CN111868317A - Multi-length, multi-denier, multi-section fiber blended yarn - Google Patents

Abstract

A yarn formed from a blend of polyester fibers customized with the following three parameters is disclosed: (1) a combination of polyester staple fibers with staple fiber lengths of 1.5 inches, 1.25 inches, 1.0 inches and 0.75 inches; (2) a combination of polyester staple fibers with staple fiber denier (tex, fineness) of 1.0 dpf, 1.2 dpf and 1.5 dpf; and (3) a combination of polyester staple fibers having at least two different staple fiber cross sections.

Description

Multi-length, multi-denier, multi-section fiber blended yarn

Background technique

The present invention relates to fibers, yarns and fabrics in the field of technical wear, sportswear or "athleisure" clothing.

The market for sportswear and casual apparel has grown significantly in recent years. This, in turn, has led to the development of specialized fabrics for such end-uses, and further hopes for the development of such specialized fabrics. As is well understood by those skilled in the textile industry, the properties of a garment are based on the fabric from which the garment is cut and sewn, wherein the fabric in turn reflects the properties of the yarns from which the fabric is woven or knitted, as well as the properties of the yarns that form the yarns. Properties of short-fiber yarns.

Thus, since the beginning of the development and understanding of polymers in the early 20th century, textile chemists have sought to mimic the best properties of natural fibers (cotton, wool, linen) and to tailor fiber properties to specific end uses.

Cotton is a very comfortable fiber in many situations, and cotton garments are still ubiquitous based on their light weight, versatility and good hand. The term "hand" is used throughout this application in a sense well understood by the skilled artisan. The term can be defined as “a fabric characteristic perceived by touching, squeezing or rubbing the fabric” (Tortora, p. 262), or as “used to describe the feel of a substrate (i.e., soft, rough, hard etc.)” (TextileGlossary [textile glossary]; Cotton Incorporated [cotton company]; www.cottoninc.com ; accessed March 15, 2018.

Nonetheless, and especially with regard to sports or gym wear, cotton has certain disadvantages. Cotton is highly absorbent, absorbing up to 27 times its weight in water, which adds undesired weight in the case of sportswear. Cotton also loses its insulating properties when wet and can be abrasive. Therefore, in cold weather, active exercise (or work, etc.), the cotton layer next to the skin quickly becomes wet, heavy and cool. In hot and cold weather, cotton underwear becomes rough when wet.

Wool has excellent insulating properties, can stretch up to 30% beyond its relaxed length, and can absorb up to 50% of its dry weight without becoming saturated, Tortora, Fairchild's Dictionary OfTextiles ], Seventh Edition (2009), p. 634. However, some types of wool are uncomfortable next to the skin, and more comfortable fibers, such as merino wool, tend to be more expensive. Silk is of course very comfortable, but is generally too expensive for widespread use in athletic apparel that is sold in large quantities.

Accordingly, much effort (and some success) has been devoted to developing synthetic-based fabrics from synthetic fibers or blends of synthetic and natural fibers (eg, polyester and wool, cotton and polyester, etc.). In addition, further efforts have been made to develop fully synthetic garments that mimic the comfortable feel of cotton while providing better moisture management than standard cotton or regular cotton-composite blends.

The term moisture management is used to describe the capacity or ability of a fabric to pull or wick moisture (sweat, moisture, rain) to the outer layer of the fabric from which it can evaporate. In many cases, body temperature (98.6°F, 37°) can help drive wicking in fabric garments, especially given that entropy will generally favor the vapor (ie, more random) state. Therefore, moisture management is typically measured using water vapor transmission rate.

However, the composition is not an automatic cure-all, as excessive cold may impart a clammy feeling to the wearer. Therefore, modern "industrial" garments usually consist of two types of yarns formed into several layers arranged such that the thermodynamics expel sweat from the skin to the first layer and then from the first layer to the outer layer. Modern industrial fabrics can have up to four or five layers for this purpose.

Furthermore, because the starting fibers help to establish the properties of the resulting fabric, the skilled artisan recognizes that, with regard to, for example, cotton, shorter fibers produce yarns that in turn give the fabric a better hand, while longer fibers give more Smoother, more refined yarns, such as those that give a cotton business shirt (again, just as an example) a more refined look, but a rougher hand.

Spinning technology (ring versus free end) also makes a difference in the look and feel of the finished garment.

Therefore, the goal remains to design specialized yarns that produce the desired combination of hand and moisture management.

