4.5 g/meter [0196] Licker in Speed=650
rpm [0197] Cylinder Speed=350 rpm [0198] Flat speed=6 inches/min
[0199] Final sliver linear density=5.0 g/meter
[0200] In a draw frame machine, six carding slivers were doubled
together and simultaneously drafted by the same amount (6.times.)
to further orient the fibers in the resultant sliver. The first
step is referred to as breaker drawing and the second step is
referred to as finisher drawing. The following parameters were
used: [0201] Machine type and model: Draw frame, L R RSB 851 [0202]
Bottom Roller gauge Front/Back=44/48 mm [0203] Trumpet diameter=3.8
mm [0204] Sliver linear density=4.5 g/meter [0205] Top cots
hardness=83.degree. degree [0206] Break drafts =1.4 in breaker, 1.4
in finisher draw frame [0207] Web tension draft=1 [0208] Creel
tension draft=1.02 [0209] Delivery speed=250 MPM in I draw frame,
350 MPM in II draw frame [0210] Doubling=6 for both I and II draw
frame [0211] Final sliver linear density=5.00 g/meter [0212]
Unevenness %=1.88 in finisher sliver
[0213] Next, roving was prepared from the sliver delivered from the
final draw frame at a speed frame machine. Partial twist is also
given in the speed frame in order to impart strength to the roving.
The following parameters were used: [0214] Machine type and Model :
Speed Frame, LF 4200 [0215] Spacer size=5.5 mm [0216] Spindle
speed=1000 rpm [0217] Twist multiplier=0.70 [0218] Roving Hank=0.75
s Ne [0219] Roller Gauge=48/55/62 mm [0220] Cradle=36 mm The roving
was found to have Uster value (unevenness) of 3.16% and Uster %
(unevenness %) of 3.26.
[0221] The roving was drafted further on a ring frame spinning
machine to produce spun yarn having a yarn count of 20s Ne. The
following parameters were used: [0222] Machine Type and Model=Ring
Frame, LR G 5/1 [0223] Roller gauge=42.5/65 mm [0224] Saddle gauge
=51/66 mm [0225] Cots hardness (front/back F/B)=68/83.degree.
[0226] Break draft=1.22 [0227] Twist multiplier/twist per
inch=3.6/16.09 [0228] Traveler size: 1/0 M1HO [0229] Spindle speed:
15500 rpm
[0230] The spun yarn was wound at ring frame on small packages
called cops, each weighing about 50 g. Many cops were joined and
cleared for any yarn defect, and finally wound into a cone on a
winding machine using the following parameters: [0231] Speed =1000
m/min [0232] Yarn tension=5-6% of yarn breaking load [0233] Package
Hardness--minimum [0234] Cone Weight=1.0 kg or more
[0235] The final spun yarn was evaluated for tensile properties and
unevenness % on Uster tensorapid-3 and Uster unevenness tester-3.
Results are shown in Table 4.
[0236] The yarn wound in the final machine was lively and could
snarl as a result of twist imparted in the spinning process. As
snarling can cause yarn breakage during fabric manufacturing, the
yarn was rendered structurally stable by conditioning the cone in
an autoclave at a maximum temperature of 70.degree. C. for 50
minutes.
Example 6
40s Ne Spun Yarn Containing 100% Melt Spun Fiber
[0237] Spun yarn was prepared using melt spun staple fiber from
Example 3 according to the procedure of Example 5 except with the
following differences:
[0238] The linear density of the final sliver was 4.75 g/meter and
the Unevenness % was 1.75
[0239] Roving was prepared as in Example 5 except that the roving
hank was 1.2 s Ne.
[0240] In the step of drafting the roving, the twist
multiplier/twist per inch was 3.6/22.6, the Traveler size was 4/0
M1HO, and the spindle speed was 16500 rpm.
[0241] The spun yarn was wound onto a cone at 1500 meters/min.
[0242] Properties of the spun yarn are given in Table 4.
Example 7
20s Ne Spun Yarn Containing 40/60 Melt Spun Fiber/Cotton
(wt/wt)
[0243] Spun yarn was prepared using melt spun staple fiber from
Example 3 and cotton (Shankar 6 variety Indian cotton obtained from
north Indian states, for example Punjab and Haryana). The cotton
staple had average length of 31 mm and fineness (fiber linear
density) of 4.1 microgram/inch, measured using an airflow method.
The spun yarn was made according to the procedure of Example 5
except with the following differences:
[0244] In the hand mixing step, two layers of cotton sliver, taken
from 100% cotton yarn spinning process after the combing machine
and broken into small tuft size of 25-30 mg, were laid over one
layer of melt spun staple fiber.
[0245] The linear density of the final sliver from the carding step
was 4.7 g/meter. Roving was prepared as in Example 5 except that
the twist multiplier was 0.85 and the roving hank was 0.7 s Ne.
[0246] The roving was drafted further as in Example 5 except with
twist per inch of 16.99.
[0247] Properties of the spun yarn are given in Table 4.
Example 8
40s Ne Spun Yarn Containing 40/60 Melt Spun Fiber/Cotton
(wt/wt)
[0248] Spun yarn was prepared using melt spun staple fiber from
Example 3 and cotton (Shankar 6 variety Indian cotton commercially
obtained from north Indian states). The cotton staple had average
length of 31 mm and linear density of 4.1 microgram/inch. The spun
yarn was made according to the procedure of Example 5 except with
the following differences:
[0249] In the hand mixing step, two layers of cotton sliver, taken
from 100% cotton yarn spinning process after the combing machine
and broken into small tuft size of 25-30 mg, were laid over one
layer of melt spun staple fiber.
[0250] The linear density of the final sliver from the carding step
was 4.7 g/meter.
[0251] After drawing, the final sliver linear density was 4.75
g/meter.
[0252] Roving was prepared as in Example 5 except that the twist
multiplier was 0.85 and the roving hank was 1.2 s Ne.
[0253] The roving was drafted further as in Example 5 except with
twist per inch of 24.02, traveler size 4/0 M1HO, and spindle speed
16500 rpm.
[0254] The spun yarn was wound onto a cone at 1500 meters/min.
[0255] Properties of the spun yarn are given in Table 4.
Example 9
20s Ne Spun Yarn Containing 40/60 Melt Spun Fiber/Tencel
[0256] Spun yarn was prepared using melt spun staple fiber from
Example 3 and commercially-obtained Tencel.RTM. staple fiber
(Lenzing).The Tencel.RTM. staple fiber had average length of 40 mm
and denier of 1.2 D. The spun yarn was made according to the
procedure of Example 5 except with the following differences:
[0257] In the hand mixing step, two layers of Tencel.RTM. fiber
(broken into small tuft size of 25-30 mg) were laid over one layer
of melt spun staple fiber.
[0258] The linear density of the final sliver from the carding step
was 4.7 g/meter.
[0259] Roving was prepared as in Example 5 except that twist
multiplier was 0.85.
[0260] The roving was drafted further as in Example 5 except with
twist per inch of 16.99.
[0261] Properties of the spun yarn are given in Table 4.
Example 10
40s Ne Spun Yarn Containing 40/60 Melt Spun Fiber/Tencel
[0262] Spun yarn was prepared using melt spun staple fiber from
Example 3 and commercially-obtained Tencel.RTM. staple fiber
(Lenzing). The Tencel.RTM. staple had average length of 40 mm and
denier of 1.2 D. The spun yarn was made according to the procedure
of Example 5 except with the following differences:
[0263] In the hand mixing step, two layers of Tencel.RTM. fiber
(broken into small tuft size of 25-30 mg) were laid over one layer
of melt spun staple fiber.
[0264] The linear density of the final sliver from the carding step
was 4.7 g/meter.
[0265] After drawing, the final sliver linear density was 4.75
g/meter.
[0266] Roving was prepared as in Example 5 except that twist
multiplier was 0.85 and the roving hank was 1.2 s Ne. The roving
was drafted further as in Example 5 except with twist per inch of
24.02, traveler size 4/0 M1HO, and spindle speed 16500 rpm.
[0267] The spun yarn was wound onto a cone at 1500 meters/min.
Properties of the spun yarn are given in Table 4.
TABLE-US-00004 TABLE 4 Properties of the Spun Yarns of Example 5
Through Example 10 and of Comparative Spun Yarns Obtained
Commercially Number of Ex. No. Breaking Imperfections or
Tenacity.sup.2 Elongation U (per km of Hairiness Yarn.sup.1 Yarn
Description (cN/Tex) (%) % yarn) Index 5 20s Ne 100% melt 24.1 26.3
8.5 9 6.60 spun staple P1 20s Ne 100% PET 35.5 14.7 8.4 30 7.79 P3
20s Ne 100% PTT 17.9 36.4 9.5 18 6.36 6 40s Ne 100% melt 22.8 21.5
11.5 74 4.81 spun staple P2 40s Ne 100% PET 30.3 9.6 11.7 118 6.06
P4 40s Ne 100% PTT 16.6 30.5 13.3 303 5.11 7 20s Ne 40/60 melt 13.9
6.6 10.0 78 7.17 spun staple/cotton PC1 20s Ne 40/60 18.7 7.4 9.3
20 6.58 PET/cotton PC3 20s Ne 40/60 10.8 7.3 10.5 70 7.43
PTT/cotton 8 40s Ne 40/60 melt 13.2 4.8 12.3 243 4.90 spun
staple/cotton PC2 40s Ne 40/60 16.2 5.6 11.8 203 4.9 PET/cotton PC4
40s Ne 40/60 10.6 6.1 13.3 446 5.15 PTT/cotton 9 20s Ne 40/60 melt
17.7 8.3 8.4 16 8.12 spun staple/Tencel .RTM. PT1 20s Ne 40/60 24.7
9.7 8.7 10 7.59 PET/Tencel .RTM. PT3 20s Ne 40/60 15.7 8.3 9.0 10
7.73 PTT/Tencel .RTM. 10 40s Ne 40/60 melt 13.9 5.0 12.1 156 6.04
spun staple/Tencel .RTM. PT2 40s Ne 40/60 21.7 8.1 11.5 164 5.59
PET/Tencel .RTM. PT4 40s Ne 40/60 13.3 5.8 11.2 166 5.80 PTT/Tencel
.RTM. Notes: .sup.1see Table 3 for abbreviations of spun yarns
obtained commercially .sup.2at 5 meter/min speed
[0268] The results in Table 4 show that the spun yarns comprising
100% melt spun staple fiber alone or in combination with cotton or
Tencel.RTM., have tenacity and breaking elongation sufficient for
weaving or knitting processes.
[0269] Spun yarns (Examples 5 and 6) consisting of only the melt
spun staple fiber of Example 3, poly(ethylene terephthalate)
staple, or poly(trimethylene terephthalate) staple were subjected
to a boiling water shrinkage test method according to ASTM D2259.
The length of yarn skeins, with the indicated dead weight attached,
were measured before and after being immersed in boiling water
(100.degree. C., 30 min in autoclave, MLR 1:40 where "MLR" means
material to liquor ratio) and the difference in skein length
divided by skein length before boiling is reported as % Shrinkage
in Table 5. PET spun yarns and PTT spun yarn were obtained
commercially.
TABLE-US-00005 TABLE 5 Boiling Water Shrinkage of Spun Yarns
Boiling Initial Final Water Length Length Shrinkage, Yarn Count
Yarn Sample (cm) (cm) % 40 s, dead Ex. 6 1 67.5 60.4 10.6 weight 1
kg 2 67.4 60.2 Average 67.4 60.3 PET 1 67.3 65.4 2.82 (P2)* 2 67.3
65.4 Average 67.3 65.4 PTT 1 67.9 64.6 4.87 (P4)* 2 67.7 64.6
Average 67.8 64.5 20 s, dead Ex. 5 1 67.5 60.9 9.93 weight 2 kg 2
67.5 60.7 Average 67.5 60.8 PET 1 67.4 65.8 2.37 (P1)* 2 67.4 65.8
Average 67.4 65.8 PTT 1 68.1 64.3 5.44 (P3)* 2 68 64.4 Average 68
64.3 *Abbreviations are defined in Table 3.
