Classifications

• • D—TEXTILES; PAPER
  • D02—YARNS; MECHANICAL FINISHING OF YARNS OR ROPES; WARPING OR BEAMING
  • D02G—CRIMPING OR CURLING FIBRES, FILAMENTS, THREADS, OR YARNS; YARNS OR THREADS
  • D02G3/00—Yarns or threads, e.g. fancy yarns; Processes or apparatus for the production thereof, not otherwise provided for
  • D02G3/02—Yarns or threads characterised by the material or by the materials from which they are made
  • D02G3/04—Blended or other yarns or threads containing components made from different materials
• • D—TEXTILES; PAPER
  • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
  • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
  • D10B2331/00—Fibres made from polymers obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. polycondensation products
  • D10B2331/04—Fibres made from polymers obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. polycondensation products polyesters, e.g. polyethylene terephthalate [PET]

Definitions

• the present invention relates to polyester blended yarn and the use of bicomponent polyester fiber in the polyester blended yarn.
• the fabrics comprising synthetic polymer fibers such as poly(ethylene terephthalate) (PET) fibers, and blends of natural and synthetic fibers have an undesirable propensity upon prolonged use to exhibit small, compact groupings of entangled fibers (i.e., fuzz balls) on the fabric surface.
• Such fiber groupings commonly are termed "pills" and tend to form and to tenaciously adhere to the surface of the fabric as the fabric encounters surface abrasion during normal use.
• the aesthetic appearance of fabric accordingly may be adversely influenced by these relatively compact groupings of entangled fibers which are retained on the surface of the fabrics.
• the pills can be traced to the relatively high strength of the synthetic fibers present in the fabric.
• the pills may be more or less permanently attached to the fabric surface by one or a few synthetic polymer fibers extending out of the fabric which will resist breakage as surface abrasion continues.
• Pills commonly are observed on the fabric formed from blends of cotton and staple poly(ethylene terephthalate) fibers following extended use. While pills may be observed in fabrics having wider variety of constructions, they are frequently observed on loosely constructed fabrics, particularly knitted fabrics using spun yarns of polyester staple fiber and cotton.
• One approach heretofore proposed is to reduce the tendency of the poly(ethylene terephthalate) fibers to pill initially by limiting the molecular weight (measured as the intrinsic viscosity) of the poly(ethylene terephthalate) polymer prior to fiber formation.
• Such reduced intrinsic viscosity provides a general indication of reduced polymeric chain length and leads to fibers having a lesser strength. Accordingly, when such entangled fibers become free on the surface of the fabric following abrasion, they tend to cleanly break away more readily and do not serve as a secure length which retains a fuzz ball at the surface of the fabric.
• polyester fiberfill blends can be made of polyester fibers and binder fibers such as bicomponent fibers.
• binder fibers such as bicomponent fibers.
• such fibers are blended and formed into an unbonded back of the desired weight that is heat treated to melt the chief material of the bicomponent fiber and then cooled to result in a bonded nonwoven fabric.
• a polyester blended yarn consisting essentially of from about 40% to about 70% by weight of matrix staple fiber, from about 1% to 20% by weight of crimped staple bicomponent fiber having a polyester core and a sheath of polyester or a copolyester having a melting point lower than that of the polyester core and complementary to total 100% by weight from about 59% to about 10% of crimped polyester staple fiber of a denier of about 0.5 to less than 10 dpf.
• the instant product overcomes the disadvantages of the prior art because of its simplicity and ease of control. Accordingly, the instant product fulfills a need for a product to render polyester blended yarn, low pilling, which is simple to use, easy to control and readily commercializable.
• the instant invention is directed to a polyester blended yarn consisting of 1% to 20% bicomponent fibers so that the resulting polyester fabric does not pill.
• the polyester blended yarn consists essentially of 40% to 70% by weight of matrix staple fibers and from about 1% to 20% by weight of crimped staple bicomponent fibers and complementary up to a total 100% by weight from about 59% to about 10% of crimped polyester staple fiber.