SUMMARY OF THE INVENTION

In one embodiment, the present invention is a yarn consisting essentially of a blend of polyester fibers customized with the following three parameters: (1) staple fiber length of 1.5 inches, 1.25 inches inch, 1.0 inch, and 0.75 inch polyester staple fibers; (2) a combination of polyester staple fibers having a staple denier (tex, fineness) of 1.0 dpf, 1.2 dpf, and 1.5 dpf; and ( 3) A combination of polyester staple fibers having at least two different staple fiber cross-sections.

In another embodiment, the present invention is an intimately blended package of polyester staple fibers, wherein the blend includes (1) staple fibers having lengths of 1.5 inches, 1.25 inches, 1.0 inches, and 0.75 inches Combinations of fibers; (2) combinations of staple fibers having a staple denier (tex, fineness) of 1.0 dpf, 1.2 dpf, and 1.5 dpf; and (3) staple fibers having at least two different staple fiber cross-sections The combination.

In another embodiment, the present invention is a fabric comprising at least some yarns consisting essentially of (1) polyester with staple fiber lengths of 1.5 inches, 1.25 inches, 1.0 inches, and 0.75 inches Combinations of staple fibers, (2) combinations of polyester staple fibers having staple denier (tex, fineness) of 1.0 dpf, 1.2 dpf, and 1.5 dpf; and (3) having at least two different staple fiber cross-sections combination of polyester staple fibers.

In another embodiment, the present invention is a resulting fabric according to a fabric selected from the group consisting of: woven fabrics, non-woven fabrics, and knitted fabrics.

In another embodiment, the present invention is a method of making a yarn precursor blend having selected moisture management and hand properties, the method comprising the steps of: at least three different deniers and at least spinning continuous synthetic filaments from each of the two different cross-sections, gathering these different continuous filaments into a single tow, and cutting the tow into at least four different staple fiber lengths using a common cutter, As well as blending these different lengths, different deniers and different cross-sections of staple fibers into tightly blended packages.

In another embodiment, the present invention is a method of making a yarn precursor blend comprising the steps of spinning these continuous synthetic filaments into staple fibers of 1.0 dpf, 1.2 dpf and 1.5 dpf denier (tex, fineness), and the tow was cut into staple fiber lengths of 1.5 inches, 1.25 inches, 1.0 inches, and 0.75 inches using the common cutter.

In another embodiment, the present invention is a method of making a yarn having selected moisture management and hand characteristics, the method comprising the steps of opening at least three different deniers, at least four different an intimately blended package of staple fibers of length and at least two different cross-sections and forming the opened staple fibers into a tow, forming the tow into a roving; and spinning the roving into a yarn.

In another embodiment, the present invention is a method of making a yarn comprising opening an intimately blended package consisting essentially of: (1) staple fiber lengths of 1.5 inches, 1.25 inches, 1.0 inches inch and 0.75 inch polyester staple fibers; (2) combinations of polyester staple fibers having a staple denier (tex, fineness) of 1.0 dpf, 1.2 dpf, and 1.5 dpf; and (3) having A combination of at least two polyester staple fibers of different staple fiber cross-sections.

In another embodiment, the present invention is a spool assembly for use with staple fiber cutting equipment, the spool assembly comprising: a cutter spool having a pair of annular rings axially spaced apart from each other spool members, wherein each spool member defines an outwardly facing axial surface having a predetermined diameter and a circumferential mating engagement portion; a plurality of cutter blades mounted in the spool member for engaging and cutting fibers; and a cover member that surrounds and is secured around one of the spool members; wherein the improvement includes spacing the cutter blades to cut synthetic filaments into 1.5 inches, 1.25 inches, 1.0 inches, and 0.75 inches of discrete staple fiber lengths.

The foregoing and other objects and advantages of the present invention and the manner in which they are achieved will become more apparent from the following detailed description taken in conjunction with the accompanying drawings.

Description of drawings

Figure 1 is a photomicrograph of a fiber having an elliptical (oval) cross-section according to the present invention.

Figure 2 is a bar graph of fiber length for a sample based on yarns according to the present invention.

FIG. 3 is a second fiber length histogram based on the same sample as FIG. 2 .

FIG. 4 is a bar graph of fineness (denier, tex) based on the same samples as in FIGS. 2 and 3 .

Figure 5 is a histogram of fiber length for a second sample based on a yarn according to the present invention.

FIG. 6 is a second fiber length histogram based on the same second sample as FIG. 5 .