[0270] Highest % boiling water shrinkage was observed for the spun
yarn of Example 6 containing only melt spun staple fiber, with the
lowest boiling water shrinkage observed for the spun yarns
comprising PET and intermediate % shrinkage values observed for the
spun yarns comprising PTT. This gives more fabric bulk after
finishing for the melt spun staple fiber-based fabrics, which is
desirable.
Woven Fabric Examples
[0271] Fabrics were evaluated using the following methods:
[0272] Fabric weight (greige and finished)--ASTM D3776 Standard
Test Methods for Mass Per Unit Area (Weight) of Fabric
[0273] Dimensional stability (for both warp and weft directions,
after 3 washes)--AATCC 135 Dimensional Changes of Fabrics After
Home laundering
[0274] Wicking--AATCC 197 Vertical Wicking of Textiles
[0275] Tear Strength (for both warp and weft directions)--ASTM
D1424 Standard Test Method for Tearing Strength of Fabrics by
Falling Pendulum (Elmendorf-Type) Apparatus
[0276] Thickness--ASTM D1777 Standard Test Method for Thickness of
Textile Materials
[0277] Pill rating (1000 rounds)--ASTM D4970 Standard Test Method
for Pilling Resistance and Other Related Surface Changes of Textile
Fabrics: Martindale Tester
[0278] Abrasion (5000 rounds)--ASTM D4966 Standard Test Method for
Abrasion Resistance of Textile Fabrics (Martindale Abrasion Tester
Method)
[0279] Drape--BS 5058 Method for the Assessment of Drape of
Fabrics
[0280] Colorfastness to rubbing--AATCC 8 Colorfastness to
Crocking
[0281] Colorfastness to washing--AATCC 61-2A (49.degree. C., 45
min, 1.5 gpl)
[0282] Bursting Strength (circular knits)--ASTM D3786 Standard Test
Method for Bursting Strength of Textile Fabrics
[0283] Stretch and Recovery (circular knits)--BS 4294 (5 kg)
Methods of Test for the Stretch and Recovery Properties of
Fabrics
[0284] Shrinkage % (in fabric, greige to finished) was determined
as follows.
[0285] Greige fabric was marked with a permanent marker to indicate
a 30 cm line in the fabric length (warp direction) and a 30 cm line
in the fabric width (weft direction). The fabric was then dyed and
finished, and the lengths of the permanent marker lines were
remeasured. For each of the length (warp) and width (weft)
directions, percent shrinkage was calculated by dividing the
difference in length of the line before and after dyeing and
finishing by 30 and multiplying by 100. This method is referred to
herein as the Percent Shrinkage Method.
[0286] Softness assessment (also referred to as subjective Hand
Value)--The subjective hand value assessment was done by assessing
the feel of the fabric by 12 experts in the field, tested in South
India Textile Research Association (SITRA), Coimbatore, India. This
is the method widely used in Textile Industry for assessment of
softness of fabrics. Fabrics were coded A and B and given to assess
the ranking of fabric based on the perception of Fabric softness
independently. The Softer fabric was ranked `1` where as less soft
fabric was ranked `2` by each expert. This was done for 100% PET
fabrics and the fabrics of Examples 11 and 14. Final ranking was
done by averaging the 12 readings. The fabric with lower rank
average was given final rank as 1 (softer) and fabric with higher
rank average was given as rank 2.
[0287] The spun yarns of Examples 5 through 10 were used to make
woven fabrics as indicated in Table 6. Woven twill (3/1) bottom
weight fabrics and plain weave (1/1) shirting fabrics were made
using the spun yarns disclosed herein as the warp and weft (fill)
yarns; comparison fabrics were made using spun yarns obtained
commercially in the warp and weft. For each woven fabric, the same
yarn was used in both the warp and the weft. Fabric evaluation
results are presented in Tables 7 and 8. Results are reported for
finished fabric unless otherwise noted.
Example 11
[0288] Spun yarn from Example 5 was used as the warp and as the
weft to prepare a bottom weight woven twill fabric. The warp yarns
were sized before beaming using a CCI single end sizing machine
using Elvanol-T25 PVA sizing agent. Using a warper at 350 m/min, a
final beam with 2150 ends, a width of 18 inches, and end lengths of
3.5 meters was prepared. With the following denting plan:
[0289] Drawing: 4 shafts
[0290] Drawing type (straight drawing (1, 2, 3, &4)
[0291] Denting: 2 ends/dent
[0292] Reed count: 75 dents/2 inch
[0293] 3/1 LHT twill fabric was woven on a CCI sample loom with
loom speed at 40 picks/minute. The pick value was set at 63
picks/inch. Greige fabric of 2 m length and 49.5 cm width was
obtained.
[0294] The greige fabric was desized on an RBE lab Jigger machine
as follows. The fabric sample was loaded into the jigger filled
with water (2 L), NaOH (2 gpl), and wetting agent; Levocol CESR
(wetting agent) was added (5 gpl) and the bath temperature was
raised to 90.degree. C. The fabric was run in the bath for 60 mins,
then the bath was drained, refilled with fresh water, and the
temperature of the bath was raised to 85.degree. C. The fabric was
hot water washed for 15 min, and the bath was drained. The bath was
again filled with water and the fabric was run through it for 15
min (cold water wash). Bath was drained, filled with water, and
neutralized by adding acetic acid (1 gpl); fabric was run for 15
min in this bath. Afterwards, the bath was drained, refilled with
fresh water, and the fabric run in cold water bath for 15 min. The
fabric was then unloaded from the jigger and dryed in atmospheric
conditions, then heat set in an RBE stenter at 160.degree. C. for
45 seconds.
[0295] The fabric was then dyed with a mixture of disperse dyes
using the following time and temperature profile: heat to
70.degree. C. and hold for 10 minutes, then raise temperature
1.5.degree. C./min to 130.degree. C. and hold for 30 minutes, then
decrease temperature 1.5.degree. C/.min to 70.degree. C. and drain.
Post dyeing, the fabric was given a reduction cleaning with Hydros
and NaOH (2 gpl each), 90.degree. C. for 20 min. The fabric was
then washed with cold water for 10 minutes, contacted with acetic
acid (2 gpl) for 15 minutes, then washed with cold water for 10
minutes. The dyed fabric was padded with finishing agent
(softener), then heat set at 160.degree. C. for 45 seconds in an
RBE lab stenter.
[0296] Fabric construction is shown in Table 6. Wicking test
results were 100%. In comparison to the fabric of Comparative
Example B, the fabric of Example 11 was found to have a softer hand
(i.e. better softness). Other fabric properties are presented in
Tables 7 and 8.
Comparative Example B
[0297] A comparative bottom weight woven 3/1 LHT twill fabric was
made using commercially available 20s Ne 100% PET staple spun yarn
("P1") as the warp and as the weft, following the procedure of
Example 11 except that the denting plan used 4 ends/dent and the
reed count was 50 dents/2 inch. The greige fabric was dyed,
finished, and heat set as for Example 11.
[0298] Fabric construction is shown in Table 6. Wicking test
results were 100%. Other fabric properties are presented in Tables
7 and 8.
Example 12
[0299] Spun yarn from Example 7 was used as the warp and as the
weft to prepare a bottom weight woven twill fabric according to the
procedure of Example 11 but with the following exceptions. The
greige fabric was desized and bleached in a Jigger machine, heat
set in a stenter, then dyed with a mixture of disperse dyes, then
additionally dyed with a reactive dye under cotton dyeing
conditions.
[0300] Fabric construction is shown in Table 6. Wicking test
results were 100%. Other fabric properties are presented in Tables
7 and 8.
Comparative Example C
[0301] A comparative bottom weight woven 3/1 LHT twill fabric was
made as in Example 12 except using commercially available 20s Ne
40/60 PET/cotton staple spun yarn ("PC1") as the warp and as the
weft.
[0302] Fabric construction is shown in Table 6. Wicking test
results were 100%. Other fabric properties are presented in Tables
7 and 8.
Example 13
[0303] Spun yarn from Example 9 was used as the warp and as the
weft to prepare a bottom weight woven twill fabric according to the
procedure of Example 12, except that no peroxide killer was used at
the end of the bleaching step.
[0304] Fabric construction is shown in Table 6. Wicking test
results were 100%. Other fabric properties are presented in Tables
7 and 8.
Comparative Example D
[0305] A comparative bottom weight woven 3/1 LHT twill fabric was
made following the procedure of Example 12 except using
commercially available 20s Ne 40/60 PET/Tencel.RTM. staple spun
yarn ("PT1") as the warp and as the weft. The greige fabric was
dyed, finished, and heat set as for Example 12 except that the
second dyeing step, with a reactive dye, was done under Tencel.RTM.
dyeing conditions.
[0306] Fabric construction is shown in Table 6. Wicking test
results were 100%. Other fabric properties are presented in Tables
7 and 8.
Example 14
[0307] Spun yarn from Example 6 was used as the warp and as the
weft to prepare a plain weave shirting fabric. The procedure was as
described for Example 11 but with the following differences: after
warping, the beam contained 1680 ends, and the reed count was 84
dents/2 inch.
[0308] Fabric construction is shown in Table 6. Wicking test
results were 100%. In comparison to the fabric of Comparative
Example E, the fabric of Example 14 was found to have a better
(softer) hand. Other fabric properties are presented in Tables 7
and 8.
Comparative Example E
[0309] A comparative plain weave shirting fabric was made following
the procedure of Example 11 except using commercially available 40s
Ne 100% PET staple spun yarn ("P2") as the warp and as the weft.
After warping, the beam contained 1680 ends, and the reed count was
84 dents/2 inch. Greige fabric of 2 m length and 47.7 cm was
obtained.
[0310] Fabric construction is shown in Table 6. Wicking test
results were 100%. Other fabric properties are presented in Tables
7 and 8.
Example 15
[0311] Spun yarn from Example 8 was used as the warp and as the
weft to prepare a plain weave shirting fabric. The procedure was as
described for Example 12, except that no peroxide killer was used
at the end of the bleaching step.
[0312] Fabric construction is shown in Table 6. Wicking test
results were 100%. Other fabric properties are presented in Tables
7 and 8.
Comparative Example F
[0313] A comparative plain weave shirting fabric was made following
the procedure of Example 11 except using commercially available 40s
Ne 40/60 PET/cotton staple spun yarn ("PC2") as the warp and as the
weft and with the following additional differences in procedure:
after warping, the beam contained 1748 ends, and the reed count was
92 dents/2 inch. Greige fabric of 2 m length and 48.7 cm width was
obtained, and was dyed as described in Example 12.
[0314] Fabric construction is shown in Table 6. Wicking test
results were 100%. Other fabric properties are presented in Tables
7 and 8.
Example 16
[0315] Spun yarn from Example 10 was used as the warp and as the
weft to prepare a plain weave shirting fabric. The procedure was as
described for Example Wfab-1, except that after warping the beam
contained 1748 ends, the reed count was 92 dents/2 inch, and the
pick value was set at 62 picks/inch. Greige fabric of 2 m length
and 48.7 cm width was obtained, and was dyed as described in
Example 12.
[0316] Fabric construction is shown in Table 6. Wicking test
results were 100%. Other fabric properties are presented in Tables
7 and 8.
Comparative Example G
[0317] A comparative shirting fabric was made following the
procedure of Example 11 except using commercially available 40s Ne
40/60 PET/Tencel.RTM. staple spun yarn ("PT2") as the warp and as
the weft and with the following additional differences in
procedure: after warping, the beam contained 1748 ends, the reed
count was 92 dents/2 inch, and the pick value was set at 62
picks/inch. Greige fabric of 2 m length and 48.7 cm width was
obtained and dyed as described in Example 12.
[0318] Fabric construction is shown in Table 6. Wicking test
results were 100%. Other fabric properties are presented in Tables
7 and 8.