• the staple fibers used in here are textile fibers having a linear density suitable for wearing apparel, i.e., less than 10 dpf per fiber, preferably less than 6 dpf per fiber in lengths from 0.75 to 2.5 inches. Crimped fibers are particularly preferred for textile aesthetics and processability.
• the matrix staple fiber used in the present invention may be any fiber whether synthetic or natural, used in conjunction with polyester fibers to make fabric.
• Such fibers may be made from cotton, wool, rayon, acrylic, nylon and polypropylene.
• cotton fibers are used in the present invention.
• the next ingredient is a polyester, in particular, poly (ethylene terephthalate) (PET).
• PET polymer can be made by either terephthalic acid or dimethyl terephthalate or copolymer processes, which are well known to those of ordinary skill in the art.
• the third essential ingredient in the blend is bicomponent fiber which is a sheath core fiber, the sheath of which comprises the lower melting binder polymer as suggested in U.S. Patent No. 4,068,036.
• the bicomponent fiber is made up of a polyester core and a sheath of a polyester or a copolyester having a melting point lower than that of the polyester core the polyester staple fibers.
• a preferred sheath material is an ethylene terephthalate/isothalate copolyester.
• the matrix staple fiber is cotton fiber.
• the process for making the fabric involves steps of first preparing a blend of about 40% to about 70% by weight of cotton fibers, from about 1 to about 20% by weight of bicomponent fibers and complementary to total 100% by weight of polyester staple fibers.
• a continuous yarn is spun from the blend.
• the spun yarn should have sufficient twist or entanglement for uses in fabric.
• the presence of cotton in the yarn provides added softness and moisture absorption.
• the fabrics made according to the process are low pill, i.e. they are low pilling fabrics.
• low pill or it's equivalent, means herein that the tested material obtains a value of 4 to 5 as defined by ASTMD3512-82 entitled "Standard Test Method for Pilling Resistance In Other Related Surface Changes Of Textile Fabrics: Random Tumble Pilling Tester Method.”
• the values of 4 or 5 indicates low pill formation whereas values between 1 and 3 indicate various levels of pilling.
• a polyester blended yarn was prepared from a 50/50 blend of a polyester staple fiber having a denier of 0.9 dpf and a length of 1.25 inch, and standard cotton staple fiber.
• the blend was carded to produce a 65 grain/yard sliver intimately blended with the mixture of fibers shown above.
• the sliver was then drawn twice to produce a 56 grain/yard sliver.
• the yarn was then spun on an open-end spinning machine to deliver a 28 singles cotton count yarn.
• the yarn was knitted to produce standard fleece circular knit fabric wherein the yarn was used for face and tie yarns with a normal 15 singles cotton count used as backing yarn.
• the fabric was dyed and finished to produce standard fleece fabric.
• the fabric was tested for pilling by being washed for 60 minutes and rated 1, 2 and 2, unacceptable levels of pilling.
• a polyester blended yarn was prepared from a blend of 10% bicomponent fiber, 40% polyester staple fiber and 50% cotton staple fiber.
• the bicomponent fiber has a polyester core and a copolyester sheath having a denier of 2.0 dpf and a length of 1.5 inch.
• the bicomponent fiber is available as Celbond® K-54 fiber from the Hoechst Celanese Corporation.
• the fabric was tested for pilling by being washed for 60 minutes and rated 5, 5 and 5 indicating low pill formation.
• the bicomponent fiber tends to soften, mill and bind to the contiguous fibers thus producing fiber locking, contributing to the low pilling.

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• Engineering & Computer Science (AREA)
• Mechanical Engineering (AREA)
• Textile Engineering (AREA)
• Yarns And Mechanical Finishing Of Yarns Or Ropes (AREA)
• Artificial Filaments (AREA)

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Cited By (7)

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Citations (6)

• 1993
  • 1993-12-28 AT AT93121003T patent/ATE149215T1/de not_active IP Right Cessation
  • 1993-12-28 DE DE69308279T patent/DE69308279T2/de not_active Expired - Fee Related
  • 1993-12-28 EP EP93121003A patent/EP0604973B1/de not_active Expired - Lifetime

Patent Citations (6)

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