FIG. 7 is a bar graph of fineness (denier, tex) based on the same samples as in FIGS. 5 and 6 .

8 is a combined view of an assembled cutter reel and an exploded cutter reel that may be used to practice aspects of the present invention.

Detailed ways

As used herein, the term polyester refers to any polymer formed by linking hydrocarbon chains to ester groups (Totora, p. 437). The US Federal Trade Commission defines polyester as: "[A] fibers manufactured in which the fiber-forming substance is any long-chain synthetic polymer composed of at least 85% by weight of Ester formations of substituted aromatic carboxylic acids, including but not limited to substituted terephthalate units." 16 C.F.R. §303.7(c) (2018).

Pack Density: A measure of weight per unit volume, usually expressed as pounds per cubic foot. Density is calculated by dividing net bale weight by bale volume (in cubic feet). Volume is determined by multiplying the bag length, width and thickness dimensions in inches. Thickness is determined by measuring from rope to rope across the top of the bag.

Universal Density (UD): The bale density is at least 28 pounds per cubic foot.

Standard Density (SD): The bale density is at least 23 lbs/cubic foot, but less than 28 lbs/cubic foot.

Gin UD: Pack in gin compressed to a density of at least 28 lbs/cubic foot.

(The bag must be strapped with strapping or wire as defined in Sections 1.1 and 1.2).

(The bag must be strapped with strapping or wire as defined in Sections 1.1 and 1.2).

Gin SD: Packs compressed at gin to a density of at least 23 lbs/cubic foot, but less than 28 lbs/cubic foot.

http://www.cotton.org/tech/bale/specs/definitions.cfm; accessed February 17, 2018 access

Glossary from the National Cotton Council of America (7193 Goodlett Farms Parkway, Cordova, TN 38016)

Spinning:

As used in the textile industry, the term "spun" has two different meanings. In a traditional sense dating back almost to ancient times, "spinning" refers to the step of twisting fibers together to make yarn. In modern technology this is (typically) done using "ring" spinning or "open end" spinning, each technique familiar to those of ordinary skill in the art; eg Tortora, Fairchilds Dictionary Of Textiles [sen Children's Textile Dictionary], 7th edition (2009) pp. 473 and 395.

In another sense, the word "spinning" is used to refer to the steps of extruding a polymer melt into individual filaments, which are then subjected to further processing, typically including texturing, cutting into "short" fiber" length and spinning polymer staple fibers into yarn in the free-end or ring spinning sense. Tortora, p. 536.

The term "opening" is likewise well understood by the skilled person and generally refers to the preliminary step of separating the short fibers taken from the compressed bales into looser clumps and removing (if necessary) heavier impurities. Tortora, p. 395.

As used herein, the term polyester refers to any polymer formed by linking hydrocarbon chains to ester groups (Totora, p. 437).

In a first aspect, the present invention is a yarn consisting essentially of a blend of polyester fibers tailored to the following three parameters: (1) staple fiber lengths of 1.5 inches, 1.25 inches, 1.0 inches and 0.75 inch polyester staple fibers; (2) combinations of polyester staple fibers having a staple denier (tex, fineness) of 1.0 dpf, 1.2 dpf, and 1.5 dpf; and (3) having at least Combination of polyester staple fibers of two different staple fiber cross sections.

In an exemplary embodiment, the yarn consists essentially of a blend of polyester fibers in the following amounts: 20% by weight polyester fibers having a staple fiber length of 1.5 inches or greater; 54% by weight short fibers Polyester fibers having a fiber length of 1.25 inches or greater; 77% by weight polyester fibers having a staple fiber length of 1 inch or greater; and 96% by weight polyester fibers having a staple fiber length of 0.75 inches or greater; where all lengths and percentages are expressed to 2 significant figures.

In such exemplary embodiments, the yarn comprises 94 wt% fibers having at least 100 mTex; 87 wt% fibers having at least 125 mTex; 76 wt% fibers having at least 150 mTex and 63% of fibers having at least 175 mTex; wherein all percentages are expressed to 2 significant figures.

Table 1 lists exemplary length and dpf blends according to the present invention.

Table 1 (Figure 1)

As used in Table 1, 30's SIRO 100% means 30Ne yarn. (Imperial yarn count; 30 x 840 yds = 25,200 yards of this yarn weighs 1 lb). It was spun on a SIRO ring spinning machine with 2 roving bobbins drawn into 1 spinning bobbin and this yarn was made of 100% polyester in the indicated proportions.