TABLE-US-00006 TABLE 6 Woven Fabric Construction Warp and Weft
Fabric Construction Fabric Weight Yarn (ends/inch * pick/inch)
(g/m.sup.2) Ex. Count Yarn Fabric Details Fiber Blend % in Fabric
Greige Finished Greige Finished 11 20s Ex 5 Bottom Weight, 100%
melt spun staple 108*70 130*92 242 250 3/1 LHT Comp. 20s P1 Bottom
Weight, 100% PET staple 108*70 114*80 222 230 Ex. B 3/1 LHT 12 20s
Ex 7 Bottom Weight, 40/60 melt spun staple/ 108*70 128*88 248 288
3/1 LHT cotton Comp. 20s PC1 Bottom Weight, 40/60 PET/cotton 108*70
124*82 238 258 Ex. C 3/1 LHT 14 20s Ex 9 Bottom Weight, 40/60 melt
spun 108*70 128*88 240 304 3/1 LHT staple/Tencel .RTM. Comp. 20s
PT1 Bottom Weight, 40/60 PET/Tencel .RTM. 108*70 122*80 225 260 Ex.
D 3/1 LHT 14 40s Ex 6 Shirting, plain 100% melt spun staple 96*66
120*88 115 142 Comp. 40s P2 Shirting, plain 100% PET staple 96*66
104*72 104 118 Ex. E 15 40s Ex 8 Shirting, plain 40/60 melt spun
staple/ 96*66 120*88 114 149 cotton Comp. 40s PC2 Shirting, plain
40/60 PET/cotton 104*66 116*76 117 127 Ex. F 16 40s Ex Shirting,
plain 40/60 melt spun 96*66 116*82 107 137 10 staple/Tencel .RTM.
Comp. 40s PT2 Shirting, plain 40/60 PET/Tencel .RTM. 96*66 104*74
100 107 Ex. G
TABLE-US-00007 TABLE 7 Woven Fabric Evaluation Results (First Half)
Dimensional Tensile Breaking Tear Stability Strength Elongation
Strength Thick- (%) (kgf) (%) (g) ness Ex. Warp Weft Warp Weft Warp
Weft Warp Weft (mm) 11 -1.9 -1.3 28.6 28.6 47.5 47.4 >6400 5056
0.55 Comp. -2.7 -1.8 29.8 32.3 17.2 23.6 >6400 >6400 0.36 Ex.
B 12 -1.5 -1.9 32.1 29.3 27.2 20.9 3008 1920 0.62 Comp. -2.6 -2.0
30.8 29.9 15.6 10.0 2880 3008 0.52 Ex. C 14 -2.1 -1.9 26.2 22.8
35.0 17.0 2752 2368 0.58 Comp. -1.2 -1.8 25.1 27.6 16.8 10.3 5376
4864 0.45 Ex. D 14 -1.9 -2.1 30.8 26.5 58.5 40.7 4416 2624 0.34
Comp. -2.2 -2.3 27.4 27.6 20.6 14.9 2944 2496 0.17 Ex. E 15 -1.6
-1.8 18.7 13.2 27.3 19.8 1280 896 0.34 Comp. -1.5 -1.7 12.9 12.4
7.7 7.6 1408 1408 0.22 Ex. F 16 -1.9 -1.6 20.2 16.2 20.6 12.5 1792
1472 0.32 Comp. -1.4 -1.5 25.8 14.5 11.4 5.7 2176 1984 0.19 Ex.
G
TABLE-US-00008 TABLE 8 Woven Fabric Evaluation Results (Second
Half) Shrinkage, Abrasion Drape Greige to Weight Area of Drape
Finishing Colorfastness Colorfastness to Washing Pill loss Drape
Coeff. Warp Weft to Rubbing Shade Ex. Rating Rating (%) (cm.sup.2)
(%) (%) (%) Dry Wet Change Acetate Cotton Nylon PET Acrylic Wool 11
2-3 3-2 0.28 358.9 64.1 8.1 14.2 4-5 4 4-5 4 4 4 4-5 4-5 4-5 Comp.
1 1 0.55 221.2 26.7 3.2 3.8 4-5 3-4 4-5 3-4 4 3 4 4-5 4-5 Ex. B 12
4-5 4-5 0.9 341.9 59.5 9.7 12.7 4-5 4 4-5 4-5 4 3-4 4-5 4-5 4-5
Comp. 2 2-3 2.02 267.5 39.3 3.1 6.3 4-5 4 4-5 4-5 4 4 4-5 4-5 4-5
Ex. C 13 4-5 3-4 2.25 187.1 17.4 7.4 12.3 4-5 4 4-5 4 4 3-4 4 4-5
4-5 Comp. 2 1 2.74 177.1 14.7 3.5 5.3 4-5 3-4 4-5 4 4 3-4 4 4-5 4-5
Ex. D 14 3 2 0.3 317.0 52.7 7.9 16.3 4-5 4 4-5 4-5 4-5 4-5 4-5 4-5
4-5 Comp. 1 1 1.66 202.3 21.5 1.2 4.6 4-5 4 4-5 4-5 4-5 4-5 4-5 4-5
4-5 Ex. E 15 4-5 4-5 3.8 291.8 45.9 9.1 11.3 4-5 4 4-5 4-5 4-5 4-5
4-5 4-5 4-5 Comp. 1 1-2 6.7 182.0 16.1 2.5 4.2 4-5 4 4-5 4-5 4-5
4-5 4-5 4-5 4-5 Ex. F 16 3-4 2-3 4.37 176.7 14.6 8.0 9.7 4-5 4 4-5
4-5 4-5 4-5 4-5 4-5 4-5 Comp. 3 1-2 7.37 163.4 11.0 2.3 4.8 4-5 4
4-5 4-5 4-5 4-5 4-5 4-5 4-5 Ex. G
[0319] The results in the preceding Tables demonstrate that the
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
bulk, as indicated by the greater thickness of the fabrics of the
Examples in comparison to Comparative Example fabrics of similar
construction. The woven fabrics of the Examples also demonstrate
less pilling (higher pill rating values), better abrasion
resistance (lower % weight loss), and better drape (higher drape
coefficient values) versus the fabrics of the Comparative Examples.
Additionally, fabrics of the Examples can also dye more deeply
(lower L* values with a D65 light source). The combination of
improved hand (softer feel) and better drape is particularly
desirable for fabrics.
Circular Knit Fabric Examples
[0320] The spun yarns of Examples 5 through 10 were used as the
knitting yarn to make circular knit fabrics as indicated in Table
9; comparison fabrics were made using spun yarns obtained
commercially. For all circular knit fabrics made using 20s Ne count
yarns, the machine gauge was 20''. For all circular knit fabrics
made using 40s Ne count yarns, the machine gauge was 24''. Fabric
evaluation results are presented in Tables 9 and 10. Results are
reported for finished fabric unless otherwise noted.
Example 17
[0321] Spun yarn from Example 5 was used to prepare a circular knit
fabric on a Mesdan lab knitter. The greige fabric was heat set in
an RBE stenter at 160.degree. C. for 45 seconds, then scoured in an
HTHP Beaker dyeing machine using the following procedure. The
fabric was scoured at 90.degree. C. for 60 minutes with NaOH (2
gpl) and wetting agent Levocol CESR (5 gpl) added. The fabric was
washed at 85.degree. C. for 15 minutes, then with cold water for 15
minutes, then with a neutralization solution containing acetic acid
(1 gpl) for 15 minutes, followed by another cold water wash for 15
minutes.
[0322] The scoured fabric was then dyed in the same machine with a
mixture of disperse dyes using the following time and temperature
profile: heat to 70.degree. C. and hold for 10 minutes, then raise
temperature 1.5.degree. C./min to 130.degree. C. and hold for 30
minutes, then decrease temperature 1.5.degree. C./min to 70.degree.
C. and drain. Post dyeing, the fabric was given a reduction
cleaning with Hydros and NaOH (2 gpl each), 90.degree. C. for 20
min. The fabric was then washed with cold water for 10 minutes,
neutralized with acetic acid (2 gpl) for 15 minutes, then washed
again with cold water for 10 minutes. The dyed fabric was padded
with finishing agent (softener), then heat set at 160.degree. C.
for 45 seconds in a lab stenter.
[0323] Fabric construction is shown in Table 9. Wicking test
results were 100%. In comparison to the fabric of Comparative
Example H, the fabric of Example 17 was found to have a softer hand
(i.e. better softness). Other fabric properties are presented in
Tables 9 and 10.
Comparative Example H
[0324] A comparative knit fabric was made using following the
procedure of Example 17 except that commercially available 20s Ne
100% PET staple spun yarn ("P1") was used.
[0325] Fabric construction is shown in Table 9. Wicking test
results were 100%. Other fabric properties are presented in Tables
9 and 10.
Example 18
[0326] Spun yarn from Example 7 was used to prepare a circular knit
fabric on a Mesdan lab knitter following the procedure of Example
17, except that after dyeing with the disperse dyes, the fabric was
dyed in the same machine with a reactive dye mixture to which salt
(60 gpl) was added, using the following time and temperature
profile: heat to 60.degree. C. and hold for 30 minutes, then add
soda ash (15 gpl) and hold for 30 minutes before draining. The
fabric was then washed with cold water for 10 minutes, washed with
acetic acid (1 gpl) for 15 minutes, then given a hot soaping with
Albatex AD (2 gpl) during which the temperature was raised to
90.degree. C. and held for 15 minutes. The fabric was then washed
with hot water (85.degree. C.) for 15 minutes, and then with cold
water for 10 minutes. The dye was fixed with Levocol HCF (0.5 gpl)
during which the temperature was raised to 50.degree. C. and held
for 20 minutes. The dyed fabric was padded with finishing agent
then heat set at 160.degree. C. for 45 seconds in a lab
stenter.
[0327] Fabric construction is shown in Table 9. Wicking test
results were 100%. Other fabric properties are presented in Tables
9 and 10.
Comparative Example I
[0328] A comparative knit fabric was made using following the
procedure of Example 18 except that commercially available 20s Ne
40/60 PET/cotton staple spun yarn ("PC1") was used.
[0329] Fabric construction is shown in Table 9. Wicking test
results were 100%. Other fabric properties are presented in Tables
9 and 10.
Example 19
[0330] Spun yarn from Example 9 was used to prepare a circular knit
fabric on a Mesdan lab knitter following the procedure of Example
18.
[0331] Fabric construction is shown in Table 9. Wicking test
results were 100%. Other fabric properties are presented in Tables
9 and 10.
Comparative Example J
[0332] A comparative knit fabric was made using following the
procedure of Example 18 except that commercially available 20s Ne
40/60 PET/Tencel.RTM. staple spun yarn ("PT1") was used.
[0333] Fabric construction is shown in Table 9. Wicking test
results were 100%. Other fabric properties are presented in Tables
9 and 10.
Example 20
[0334] Spun yarn from Example 6 was used to prepare a circular knit
fabric on a Mesdan lab knitter following the procedure of Example 1
except that a different mixture of disperse dyes was used.
[0335] Fabric construction is shown in Table 9. Wicking test
results were 100%. In comparison to the fabric of Comparative
Example K, the fabric of Example 20 was found to have a better hand
(i.e. better softness). Other fabric properties are presented in
Tables 9 and 10.
Comparative Example K
[0336] A comparative knit fabric was made using following the
procedure of Example 17 except that commercially available 40s Ne
100% PET staple spun yarn ("P2") and a different mixture of
disperse dyes were used.
[0337] Fabric construction is shown in Table 9. Wicking test
results were 100%. Other fabric properties are presented in Tables
9 and 10.
Example 21
[0338] Spun yarn from Example 8 was used to prepare a circular knit
fabric on a Mesdan lab knitter following the procedure of Example
18, except that a different mixture of disperse dyes was used.
[0339] Fabric construction is shown in Table 9. Wicking test
results were 100%. Other fabric properties are presented in Tables
9 and 10.
Comparative Example L
[0340] A comparative knit fabric was made using following the
procedure of Example 18 except that commercially available 40s Ne
40/60 PET/cotton staple spun yarn ("PC2"), a different mixture of
disperse dyes, and a different mixture of reactive dyes used were
used.
[0341] Fabric construction is shown in Table 9. Wicking test
results were 100%. Other fabric properties are presented in Tables
9 and 10.
Example 22
[0342] Spun yarn from Example 10 was used to prepare a circular
knit fabric on a Mesdan lab knitter following the procedure of
Example 18, except with a different mixture of disperse dyes and a
different mixture of reactive dyes.
[0343] Fabric construction is shown in Table 9. Wicking test
results were 100%. Other fabric properties are presented in Tables
9 and 10.
Comparative Example M
[0344] A comparative knit fabric was made using following the
procedure of Example 18 except that commercially available 40s Ne
40/60 PET/Tencel.RTM. staple spun yarn ("PT2"), a different mixture
of disperse dyes, and a different reactive dye were used.
[0345] Fabric construction is shown in Table 9. Wicking test
results were 100%. Other fabric properties are presented in Tables
9 and 10.
TABLE-US-00009 TABLE 9 Circular Knit (CK) Fabric Construction and
Evaluation Results Dimensional Abrasion Yarn Fabric Weight
Stability Bursting Weight Count Fiber Blend % in (g/m.sup.2) Length
Width Strength Pill Loss Thickness Ex. (Ne) Yarn CK fabric Greige
Finished (%) (%) (kg/cm.sup.2) Rating Grade (%) (mm) 17 20s Ex 5
100% melt 165 258 -1.4 -2.8 9.2 3-4 3-4 0.16 0.55 spun staple Comp.
20s P1 100% PET 156 188 -1.1 -2.5 12.7 1-2 1 0.97 0.41 Ex. H staple
18 20s Ex 7 40/60 melt 166 248 -2.9 -2.2 6.4 3 3-4 0.48 0.7 spun
staple/ cotton Comp. 20s PC1 40/60 172 182 -2.7 -2.4 7.3 1-2 1-2
1.73 0.51 Ex. I PET/cotton 19 20s Ex 9 40/60 melt 180 253 -1.7 -1.9
6.8 4-5 2 3.94 0.62 spun staple/Tencel .RTM. Comp. 20s PT1 40/60
167 197 -2.0 -1.5 7.5 1-2 1-2 6.07 0.48 Ex. J PET/Tencel .RTM. 20
40s Ex 6 100% melt 107 161 -2.6 -1.8 7.2 2-3 1-2 0.13 0.46 spun
staple Comp. 40s P2 100% PET 100 124 -1.7 -1.3 8.7 1 1 0.94 0.31
Ex. K staple 21 40s Ex 8 40/60 melt 108 153 -1.6 -2.7 5.8 4 3-4
0.68 0.52 spun staple/ cotton Comp. 40s PC2 40/60 102 117 -2.4 -2.8
5.9 1-2 1 1.69 0.35 Ex. L PET/cotton 22 40s Ex 10 40/60 melt spun
101 130 -1.8 -2.1 4.9 3-4 2 6.21 0.42 staple/Tencel .RTM. Comp. 40s
PT2 40/60 101 130 -2.0 -2.4 5.3 1-2 1 7.36 0.3 Ex. M PET/Tencel
.RTM.
TABLE-US-00010 TABLE 10 Circular Knit (CK) Fabric Evaluation
Results Continued Stretch & Recovery (%) 30 60 30 60 Length 1
min min min Width 1 min min min Colorfastness Colorfastness to
Washing Stretch recov recov recov stretch recov recov recov to
Rubbing Shade Ex. (%) (%) (%) (%) (%) (%) (%) (%) Dry Wet change
Acetate Cotton Nylon PET Acrylic Wool 17 36.0 91.3 94.2 97.1 67.0
96.9 98.4 98.4 4-5 4-5 4-5 4-5 4-5 4 4 4 4-5 Comp. 40.0 63.3 68.8
71.8 80.0 62.3 66.6 68.8 4-5 4 4-5 4 4 3-4 4 4 4-5 Ex. H 18 51.0
83.5 83.5 87.6 82.0 83.3 89.7 91.0 4-5 4 4-5 4-5 4-5 4-5 4-5 4-5
4-5 Comp. 50.0 73.8 74.4 75.6 84.0 73.2 73.8 74.4 4-5 3-4 4-5 4-5
4-5 3-4 4-5 4-5 4-5 Ex. I 19 52.0 89.9 93.9 93.9 86.0 86.5 90.2
90.2 4-5 4 4-5 4-5 4-5 4 4-5 4-5 4-5 Comp. 63.0 74.8 76.2 77.5 90.0
73.8 75.4 76.7 4-5 4 4-5 4-5 4-5 4-5 4-5 4-5 4-5 Ex. J 20 38.0 91.7
94.5 94.5 95.0 92.3 96.7 97.8 4-5 4 4-5 4-5 4-5 4-5 4-5 4-5 4-5
Comp. 43.0 75.4 77.0 79.5 104.0 74.5 77.8 79.3 4-5 4 4-5 4-5 4-5
4-5 4-5 4-5 4-5 Ex. K 21 55.0 82.8 84.7 85.5 115.0 87.0 87.7 88.2
4-5 4 4-5 4-5 4-5 4-5 4-5 4-5 4-5 Comp. 58.0 73.6 75.0 76.4 120.0
75.3 76.7 78.3 4-5 4 4-5 4-5 4-5 4-5 4-5 4-5 4-5 Ex. L 22 65.0 80.6
87.0 88.7 150.0 80.6 82.2 84.9 4-5 4 4-5 4-5 4-5 4-5 4-5 4-5 4-5
Comp. 55.0 72.7 75.1 76.4 145.0 74.1 75.5 77.1 4-5 4 4-5 4-5 4-5
4-5 4-5 4-5 4-5 Ex. M
[0346] The results in Tables 9 and 10 demonstrate that the circular
knit fabrics of the Examples provide advantages over the fabrics of
the Comparative Examples. For example, the circular knit fabrics
containing spun yarns comprising the melt spun staple fibers
disclosed herein have greater bulk in comparison to the fabrics of
the Comparative Examples, as shown by the greater thickness of the
fabrics. The circular knit fabrics of the Examples also demonstrate
less pilling (higher pill rating values) and better abrasion
resistance (lower % weight loss). Additionally, the fabrics of the
Examples have better stretch recovery than the Comparative Example
fabrics, both at shorter and longer recovery times.
Example 23
2/64s Nm Spun Yarn Containing 70/30 Wool/Melt Spun Staple Fiber
[0347] Spun yarn was made using the worsted spinning system,
according to the following procedure.
[0348] Melt spun staple fiber from Example 4 was used to prepare
the spun yarn of Example 23. The melt spun staple fiber, 2.5 denier
and of 84 mm average length, was taken and converted to sliver in
cotton card spinning system as per regular process of carding
normally used in spinning mills. This sliver was blended with wool
top (Australian Merino of 20.5 micron, 68 mm average mean length)
and spun in worsted spinning system in 70/30 (wt/wt) wool/melt spun
staple fiber blend proportion. The nominal count spun for the spun
yarn was 2/64s Nm.
Example 24
[0349] Spun yarn from Example 23 was used as the warp and as the
weft to prepare a bottom weight twill fabric. The warp yarns were
sized before beaming using a CCI single end sizing machine using
Elvanol-T25 PVA sizing agent and a softener. Using a warper at 350
m/min, a final beam with 1770 ends, a width of 18 inches, and end
lengths of 3.5 meters was prepared. With the following denting
plan:
[0350] Drawing: 3 shafts
[0351] Drawing type (straight drawing (1, 2, &3))
[0352] Denting: 3 ends/dent
[0353] Reed count: 60 dents/2 inch
[0354] 2/1 RHT twill fabric was woven on a CCI sample loom with
loom speed at 40 picks/minute. The pick value was set at 63
picks/inch. Greige fabric of 2 m length and 50 cm width was
obtained.
[0355] The greige fabric was desized in a Jigger machine using a
procedure similar to that of Example 11, except that Albatex AD was
used in conjunction with Levocol CESR. The fabric was then
subjected to a hot water wash (85.degree. C. for 15 minutes), a
cold water wash (15 minutes), a neutralization step with acetic
acid (15 minutes), and another cold water wash (15 minutes). The
fabric was allowed to dry flat in atmospheric conditions, then heat
set at 170.degree. C. for 45 seconds.
[0356] The fabric was then dyed with a mixture of disperse dyes
using the following time and temperature profile: heat to
70.degree. C. and hold for 10 minutes, then raise temperature
1.5.degree. C./min to 130.degree. C. and hold for 30 minutes, then
decrease temperature 1.5.degree. C./min to 70.degree. C. and drain.
The fabric was given a reduction cleaning with Hydros and NaOH (1
gpl each), 90.degree. C. for 20 min. The fabric was then washed
with cold water for 10 minutes, contacted with acetic acid (2 gpl)
for 15 minutes, then washed with cold water for 10 minutes.
[0357] The fabric was then dyed with a mixture of acid dyes using
the following time and temperature profile: heat to 70.degree. C.
and hold for 10 minutes, then raise temperature 1.5.degree. C./min
to 98.degree. C. and hold for 45 minutes, then decrease temperature
1.5.degree. C./min to 70.degree. C. and drain. The fabric was
washed in cold water (10 minutes), treated with acetic acid (1 gpl
for 15 minutes), subjected to a hot soaping with Albatex AD
(90.degree. C. for 15 minutes), washed with hot water (85.degree.
C. for 15 minutes), washed with cold water (10 minutes), then
contacted with Levocol HCF (0.5 gpl) at 50.degree. C. for 20
minutes to fix the dye.
[0358] The fabric was decatized in an autoclave (130.degree. C. for
3 minutes) then padded with finishing agent before being heat set
at 160.degree. C. for 45 seconds in a lab stenter, and then
decatized again in an autoclave (130.degree. C. for 3 minutes). The
greige and finished fabrics were evaluated. Results are as
follows:
[0359] Greige fabric construction: 96*54 (end/inch*pick/inch)
[0360] Finished fabric construction: 114*63
(end/inch*pick/inch)
[0361] Greige fabric weight: 198 g/m.sup.2
[0362] Finished fabric weight: 249 g/m.sup.2
[0363] Dimensional stability (%): [0364] Length -2.8%; [0365] Width
-1.7%
[0366] Wicking test: 100%
[0367] Tear strength: warp 1984 g, weft 896 g
[0368] Stretch %: 42.7
[0369] Recovery at 1 minute, %: 83.1
[0370] Recovery at 30 minutes, %: 90.9
[0371] Recovery at 60 minutes, %: 93.51
Example 25
Undrawn Melt Spun Fiber Containing PTT and Co-PET
[0372] Pellets of polytrimethylene terephthalate (PTT) containing
0.3% TiO.sub.2 and having an intrinsic viscosity of 0.96 dL/g and
pellets of polyethylene terephthalate co-ethylene isophthalate
(Co-PET) (from Nan Ya Plastics) having an intrinsic viscosity of
0.80 dL/g were dried separately at 120.degree. C. under nitrogen
blanket in a vacuum oven for 16 hours. Dried pellets of PTT and
dried pellets of Co-PET were blended together in a small drum by
hand shaking and rolling actions of the drum in the ratios give in
Table 11. Each of the salt-and-pepper blends thus created was
melt-extruded into round cross-section, 34-filament yarn bundle
using a twin-screw extruder spinning machine. Extruder melt zone
temperatures were maintained from 180-265.degree. C. Polymer
throughput, winder speed, spun denier per filament, and dry heat
shrinkage of yarn bundles (tow) are provided in Table 11.