40's CPRS 60/40 means 40Ne yarn (imperial yarn count; 40 x 840 yds = 33,600 yards of this yarn weighs 1 pound). The CP descriptor means combed cotton, so this sample represents 60% combed cotton blended with 40% polyester according to the invention. The RS designation means that this yarn is spun on a standard ring spinning machine, where 1 roving bobbin feeds 1 spinning position. To suggest an alternative, the nomenclature will use the acronym OE, which stands for Open End Spinning, also known as Rotor Spinning.

The above yarn counts are based on length/weight and yard/pound standards of yarn. This is the inverse of the weight/length based denier system.

AFIS PRO 2纤维过程控制系统(乌斯特技术公司(Uster Technologies AG),Sonnenbergstrasse 10,8610乌斯特,瑞士；www.uster.com；https://www.textilemates.com/siro-spinning-application；于2018年2月24日访问)上测试的纱线样品上收集的。列出的值定义如下：The data in Tables 2 and 3 were prepared in accordance with the present invention and in

AFIS PRO 2 Fiber Process Control System (Uster Technologies AG, Sonnenbergstrasse 10, 8610 Uster, Switzerland; www.uster.com ; https://www.textilemates.com/siro-spinning-application ; accessed 24 February 2018) on yarn samples tested. The listed values are defined as follows:

Table 2 and Table 3; Numerical output of results

Neps (neps are defined as small knots of entangled fibers, often considered a defect, but sometimes introduced as an effect. http://www.textileglossary.com/terms/nep.html ; accessed February 2018 Accessed on 25 March).

Total Nep Count: The count of all neps (fiber and seed dust neps) in the sample.

Total Neps Average Size: The average size (in microns) of all neps (fiber and seed dust neps) counted.

Fiber Neps Count: A count of all fiber neps.

Fiber Neps Average Size: The average size (in microns) of all fiber neps.

SC Nep Count: Count of all seed dust neps.

SC Neps Average Size: The average size of all seed dust neps (in microns).

length

L(w) Average fiber length by weight of all cotton fibers in the sample.

The change in L(w)CV% fiber length around the mean is expressed as

Length change or CV% by weight. CV is used in its well-understood statistical significance to express the ratio of the standard deviation to the mean.

Weight percent of all fibers shorter than 12.7 mm (0.5 inches) in the SFC(w)% cotton sample.

UQL(w)% Length over which 25 wt% of all fibers in the cotton sample exceed.

L(n) Average fiber length by number of all cotton fibers in the sample.

The change in fiber length around the mean is expressed as the change in length by number or CV%.

Number percent of all fibers shorter than 12.7 mm (0.5 inches) in the SFC(n)% cotton sample.

The length of the longer 5% of all fibers in a 5% L(n) cotton sample.

Impurities (Trash)

Total Impurity Count: Count of all particles (dust and foreign particles).

Total trash size: The average size of all particles (dust and trash particles) counted.

Dust Count: Count of all particles smaller than 500 microns in size.

Dust Average Size: The average size of all dust particles counted.

Impurity Count: Count of all particles larger than 500 microns in size.

Mean Impurity Size: Average size of all impurity particles counted, VFM %: Calculation taking into account the content and size of dust and impurities; involves gravimetric impurity measurement methods such as Shirley Analyzer.

Statistics Statistics: Overall measurement scheme with statistics in the results.

Columns : Mean/Average, Standard Deviation, Coefficient of Variation CV%, 99% Confidence Range, Min, Max.

Some of the data in Tables 2 and 3 are shown in Figures 2-7 as bar graphs. Figures 2-4 correspond to Table 2 and Figures 5-7 correspond to Table 3.

Figure 2 is a bar graph of fiber length in percent combined with a graph of fiber length versus cumulative percent, both factors expressed by weight. As further indicated by the tally column, less than 13% of the blends (expressed as two significant figures) had lengths greater than 1.5 inches, and only about 2.5% had lengths less than 0.75 inches.

Figure 3 is a second histogram and graph based on the same sample, with nearly identical results: less than 14% are greater than 1.5 inches in length, and only about 5.6% are less than 0.75 inches in length.

Figure 4 is a bar graph of fineness based on the same samples as Figures 2 and 3 and selected denier (1, 1.2, 1.5) blends, expressed in millitex (ie, 111, 133 and 167; all to 3 significant digits). Figure 4 shows that 80% of the fibers (expressed to two significant figures) are between 250 and 100 mTex (inclusive) and 67% (2/3) are between 225 and 125 mTex between (including endpoints).