TABLE-US-00011 TABLE 11 Example 25 Spinning Conditions and Dry Heat
Shrinkage of Tow Winder Dry Heat PTT, Co-PET, Throughput, Speed,
Shrinkage, % % g/min m/m % 90 10 21.52 1250 21.5 80 20 21.52 1250 5
70 30 21.52 1250 3.9 50 50 21.52 1250 2.1 30 70 21.52 1250 2.1 20
80 21.52 1250 1.7 10 90 21.52 1250 1.7
Example 26
Undrawn Melt Spun Fiber Containing Co-PET and PBT
[0373] Pellets of polyethylene terephthalate co-ethylene
isophthalate (Co-PET) (from Nan Ya Plastics) having an intrinsic
viscosity of 0.80 dL/g and pellets of CRASTIN.RTM. 6130C NC010
polybutylene terephthalate (PBT) having an intrinsic viscosity of
1.15 dL/g were dried separately at 120.degree. C. under nitrogen
blanket in a vacuum oven for 16 hours. The dried pellets of PTT and
PBT were blended together in a small drum by hand shaking and
rolling actions of the drum in the ratios give in Table 12. Each of
the salt-and-pepper blends thus created was melt-extruded into
round cross-section, 34-filament yarn bundle using a twin-screw
extruder spinning machine. Extruder melt zone temperatures were
maintained from 180-265.degree. C. Polymer throughput, winder
speed, spun denier per filament and dry heat shrinkage of yarn
bundles (tow) are provided in Table 12.
TABLE-US-00012 TABLE 12 Example 26 Spinning Conditions and Dry Heat
Shrinkage of Tow Winder Dry Heat PBT, Co-PET, Throughput, Speed,
Shrinkage, % % g/min m/m % 90 10 21.52 1250 2.6 80 20 21.52 1250
3.1 70 30 21.52 1250 3.4 50 50 21.52 1250 3.8 30 70 21.52 1250 2.2
20 80 21.52 1250 2.1 10 90 21.52 1250 1.4
Example 27
Melt Spun Staple Fiber Containing Salt-and-Pepper Blends of 20 wt %
PTT and 80 wt % Co-PET
[0374] A single-screw extruder was used to co-feed polytrimethylene
terephthalate and co-PET (from Nan Ya Plastics) a 7590-hole
spinneret in 20:80 weight ratio. Polytrimethylene terephthalate
contained 0.3% TiO.sub.2 and had an intrinsic viscosity of 0.96
dL/g. Round cross-section filaments were spun at an extruder
throughput of 100 kg/h using radial quench. Extruder melt zone
temperatures were maintained from 252-263.degree. C. Polymer
throughput was 0.220 g/min/hole and feed roll speed was 650 m/m.
Spun dpf was nominally 3.4. Spun fibers were collected in cans.
[0375] Sixteen (16) cans, totaling 412,896 denier, fed
draw-crimp-cut/bale module. A typical cotton count staple process
utilizing multi-stage draw, crimper, annealer, and cutter was used
to produce staple melt spun fiber. Tow was dipped in a finish bath
(0.5% concentration, commercially available, Duron 3176 from CHT)
at 22.degree. C. Tow was first drawn, in a 0.5% concentration
finish bath at 75.degree. C. between a 18.degree. C. feed roll
running at 30 m/m and heated draw rolls at 80.degree. C. running at
84 m/m, giving a first stage draw ratio of 2.8. Drawn tow was
pulled through a steam chest at 100.degree. C. by a downstream
heated roll at 165.degree. C. and running at 88.20 m/m. Tow was
passed over another set of rolls heated at 165.degree. C. running
at 88.20 m/m. Finish (2% concentration, Duron 14+Duron 1105 PE,
30/70 active substance, both by comp. CHT) was sprayed and tow was
passed over cooling drum rolls at 25.degree. C., running at 86.44
m/m. Tow entered a steam box at 100.degree. C. prior to entering a
40-mm crimper. Crimper speed was 90.76 m/m. Crimper roller
temperature and pressure was 65.degree. C. and 0.8 bar,
respectively. Crimped tow was annealed for 4 min at 100.degree. C.
in a plate belt drier, Crimped tow was finally cut to produce
staple melt spun fiber having the following properties (which were
determined using the methods disclosed herein above):
[0376] Denier per filament (dpf)=1.28, Coefficient of variation
(CV)=15.47%
[0377] Tenacity=5.24 g/d, CV=13.05%
[0378] Elongation=53.37%, CV=39.14%
[0379] Staple length=38 mm
[0380] Number of crimp (full-sinus arc)=12.9/inch
[0381] Crimp stability=64.08%, CV=17.67%
[0382] Finish on yarn=0.26%
Example 28
Melt Spun Staple Fiber Containing Salt-and-Pepper Blends of 50 wt %
PTT and 50 wt % Co-PET
[0383] A single-screw extruder was used to co-feed polytrimethylene
terephthalate and co-PET (from Nan Ya Plastics) in 50:50 weight
ratio through a 7590-hole spinneret. Polytrimethylene terephthalate
contained 0.3% TiO.sub.2 and had an intrinsic viscosity of 0.96
dL/g. Round cross-section filaments were spun at an extruder
throughput of 122.2 kg/h using radial quench. Extruder melt zone
temperatures were maintained from 252-263.degree. C. Polymer
throughput was 0.268 g/min/hole and feed roll speed was 792 m/m.
Spun dpf was nominally 3.4. Spun fibers were collected in cans.
[0384] Sixteen (16) cans, totaling 412,896 denier, fed
draw-crimp-cut/bale module. A typical cotton count staple process
utilizing multi-stage draw, crimper, annealer, and cutter was used
to produce staple melt spun fiber. Tow was dipped in a finish bath
(0.5% concentration, commercially available, Duron 3176 from CHT)
at 22.degree. C. Tow was first drawn, in a 0.5% concentration
finish bath at 75.degree. C. between a 18.degree. C. feed roll
running at 30 m/m and heated draw rolls at 80.degree. C. running at
87 m/m, giving a first stage draw ratio of 2.9. Drawn tow was
pulled through a steam chest at 100.degree. C. by a downstream
heated roll at 165.degree. C. and running at 92.22 m/m. Tow was
passed over another set of rolls heated at 165.degree. C. running
at 90.38 m/m. Finish (2% concentration, Duron 14 +Duron 1105 PE,
30/70 active substance, both by comp. CHT) was sprayed and tow was
passed over cooling drum rolls at 25.degree. C., running at 90.38
m/m. Tow entered a steam box at 100.degree. C. prior to entering a
40-mm crimper. Crimper speed was 94.89 m/m. Crimper roller
temperature and pressure was 65.degree. C. and 0.8 bar,
respectively. Crimped tow was annealed for 4 min at 100.degree. C.
in a plate belt drier, Crimped tow was finally cut to produce
staple melt spun fiber having the following properties (which were
determined using the methods disclosed herein above):
[0385] Denier per filament (dpf)=1.31, Coefficient of variation
(CV)=10.13%
[0386] Tenacity=4.66 g/d, CV=9.72%
[0387] Elongation=53.86%, CV=25.47%
[0388] Staple length=38 mm
[0389] Number of crimp (full-sinus arc)=13.1/inch
[0390] Crimp stability=79.51%, CV=9.45%
[0391] Finish on yarn=0.20%
Example 29
Melt Spun Staple Fiber Containing Salt-and-Pepper Blends of 50 wt %
PTT and 50 wt % Co-PET
[0392] A single-screw extruder was used to co-feed polytrimethylene
terephthalate and co-PET (from Nan Ya Plastics) in 50:50 weight
ratio through a 7590-hole spinneret. Polytrimethylene terephthalate
contained 0.3% TiO.sub.2 and had an intrinsic viscosity of 0.96
dL/g. Round cross-section filaments were spun at an extruder
throughput of 122.2 kg/h using radial quench. Extruder melt zone
temperatures were maintained from 252-263.degree. C. Polymer
throughput was 0.268 g/min/hole and feed roll speed was 400 m/m.
Spun dpf was nominally 6.4. Spun fibers were collected in cans.
[0393] Eight (8) cans, totaling 388,608 denier, fed
draw-crimp-cut/bale module. A typical worsted count staple process
utilizing multi-stage draw, crimper, annealer, and cutter was used
to produce staple melt spun fiber. Tow was dipped in a finish bath
(0.5% concentration, commercially available, Duron 3176 from CHT)
at 22.degree. C. Tow was first drawn, in a 0.5% concentration
finish bath at 75.degree. C. between a 18.degree. C. feed roll
running at 30 m/m and heated draw rolls at 80.degree. C. running at
114 m/m, giving a first stage draw ratio of 3.8. Drawn tow was
pulled through a steam chest at 100.degree. C. by a downstream
heated roll at 165.degree. C. and running at 108.3 m/m. Tow was
passed over another set of rolls heated at 165.degree. C. running
at 106.1 m/m. Finish (2% concentration, Duron 14 +Duron 1105 PE,
30/70 active substance, both by comp. CHT) was sprayed and tow was
passed over cooling drum rolls at 25.degree. C., running at 107.2
m/m. Tow entered a steam box at 100.degree. C. prior to entering a
40-mm crimper. Crimper speed was 112.56 m/m. Crimper roller
temperature and pressure was 65.degree. C. and 0.8 bar,
respectively. Crimped tow was annealed for 4 min at 100.degree. C.
in a plate belt drier, Crimped tow was finally cut to produce
multiple cut length staple melt spun fiber having the following
properties (which were determined using the methods disclosed
herein above):
[0394] Denier per filament (dpf)=2.08, Coefficient of variation
(CV)=7.47%
[0395] Tenacity=4.31 g/d, CV=15.67%
[0396] Elongation=67.77%, CV=24.33%
[0397] Staple length=multiple cut length, 59.5/79.3/119 mm
[0398] Number of crimp (full-sinus arc)=12/inch
[0399] Crimp stability=72.11%, CV=12.8%
[0400] Finish on yarn=0.09%
Example 30
Melt Spun Staple Fiber Containing Salt-and-Pepper Blends of 20 wt %
PBT and 80 wt % Co-PET
[0401] A single-screw extruder was used to co-feed CRASTIN.RTM.
6130C NC010 polybutylene terephthalate (PBT) having an intrinsic
viscosity of 1.15 dL/g and co-PET (from Nan Ya Plastics) in 20:80
weight ratio through a 7590-hole spinneret. Round cross-section
filaments were spun at an extruder throughput of 100 kg/h using
radial quench. Extruder melt zone temperatures were maintained from
252-263.degree. C. Polymer throughput was 0.220 g/min/hole and feed
roll speed was 650 m/m. Spun dpf was nominally 3.18. Spun fibers
were collected in cans.
[0402] Sixteen (16) cans, totaling 386,179 denier, fed
draw-crimp-cut/bale module. A typical cotton count staple process
utilizing multi-stage draw, crimper, annealer, and cutter was used
to produce staple melt spun fiber. Tow was dipped in a finish bath
(0.5% concentration, commercially available, Duron 3176 from CHT)
at 22.degree. C. Tow was first drawn, in a 0.5% concentration
finish bath at 75.degree. C. between a 18.degree. C. feed roll
running at 30 m/m and heated draw rolls at 80 .degree. C. running
at 88.2 m/m, giving a first stage draw ratio of 2.94. Drawn tow was
pulled through a steam chest at 100.degree. C. by a downstream
heated roll at 165.degree. C. and running at 92.61 m/m. Tow was
passed over another set of rolls heated at 165.degree. C. running
at 92.61 m/m. Finish (2% concentration, Duron 14 +Duron 1105 PE,
30/70 active substance, both by comp. CHT) was sprayed and tow was
passed over cooling drum rolls at 25.degree. C., running at 90.76
m/m. Tow entered a steam box at 100.degree. C. prior to entering a
40-mm crimper. Crimper speed was 95.30 m/m. Crimper roller
temperature and pressure was 65.degree. C. and 0.8 bar,
respectively. Crimped tow was annealed for 4 min at 100.degree. C.
in a plate belt drier, Crimped tow was finally cut to produce
staple melt spun fiber having the following properties (which were
determined using the methods disclosed herein above):
[0403] Denier per filament (dpf)=1.24, Coefficient of variation
(CV)=13.51%
[0404] Tenacity=5.36 g/d, CV=11.77%
[0405] Elongation=47.07%, CV=39.30%
[0406] Staple length=40 mm
[0407] Number of crimp (full-sinus arc)=10.4/inch
[0408] Crimp stability=56.2%, CV=13.9%
[0409] Finish on yarn=0.31%
Example 31
Melt Spun Staple Fiber Containing Salt-and-Pepper Blends of 50 wt %
PBT and 50 wt % Co-PET
[0410] A single-screw extruder was used to co-feed CRASTIN.RTM.
6130C NC010 polybutylene terephthalate (PBT) having an intrinsic
viscosity of 1.15 dL/g and co-PET (from Nan Ya Plastics) in 50:50
weight ratio through a 7590-hole spinneret. Round cross-section
filaments were spun at an extruder throughput of 122.2 kg/h using
radial quench. Extruder melt zone temperatures were maintained from
252-263.degree. C. Polymer throughput was 0.268 g/min/hole and feed
roll speed was 792 m/m. Spun dpf was nominally 3.42. Spun fibers
were collected in cans.
[0411] Sixteen (16) cans, totaling 415,324 denier, fed
draw-crimp-cut/bale module. A typical cotton count staple process
utilizing multi-stage draw, crimper, annealer, and cutter was used
to produce staple melt spun fiber. Tow was dipped in a finish bath
(0.5% concentration, commercially available, Duron 3176 from CHT)
at 22.degree. C. Tow was first drawn, in a 0.5% concentration
finish bath at 75.degree. C. between a 18.degree. C. feed roll
running at 30 m/m and heated draw rolls at 80.degree. C. running at
87.90 m/m, giving a first stage draw ratio of 2.93. Drawn tow was
pulled through a steam chest at 100.degree. C. by a downstream
heated roll at 165.degree. C. and running at 94.93 m/m. Tow was
passed over another set of rolls heated at 165.degree. C. running
at 94.93 m/m. Finish (2% concentration, Duron 14+Duron 1105 PE,
30/70 active substance, both by comp. CHT) was sprayed and tow was
passed over cooling drum rolls at 25.degree. C., running at 93.03
m/m. Tow entered a steam box at 100.degree. C. prior to entering a
40-mm crimper. Crimper speed was 97.69 m/m. Crimper roller
temperature and pressure was 65.degree. C. and 0.8 bar,
respectively. Crimped tow was annealed for 4 min at 100.degree. C.
in a plate belt drier, Crimped tow was finally cut to produce
staple melt spun fiber having the following properties (which were
determined using the methods disclosed herein above):
[0412] Denier per filament (dpf)=1.17, Coefficient of variation
(CV)=13.6%
[0413] Tenacity=5.48 g/d, CV=12.38%
[0414] Elongation=39.74%, CV=27.57%
[0415] Staple length=40 mm
[0416] Number of crimp (full-sinus arc)=11.8/inch
[0417] Crimp stability=60.23%, CV=8.30%
[0418] Finish on yarn=0.24%
Example 32
40s Ne Spun Yarn Containing 100% Melt Spun Fiber
[0419] Spun yarn was prepared using melt spun staple fiber from
Example 28 according to the procedure of Example 5 except with the
following differences:
[0420] The linear density of the final sliver was 4.75 g/meter and
the Unevenness % was 1.75.
[0421] The roving hank was 1.2 s Ne.
[0422] In the step of drafting the roving, the twist
multiplier/twist per inch was 3.6/22.6, the Traveler size was 4/0
M1HO, and the spindle speed was 16500 rpm.
[0423] The spun yarn was wound onto a cone at 1500 meters/min.
Properties of the spun yarn are given in Table 13. Properties of
the spun yarns of this and the following Examples were determined
using the methods disclosed herein above.
Example 33
40s Ne Spun Yarn Containing 100% Melt Spun Fiber
[0424] Spun yarn was prepared using melt spun staple fiber from
Example 27 according to the procedure of Example 32. Properties of
the spun yarn are given in Table 13.
Example 34
40s Ne Spun Yarn Containing 100% Melt Spun Fiber
[0425] Spun yarn was prepared using melt spun staple fiber from
Example 31 according to the procedure of Example 32. Properties of
the spun yarn are given in Table 13.
Example 35
40s Ne Spun Yarn Containing 100% Melt Spun Fiber
[0426] Spun yarn was prepared using melt spun staple fiber from
Example 30 according to the procedure of Example 32. Properties of
the spun yarn are given in Table 13.
Example 36
40s Ne Spun Yarn Containing 40/60 (wt/wt) Melt Spun
Fiber/Cotton
[0427] Spun yarn was prepared using melt spun staple fiber from
Example 28 and cotton (Shankar 6 variety Indian cotton commercially
obtained from north Indian states). The cotton staple had average
length of 31 mm and linear density of 4.1 microgram/inch (1.6
microgram/cm). The spun yarn was made according to the procedure of
Example 32. Properties of the spun yarn are given in Table 13.
Example 37
40s Ne Spun Yarn Containing 40/60 (wt/wt) Melt Spun
Fiber/Cotton
[0428] Spun yarn was prepared using melt spun staple fiber from
Example 27 and cotton (Shankar 6 variety Indian cotton commercially
obtained from north Indian states). The cotton staple had average
length of 31 mm and linear density of 4.1 microgram/inch (1.6
microgram/cm). The spun yarn was made according to the procedure of
Example 8. Properties of the spun yarn are given in Table 13.
Example 38
40s Ne Spun Yarn Containing 40/60 (wt/wt) Melt Spun
Fiber/Cotton
[0429] Spun yarn was prepared using melt spun staple fiber from
Example 31 and cotton (Shankar 6 variety Indian cotton commercially
obtained from north Indian states). The cotton staple had average
length of 31 mm and linear density of 4.1 microgram/inch (1.6
microgram/cm). The spun yarn was made according to the procedure of
Example 8. Properties of the spun yarn are given in Table 13.
Example 39
40s Ne Spun Yarn Containing 40/60 (wt/wt) Melt Spun
Fiber/Cotton
[0430] Spun yarn was prepared using melt spun staple fiber from
Example 30 and cotton (Shankar 6 variety Indian cotton commercially
obtained from north Indian states). The cotton staple had average
length of 31 mm and linear density of 4.1 microgram/inch (1.6
microgram/cm). The spun yarn was made according to the procedure of
Example 8. Properties of the spun yarn are given in Table 13.
Example 40
40s Ne Spun Yarn Containing 40/60 Melt Spun Fiber/Tencel
[0431] Spun yarn was prepared using melt spun staple fiber from
Example 28 and commercially-obtained Tencel.RTM. staple fiber
(Lenzing). The Tencel.RTM. staple had average length of 40 mm and
denier of 1.2 D. The spun yarn was made according to the procedure
of Example 10. Properties of the spun yarn are given in Table
13.
Example 41
40s Ne Spun Yarn Containing 40/60 Melt Spun Fiber/Tencel
[0432] Spun yarn was prepared using melt spun staple fiber from
Example 27 and commercially-obtained Tencel.RTM. staple fiber
(Lenzing). The Tencel.RTM. staple had average length of 40 mm and
denier of 1.2 D. The spun yarn was made according to the procedure
of Example 10. Properties of the spun yarn are given in Table
13.
Example 42
40s Ne Spun Yarn Containing 40/60 Melt Spun Fiber/Tencel
[0433] Spun yarn was prepared using melt spun staple fiber from
Example 31 and commercially-obtained Tencel.RTM. staple fiber
(Lenzing). The Tencel.RTM. staple had average length of 40 mm and
denier of 1.2 D. The spun yarn was made according to the procedure
of Example 10. Properties of the spun yarn are given in Table
13.
Example 43
40s Ne Spun Yarn Containing 40/60 Melt Spun Fiber/Tencel
[0434] Spun yarn was prepared using melt spun staple fiber from
Example 30 and commercially-obtained Tencel.RTM. staple fiber
(Lenzing). The Tencel.RTM. staple had average length of 40 mm and
denier of 1.2 D. The spun yarn was made according to the procedure
of Example 10. Properties of the spun yarn are given in Table
13.
Example 44
2/68s Nm Spun Yarn Containing 45/55 Wool/Melt Spun Staple Fiber
[0435] Spun yarn was made using the worsted spinning system,
according to the following procedure.
[0436] Melt spun staple fiber from Example 29 was used to prepare
the spun yarn of Example 44. The melt spun staple fiber, 2.5 denier
and of 84 mm average length, was taken and converted to sliver in
cotton card spinning system as per regular process of carding
normally used in spinning mills. This sliver was blended with wool
top (Australian Merino of 20.5 micron, 68 mm average mean length)
and spun in worsted spinning system in 45/55 (wt/wt) wool/melt spun
staple fiber blend proportion. The nominal count spun for the spun
yarn was 2/68s Nm.
[0437] In Table 13, the reported Boiling Water Shrinkage values
were obtained according to method ASTM D2259 and using a 1 kg
weight.
TABLE-US-00013 TABLE 13 Properties of the Spun Yarns of Example 32
Through Example 44 Boiling Water Number of Shrinkage Melt Spun
Breaking Imperfections (BWS) (%), Yarn Staple from Tenacity
Elongation U (per km Hairiness at 1 kg dead Example Yarn
Description Example (cN/Tex) (%) (%) of yarn) Index weight 32 40s
Ne 100% melt spun 28 22.3 17.7 12.0 231 4.86 15.13 staple 33 40s Ne
100% melt spun 27 25.4 13.5 11.3 46 4.79 8.57 staple 34 40s Ne 100%
melt spun 31 24.2 12.6 13.3 548 4.98 8.00 staple 35 40s Ne 100%
melt spun 30 31.4 14.4 10.7 85 4.7 6.50 staple 36 40s Ne 40/60 melt
spun 28 12.11 4.3 13.3 659 6.07 10.27 staple/cotton 37 40s Ne 40/60
melt spun 27 10.8 4.6 14.4 1188 6.29 6.84 staple/cotton 38 40s Ne
40/60 melt spun 31 13.8 5.7 13.0 595 6.22 6.34 staple/cotton 39 40s
Ne 40/60 melt spun 30 14.9 5.3 13.4 588 5.84 5.07 staple/cotton 40
40s Ne 40/60 melt spun 28 18.2 8.0 11.1 219 5.26 7.36 staple/Tencel
.RTM. 41 40s Ne 40/60 melt spun 27 22.1 8.8 11.4 195 5.43 5.47
staple/Tencel .RTM. 42 40s Ne 40/60 melt spun 31 25.7 9.7 10.1 126
-- 4.88 staple/Tencel .RTM. 43 40s Ne 40/60 melt spun 30 23.7 9.0
11.7 475 5.93 3.06 staple/Tencel .RTM. 44 2/68s Nm 45/55 29 17.0
38.9 12.7 109 -- 4.82 Wool/melt spun staple
[0438] The results in Table 13, as compared to the results in Table
4 and 5, show that the tenacities of spun yarns incorporating
salt-and-pepper blended PET/PTT 50:50 melt spun staple are similar
to those of spun yarns incorporating compounded PET/PTT 50:50 melt
spun staple. Boiling water shrinkage percent is higher for spun
yarns incorporating salt-and-pepper PET/PTT 50:50 melt spun staple
as compared to that of spun yarns incorporating compounded PET/PTT
50:50 melt spun staple. All other properties were found to be
similar.
Woven Fabric Examples
[0439] The spun yarns of Examples 32 through 44 were used to make
woven fabrics as indicated in Table 14. Plain weave (1/1) shirting
fabrics were made using the spun yarns disclosed herein as the warp
and weft (fill) yarns. For each woven fabric, the same yarn was
used in both the warp and the weft. Fabric evaluation results are
presented in Tables 15 and 16. Results are reported for finished
fabric unless otherwise noted. Fabric properties of this and the
following Examples were determined using the methods disclosed
herein above.