5 is a bar graph of fiber length in percent combined with a graph of fiber length versus cumulative percent for a second sample in accordance with the present invention, both factors expressed by weight. As further indicated in the statistical column of Figure 5, 8.0% of the blends (expressed as two significant figures) had lengths greater than 1.5 inches, and only about 4.8% had lengths less than 0.75 inches.

Figure 6 is a second histogram and graph based on the same sample, with nearly identical results: less than 12% are greater than 1.5 inches in length, and only about 4.0% are less than 0.75 inches in length.

Figure 7 is a bar graph of fineness based on the same second sample as Figures 5 and 6 and selected denier (1, 1.2, 1.5) blends, expressed in millitex (ie, 111, 133 and 167 ; all expressed to 3 significant figures). Figure 7 shows that 81% of the fibers (expressed to two significant figures) are between 250 and 100 mTex (inclusive), and 68% (slightly more than 2/3) are between 225 and 125 mTex tex between (inclusive).

method

In another aspect, the present invention is a method of forming a yarn precursor blend having selected moisture management and hand properties. In this regard, the present invention includes the steps of spinning continuous synthetic filaments at each of at least three different deniers and at least two different cross-sections, and gathering these different continuous filaments into a single tow, The tow is cut into at least four different staple fiber lengths using a common cutter, and these different lengths, different deniers, and different cross-sections of the staple fibers are blended into an intimately blended package. In particular, the method includes spinning these continuous synthetic filaments into staple denier (tex, fineness) of 1.0 dpf, 1.2 dpf and 1.5 dpf; and cutting the tow using the common cutter Cut into staple fiber lengths of 1.5 inches, 1.25 inches, 1.0 inches and 0.75 inches.

In an exemplary embodiment, the filaments (and then fibers) are circular and oval in cross-section. The oval (or elliptical) cross-section provides increased surface area relative to other similarly sized round filaments or fibers, and thus provides an additional design factor for moisture management.

In contrast to drawing from multiple bales (each having one of its individual characteristics), common cutters allow feeding and opening from one bale. As is known to those skilled in the art, the earlier the different fibers are blended (ie, the earlier in the spinning process; baling, opening, drafting, etc.), the sooner the characteristics (for which the yarns are blended) will be. Consistent.

Thus, in another aspect, the present invention is an intimately blended package of polyester staple fibers comprising a combination of staple fibers having staple fiber lengths of 1.5 inches, 1.25 inches, 1.0 inches, and 0.75 inches; the staple fibers Combinations of staple fibers having denier (tex, fineness) of 1.0 dpf, 1.2 dpf, and 1.5 dpf; and combinations of staple fibers having at least two different staple fiber cross-sections. Thus, this type of opened bale and the yarn spun from this bale share the length, denier and cross-sectional characteristics of the intimately blended bale.

The intimately blended package allows adjustment within a single package and avoids the need to carefully meter fibers from multiple packages with different characteristics. The result is the yarn, and thus the resulting fabric, that is more consistent and accurate in weight on a weight basis, and likewise avoids some of the more cumbersome aspects of other blending methods.

Thus, in another aspect, the present invention is a fabric comprising at least some yarns consisting essentially of (1) polyester having staple fiber lengths of 1.5 inches, 1.25 inches, 1.0 inches, and 0.75 inches Combinations of staple fibers; (2) combinations of polyester staple fibers having staple denier (tex, fineness) of 1.0 dpf, 1.2 dpf, and 1.5 dpf; and (3) having at least two different staple fiber cross-sections combination of polyester staple fibers.

Such fabrics may be selected from the group consisting of woven fabrics, non-woven fabrics and knitted fabrics.

Exemplary fabric examples include a blend of polyester fibers in the following amounts: 20% by weight polyester fibers having a staple length of 1.5 inches or greater; 54% by weight staple fibers having a length of 1.25 inches or greater 77% by weight polyester fibers with a staple fiber length of 1 inch or greater; and 96% by weight polyester fibers with a staple fiber length of 0.75 inches or greater; all lengths and percentages are expressed to 2 significant digits.

Such exemplary fabrics can also be described as including 94 wt% fibers having at least 100 mTex; 87 wt% fibers having at least 125 mTex; 76 wt% fibers having at least 150 mTex and 63% of fibers having at least 175 mTex; wherein all percentages are expressed to 2 significant figures.