Example 45
[0440] Spun yarn from Example 32 was used as the warp and as the
weft to prepare a plain weave (1/1) shirting fabric. The warp yarns
were sized before beaming using a CCI single end sizing machine
using Elvanol-T25 PVA sizing agent. Using a warper at 350 m/min, a
final beam with 1680 ends, a width of 18 inches, and end lengths of
3.5 meters was prepared. With the following denting plan:
[0441] Drawing: 4 shafts
[0442] Drawing type (straight drawing (1, 2, 3, &4)
[0443] Denting: 2 ends/dent
[0444] Reed count: 84 dents/2 inch
[0445] 1/1 plain fabric was woven on a CCI sample loom with loom
speed at 40 picks/minute. The pick value was set at 49
picks/inch.
[0446] The greige fabric was desized on an RBE lab Jigger machine
as follows. The fabric sample was loaded into the jigger filled
with water (2 L), NaOH (2 gpl), and wetting agent; Levocol CESR
(wetting agent) was added (5 gpl) and the bath temperature was
raised to 90.degree. C. The fabric was run in the bath for 60 mins,
then the bath was drained, refilled with fresh water, and the
temperature of the bath was raised to 85.degree. C. The fabric was
hot water washed for 15 min, and the bath was drained. The bath was
again filled with water and the fabric was run through it for 15
min (cold water wash). Bath was drained, filled with water, and
neutralized by adding acetic acid (1 gpl); fabric was run for 15
min in this bath. Afterwards, the bath was drained, refilled with
fresh water, and the fabric run in cold water bath for 15 min. The
fabric was then unloaded from the jigger and dried in atmospheric
conditions, then heat set in an RBE stenter at 160.degree. C. for
45 seconds.
[0447] The fabric was then dyed with a mixture of disperse dyes
using the following time and temperature profile: heat to
70.degree. C. and hold for 10 minutes, then raise temperature
1.5.degree. C./min to 130.degree. C. and hold for 30 minutes, then
decrease temperature 1.5.degree. C./min to 70.degree. C. and drain.
Post dyeing, the fabric was given a reduction cleaning with Hydros
and NaOH (2 gpl each), 90.degree. C. for 20 min. The fabric was
then washed with cold water for 10 minutes, contacted with acetic
acid (2 gpl) for 15 minutes, then washed with cold water for 10
minutes. The dyed fabric was padded with finishing agent
(softener), then heat set at 160.degree. C. for 45 seconds in an
RBE lab stenter.
[0448] Fabric construction is shown in Table 14. Wicking test
results were 100%. Other fabric properties are presented in Tables
15 and 16.
Example 46
[0449] Spun yarn from Example 33 was used as the warp and as the
weft to prepare a plain weave shirting fabric as per procedure
given in Example 45.
[0450] Fabric construction is shown in Table 14. Wicking test
results were 100%. Other fabric properties are presented in Tables
15 and 16.
Example 47
[0451] Spun yarn from Example 34 was used as the warp and as the
weft to prepare a plain weave shirting fabric as per procedure
given in Example 45. Fabric construction is shown in Table 14.
Wicking test results were 100%. Other fabric properties are
presented in Tables 15 and 16.
Example 48
[0452] Spun yarn from Example 35 was used as the warp and as the
weft to prepare a plain weave shirting fabric. as per procedure
given in Example 45. Fabric construction is shown in Table 14.
Wicking test results were 100%. Other fabric properties are
presented in Tables 15 and 16.
Example 49
[0453] Spun yarn from Example 36 was used as the warp and as the
weft to prepare a plain weave shirting fabric according to the
procedure of Example 45 but with the following exceptions. The pick
value was set at 58 picks/inch on the loom. The greige fabric was
desized and bleached in a Jigger machine, heat set in a stenter,
then dyed with a mixture of disperse dyes, then additionally dyed
with a reactive dye under cotton dyeing conditions. Fabric
construction is shown in Table 14. Wicking test results were 100%.
Other fabric properties are presented in Tables 15 and 16.
Example 50
[0454] Spun yarn from Example 37 was used as the warp and as the
weft to prepare a plain weave shirting fabric according to the
procedure of Example 49 but with the following exceptions. The
greige fabric was desized and bleached in a Jigger machine, heat
set in a stenter, then dyed with a mixture of disperse dyes, then
additionally dyed with a reactive dye under cotton dyeing
conditions. Fabric construction is shown in Table 14. Wicking test
results were 100%. Other fabric properties are presented in Tables
15 and 16.
Example 51
[0455] Spun yarn from Example 38 was used as the warp and as the
weft to prepare a plain weave shirting fabric according to the
procedure of Example 49 but with the following exceptions. The
greige fabric was desized and bleached in a Jigger machine, heat
set in a stenter, then dyed with a mixture of disperse dyes, then
additionally dyed with a reactive dye under cotton dyeing
conditions. Fabric construction is shown in Table 14. Wicking test
results were 100%. Other fabric properties are presented in Tables
15 and 16.
Example 52
[0456] Spun yarn from Example 39 was used as the warp and as the
weft to prepare a plain weave shirting fabric according to the
procedure of Example 49 but with the following exceptions. The
greige fabric was desized and bleached in a Jigger machine, heat
set in a stenter, then dyed with a mixture of disperse dyes, then
additionally dyed with a reactive dye under cotton dyeing
conditions.
[0457] Fabric construction is shown in Table 14. Wicking test
results were 100%. Other fabric properties are presented in Tables
15 and 16.
Example 53
[0458] Spun yarn from Example 40 was used as the warp and as the
weft to prepare a plain weave shirting fabric according to the
procedure of Example 49, except that no peroxide killer was used at
the end of the bleaching step. The pick value was set at 65
picks/inch on the loom.
[0459] Fabric construction is shown in Table 14. Wicking test
results were 100%. Other fabric properties are presented in Tables
15 and 16.
Example 54
[0460] Spun yarn from Example 41 was used as the warp and as the
weft to prepare a plain weave shirting fabric according to the
procedure of Example 53. Fabric construction is shown in Table 14.
Wicking test results were 100%. Other fabric properties are
presented in Tables 15 and 16.
Example 55
[0461] Spun yarn from Example 42 was used as the warp and as the
weft to prepare a plain weave shirting fabric according to the
procedure of Example 53. Fabric construction is shown in Table 14.
Wicking test results were 100%. Other fabric properties are
presented in Tables 15 and 16.
Example 56
[0462] Spun yarn from Example 42 was used as the warp and as the
weft to prepare a plain weave shirting fabric according to the
procedure of Example 53.
[0463] Fabric construction is shown in Table 14. Wicking test
results were 100%. Other fabric properties are presented in Tables
15 and 16.
Example 57
[0464] Spun yarn from Example 34 was used as the warp and as the
weft to prepare a suiting fabric of 2/1 twill construction. The
warp yarns were sized before beaming using a CCI single end sizing
machine using Elvanol-T25 PVA sizing agent and a softener. Using a
warper at 350 m/min, a final beam with 1518 ends, a width of 18
inches, and end lengths of 3.5 meters was prepared. With the
following denting plan:
[0465] Drawing: 3 shafts
[0466] Drawing type (straight drawing (1, 2, &3)
[0467] Denting: 3 ends/dent
[0468] Reed count: 51.5 dents/2 inch
[0469] 2/1 RHT twill fabric was woven on a CCI sample loom with
loom speed at 40 picks/minute. The pick value was set at 53
picks/inch. Greige fabric of 2 m length and 48.3 cm width was
obtained.
[0470] The greige fabric was desized in a Jigger machine using a
procedure similar to that of Example 49, except that Albatex AD was
used in conjunction with Levocol CESR. The fabric was then
subjected to a hot water wash (85.degree. C. for 15 minutes), a
cold water wash (15 minutes), a neutralization step with acetic
acid (15 minutes), and another cold water wash (15 minutes). The
fabric was allowed to dry flat in atmospheric conditions, then heat
set at 170.degree. C. for 45 seconds.
[0471] The fabric was then dyed with a mixture of disperse dyes
using the following time and temperature profile: heat to
70.degree. C. and hold for 10 minutes, then raise temperature
1.5.degree. C./min to 130.degree. C. and hold for 30 minutes, then
decrease temperature 1.5.degree. C./.min to 70.degree. C. and
drain. The fabric was given a reduction cleaning with Hydros and
NaOH (1 gpl each), 90.degree. C. for 20 min. The fabric was then
washed with cold water for 10 minutes, contacted with acetic acid
(2 gpl) for 15 minutes, then washed with cold water for 10
minutes.
[0472] The fabric was then dyed with a mixture of acid dyes using
the following time and temperature profile: heat to 70.degree. C.
and hold for 10 minutes, then raise temperature 1.5.degree. C./min
to 98.degree. C. and hold for 45 minutes, then decrease temperature
1.5.degree. C./min to 70.degree. C. and drain. The fabric was
washed in cold water (10 minutes), treated with acetic acid (1 gpl
for 15 minutes), subjected to a hot soaping with Albatex AD
(90.degree. C. for 15 minutes), washed with hot water (85.degree.
C. for 15 minutes), washed with cold water (10 minutes), then
contacted with Levocol HCF (0.5 gpl) at 50.degree. C. for 20
minutes to fix the dye.
[0473] The fabric was decatized in an autoclave (130.degree. C. for
3 minutes) then padded with finishing agent, Levofin HYP-5gp1
Levocol PNLI-10gpl, before being heat set at 160.degree. C. for 45
seconds in a lab stenter, and then decatized again in an autoclave
(130.degree. C. for 3 minutes).
[0474] The greige and finished fabrics were evaluated. The fabric
construction and testing results are given in Tables 14, 15, and
16. Wicking test results were 100%.
TABLE-US-00014 TABLE 14 Woven Fabric Construction for Fabric
Examples 45-57 Spun Yarn Fabric Details Fabric Construction Fabric
Weight Fabric from (same yarn in (ends/inch * pick/inch)
(g/m.sup.2) Example Example warp and weft) Greige Finished Greige
Finished 45 32 Shirting, plain 92*52 110*71 93 145 46 33 Shirting,
plain 90*52 98*62 92 122 47 34 Shirting, plain 90*52 102*62 91 113
48 35 Shirting, plain 90*54 96*61 100 124 49 36 Shirting, plain
93*62 106*78 95 130 50 37 Shirting, plain 92*60 98*72 83 102 51 38
Shirting, plain 92*62 102*76 98 117 52 39 Shirting, plain 91*61
98*71 95 109 53 40 Shirting, plain 92*66 110*79 95 127 54 41
Shirting, plain 92*69 102*81 95 115 55 42 Shirting, plain 92*67
101*81 102 120 56 43 Shirting, plain 92*69 102*79 104 123 57 44
Suiting, twill, 2/1 RHT 81*55 93*73 163 245
TABLE-US-00015 TABLE 15 Woven Fabric Evaluation Results (First
Half) for Fabric Examples 45-57 Dimensional Tear Tensile Breaking
Abrasion Stability Strength Strength Elongation Weight Fabric (%)
(g) (kgf) (%) Thickness Pill Loss Example warp weft warp weft warp
weft warp weft (mm) Rating Rating (%) 45 -0.8 -1.5 >6400 5150
29.5 18.9 100.9 71.3 0.30 3-4 2 0.18 46 -0.9 -1.3 3840 3968 28.2
24.9 71.8 45.4 0.27 2-3 1 0.31 47 -1.0 -1.2 3264 2432 27.9 22.8
61.3 45.2 0.26 3 1 0.52 48 -1.1 -1.2 4160 2944 27.4 25.5 67.0 41.9
0.28 3 1 0.06 49 -0.7 -1.6 1056 896 16.1 11.7 43.3 37.2 0.31 3 4
0.93 50 -0.7 -0.7 896 704 17.9 9.6 27.7 19.4 0.29 2-3 3 2.06 51
-1.2 -0.9 1154 768 20.8 13.7 33.7 24.2 0.28 3 3-4 1.65 52 -1.5 -0.8
960 896 19.6 11.7 27.5 19.3 0.28 3 3 1.25 53 -1.5 -1.9 1920 1600
17.0 13.0 46.1 27.7 0.32 2-3 3 3.53 54 -1.6 -1.2 832 768 20.8 17.0
26.4 21.7 0.28 2 2-3 3.29 55 -1.1 -1.6 960 768 25.9 19.5 32.6 21.6
0.27 2-3 3 2.19 56 -1.9 -1.5 960 960 21.8 18.7 27.2 19.7 0.26 2-3 3
2.32 57 -2.1 -1.6 3328 1920 24.4 18.5 115.7 71.1 0.58 5 4 4.36
TABLE-US-00016 TABLE 16 Woven Fabric Evaluation Results (Second
Half) for Fabric Examples 45-57 Drape Shrinkage, Area Greige
Stretch & Recovery of Drape to Finishing Recovery Recovery
Colorfastness Colorfastness to Washing Fabric Drape Coeff. Warp
Weft Stretch in 1 min in 60 mins to Rubbing Shade Example
(cm.sup.2) (%) (%) (%) (%) (%) (%) Dry Wet Change Acetate Cotton
Nylon Polyester Acrylic Wool 45 202.5 21.6 -22.7 -15.1 3.8 76.7 80
4-5 4-5 4-5 4-5 4-5 4-5 4-5 4-5 4-5 46 179.4 15.4 -16.1 -9.3 4 68.8
81.3 4-5 4-5 4-5 4-5 4-5 4-5 4-5 4-5 4-5 47 175.6 14.3 -16.2 -10.0
3 75.0 83.3 4-5 4-5 4-5 4-5 4-5 4-5 4-5 4-5 4-5 48 191.0 18.5 -17.2
-7.4 2.5 70.0 80.0 4-5 4-5 4-5 4-5 4-5 4-5 4-5 4-5 4-5 49 266.6
39.0 -23.4 -13.3 6 58.3 70.8 4-5 4-5 4-5 4-5 4-5 4-5 4-5 4-5 4-5 50
221.7 26.9 -13.0 -8.3 6.5 57.7 69.2 4-5 4-5 4-5 4-5 4-5 4-5 4-5 4-5
4-5 51 215.3 25.1 -12.0 -7.0 7.5 53.3 63.3 4-5 4-5 4-5 4-5 4-5 4-5
4-5 4-5 4-5 52 232.0 29.6 -11.2 -7.1 6.3 60.0 76.0 4-5 4-5 4-5 4-5
4-5 4-5 4-5 4-5 4-5 53 219.2 26.2 -20.5 -10.9 8.6 58.0 73.9 4-5 4
4-5 4-5 4 4 4-5 4-5 4-5 54 193.5 19.2 -15.2 -7.8 6 58.3 75.0 4-5 4
4-5 4-5 4 4 4-5 4-5 4-5 55 192.3 18.9 -16.1 -6.7 6.5 57.7 73.1 4-5
4 4-5 4-5 4 4 4-5 4-5 4-5 56 194.8 19.6 -13.0 -6.2 6 66.7 83.3 4-5
4 4-5 4-5 4 4 4-5 4-5 4-5 57 214.0 24.8 -25.9 -17.2 7 64.3 82.1 4-5
4 4-5 4 4-5 3-4 4-5 4-5 3-4
[0475] The results shown in Tables 14, 15, and 16, and also
previous Tables 6, 7, and 8, demonstrate that the spun yarns
disclosed herein can be used to make woven fabrics having desirable
properties.
Circular Knit Fabric Examples
[0476] The spun yarns of Examples 32 through 44 were used as the
knitting yarn to make circular knit fabrics as indicated in Table
17. For all circular knit fabrics made using 40s Ne count yarns,
the machine gauge was 24''. Fabric evaluation results are presented
in Table 18. Results are reported for finished fabric unless
otherwise noted.
Examples 58, 59, 60, and 61
[0477] Spun yarns from Examples 32, 33, 34, and 35 were each used
to prepare circular knit fabrics on a Mesdan lab knitter. The
greige fabric was heat set in an RBE stenter at 160.degree. C. for
45 seconds, then scoured in an HTHP Beaker dyeing machine using the
following procedure. The fabric was scoured at 90.degree. C. for 60
minutes with NaOH (2 gpl) and wetting agent Levocol CESR (5 gpl)
added. The fabric was washed at 85.degree. C. for 15 minutes, then
with cold water for 15 minutes, then with a neutralization solution
containing acetic acid (1 gpl) for 15 minutes, followed by another
cold water wash for 15 minutes.
[0478] The scoured fabrics were then dyed in the same machine with
a mixture of disperse dyes using the following time and temperature
profile: heat to 70.degree. C. and hold for 10 minutes, then raise
temperature 1.5.degree. C./min to 130.degree. C. and hold for 30
minutes, then decrease temperature 1.5.degree. C./min to 70.degree.
C. and drain. Post dyeing, the fabric was given a reduction
cleaning with Hydros and NaOH (2 gpl each), 90.degree. C. for 20
min. The fabric was then washed with cold water for 10 minutes,
neutralized with acetic acid (2 gpl) for 15 minutes, then washed
again with cold water for 10 minutes. The dyed fabric was padded
with finishing agent (softener), then heat set at 160.degree. C.
for 45 seconds in a lab stenter. Fabrics construction and testing
results are presented in Tables 17 and 18. Wicking test results
were 100% for all the fabrics
Examples 62, 63, 64, and 65
[0479] Spun yarns from Example 36, 37, 38, and 39 were each used to
prepare circular knit fabrics on a Mesdan lab knitter following the
procedure of Example 58, except that after dyeing with the disperse
dyes, the fabric was dyed in the same machine with a reactive dye
mixture to which salt (60 gpl) was added, using the following time
and temperature profile: heat to 60.degree. C. and hold for 30
minutes, then add soda ash (15 gpl) and hold for 30 minutes before
draining. The fabric was then washed with cold water for 10
minutes, washed with acetic acid (1 gpl) for 15 minutes, then given
a hot soaping with Albatex AD (2 gpl) during which the temperature
was raised to 90.degree. C. and held for 15 minutes. The fabric was
then washed with hot water (85.degree. C.) for 15 minutes, and then
with cold water for 10 minutes. The dye was fixed with Levocol HCF
(0.5 gpl) during which the temperature was raised to 50.degree. C.
and held for 20 minutes. The dyed fabric was padded with finishing
agent then heat set at 160.degree. C. for 45 seconds in a lab
stenter. Fabric construction and testing results are presented in
Tables 17 and 18. Wicking test results were 100% for all the
fabrics
Examples 66, 67, 68, and 69
[0480] Spun yarns from Example 40, 41, 42, and 43 were each used to
prepare circular knit fabrics on a Mesdan lab knitter following the
procedure of Example 18, except with a different mixture of
disperse dyes and a different mixture of reactive dyes and no
peroxide killer was used at the end of the bleaching step. Fabric
construction and testing results are presented in Tables 17 and 18.
Wicking test results were 100% for all the fabrics
Example 70
[0481] Spun yarn from Example 44 was used to prepare a circular
knit fabric on a Mesdan lab knitter following the procedure of
Example 14. The fabric was dyed and finished following the example
of 57. Fabrics construction and testing results are presented in
Tables 17 and 18. Wicking test results were 100% for all the
fabrics
TABLE-US-00017 TABLE 17 Circular Knit (CK) Fabric Construction and
Evaluation Results for Examples 58 Through 70 Spun Abrasion Yarn
Fabric Weight Dimensional Stability Bursting Weight Colorfastness
Fabric from (g/m.sup.2) (%) Strength Pill Loss Thickness to Rubbing
Example Example Greige Finished Lengthwise Widthwise (kg/cm.sup.2)
Rating Rating (%) (mm) Dry Wet 58 32 112 202 -1.1 -1.2 6.7 3 1-2
0.23 0.41 4-5 4-5 59 33 110 173 -1.7 -1.9 8.5 1-2 1 0.36 0.40 4-5
4-5 60 34 113 148 -1.6 -1.3 8.5 1-2 1 0.28 0.39 4-5 4-5 61 35 106
188 -1.1 -1.2 6.7 2-3 1 0.14 0.40 4-5 4-5 62 36 105 159 -1.8 -1.6
5.1 4 1-2 1.11 0.50 4-5 4-5 63 37 98 133 -1.0 1.0 4.8 3-4 1 1.26
0.42 4-5 4-5 64 38 105 138 -1.4 -1.1 5.4 3-4 1 1.69 0.43 4-5 4-5 65
39 98 147 -1.5 -1.7 6.0 3-4 1 1.27 0.42 4-5 4-5 66 40 105 171 -1.2
-1.7 5.7 3-4 2 2.24 0.50 4-5 4-5 67 41 102 144 -0.9 -1.2 5.3 3 2
2.07 0.42 4-5 4-5 68 42 105 149 -1.4 -1.7 5.0 2-3 2 1.79 0.41 4-5
4-5 69 43 106 147 -1.2 -1.6 5.6 2 2 3.04 0.42 4-5 4-5 70 44 198 320
-0.9 -0.7 6.4 4 2-3 2.93 0.64 4-5 4
TABLE-US-00018 TABLE 18 Circular Knit (CK) Fabric Evaluation
Results Continued for Examples 58 Through 70 Stretch (%) and
Recovery ("Recov") (%) Lengthwise Widthwise Recov. Recov. Recov.
Recov. Recov. Recov. Colorfastness to Washing Fabric in 1 in 30 in
60 in 1 in 30 in 60 Shade Example Stretch min min min Stretch min
min min Change Acetate Cotton Nylon Polyester Acrylic Wool 58 20
86.9 92.1 92.1 93.0 91.5 94.3 95.5 4-5 4-5 4-5 4-5 4-5 4-5 4-5 59
33 95.2 96.8 98.4 123.0 95.7 97.4 97.9 4-5 4-5 4-5 4-5 4-5 4-5 4-5
60 39 89.2 91.9 93.3 127.0 88.4 93.4 94.2 4-5 4-5 4-5 4-5 4-5 4-5
4-5 61 36 91.2 94.2 95.6 133.0 94.0 96.4 97.2 4-5 4-5 4-5 4-5 4-5
4-5 4-5 62 55 81.1 82.8 86.6 114.0 83.9 86.8 87.7 4-5 4-5 4-5 4-5
4-5 4-5 4-5 63 56 81.6 83.1 87.7 137.0 87.7 89.7 91.0 4-5 4-5 4-5
4-5 4-5 4-5 4-5 64 57 80.5 82.6 87.1 126.0 86.1 87.9 89.1 4-5 4-5
4-5 4-5 4-5 4-5 4-5 65 55 78.0 81.5 89.5 131.0 86.2 88.3 89.2 4-5
4-5 4-5 4-5 4-5 4-5 4-5 66 47 79.9 84.3 87.7 110.0 84.4 86.6 87.7
4-5 4-5 4-5 4-5 4-5 4-5 4-5 67 51 79.4 85.6 88.7 131.0 87.2 89.5
90.5 4-5 4-5 4-5 4-5 4-5 4-5 4-5 68 50 82.1 88.4 90.5 127.0 86.6
88.9 89.7 4-5 4-5 4-5 4-5 4-5 4-5 4-5 69 47 84.3 92.2 93.3 135.0
87.0 88.9 89.7 4-5 4-5 4-5 4-5 4-5 4-5 4-5 70 37 91.5 94.3 95.8
43.0 92.7 95.1 96.3 4-5 4 4-5 3-4 4-5 4-5 3-4
[0482] The results shown in Tables 17 and 18, and also previous
Tables 9 and 10, demonstrate that the spun yarns disclosed herein
can be used to make circular knit fabrics having desirable
properties.
* * * * *