In yet another aspect, the present invention is a method of making a yarn having selected moisture management and hand characteristics. In this aspect, the method includes the steps of opening at least three different denier, at least four different lengths, and at least two different cross-sections of the closely blended package of staple fibers, and opening the opened The staple fibers are formed into tows; the tows are formed into rovings; and the rovings are spun into yarns.

The intimately blended package includes a combination of polyester staple fibers with staple fiber lengths of 1.5 inches, 1.25 inches, 1.0 inches, and 0.75 inches; polyester staple fibers with staple fiber deniers of 1.0 dpf, 1.2 dpf, and 1.5 dpf a combination of polyester staple fibers having at least two different staple fiber cross-sections; 20 wt% polyester fibers having a staple fiber length of 1.5 inches or greater; 54 wt% staple fibers having a length of 1.25 inches or greater 77% by weight polyester fibers with a staple fiber length of 1 inch or greater; and 96% by weight polyester fibers with a staple fiber length of 0.75 inches or greater; where all denier, length and percentage Both are expressed to 2 significant figures.

In this aspect, the method can include opening a package comprising 94 wt% fibers having at least 100 mTex; 87 wt% fibers having at least 125 mTex; 76 wt% fibers having at least 125 mTex Fibers of at least 150 mTex; and 63% of fibers having at least 175 mTex; wherein all percentages are expressed to 2 significant figures.

Combination lines are typically used for carding a mixture of synthetic and natural fibers. Because the fiber blends according to the invention have variable cut lengths that replicate the cumulative fiber length distribution curve of Pima cotton fibers (as tested on Uster AFIS (Advanced Fiber Information System)) ), so a card with a combined thread was used to produce 75 grains/yd sliver.

There is a tendency for high fiber-to-fiber cohesion to result in fiber snapbacks when fibers are only slightly extended during drafting. In order to produce yarns with better uniformity values and fewer annoying fines and thicks, the synthetic fibers should be extended far enough from each other to reduce the cohesion between the fibers to eliminate the tendency to snap back s level.

When processing 100% cotton fibers, the drawing creel weight is typically high (500 grains or more) and the draw frame draft is generally low (5.0 to 5.5) (between the low fiber based cotton cohesion). However, high creel weights using synthetic fibers can create too much volume between the steel rolls and the top cot, limiting the amount of fiber control and reducing quality.

To manage cohesion between fibers, a two-step draw frame process is used to combine different slivers, resulting in a more uniform blend of fibers. At the same time, the use of medium to high drafts (6.3 to 6.9) extends the individual fibers further past each other, which reduces the cohesion between the fibers.

By choosing a finer 1.3 HR (hank roving), the draft in the roving is shifted up to the mid-high range (9.67), which further extends the fibers past each other and further controls the cohesion between fibers.

The finer 1.3HR reduces the ring spinning draft, which in turn allows better fiber control for the ring spinning machine draft rolls. When spinning synthetic fibers, it is important to manage roll chatter resulting from high fiber-to-fiber cohesion and improper overall draft and draft distribution. High untwisting drafts (1.4 to 1.53) resulted in slip-stick drafts of the fibers. The lower untwisting draft (1.20) eliminates chatter effects and produces better yarn evenness and fewer defects.

In all drafting processes, first pass draw frame, last pass draw frame, roving and spinning, adjust the roll spacing setting based on the longest 5% length (as measured on Uster AFIS (Advanced Fiber Information System)) to Unwanted fiber damage is prevented and at the same time the longest fibers are further extended by removing hooks formed in carding. Each process was also evaluated on a Uster Evennes tester (i.e. CV). The roll spacing and untwist draft were adjusted to obtain a mass map with no coarse or fine spots and a spectrogram without build-up (indicating fiber floating) or mechanical failure. Table 4 lists the settings in each process.

Table 4

Additional descriptions of the overall process of introducing staple fibers into finished yarns can be found in Tortora above or from Reiter Corporation ( www.reiter.com/en/rikipedia ) or Cotton Corporation ( www.cottoninc.com ).

In another aspect, the present invention is an improvement on the cutter reel, wherein the improvement includes spacing the blades at positions to cut fibers into desired combinations of lengths on a single reel.

Figure 8 shows the cutter reel assembled 10 and disassembled 11. The cutter reel includes a top split cover 12 , a bottom split cover 13 and a blade retainer 14 . The top pin holder 15 and bottom pin holder 16 together support a plurality of blade support pins 17 . A slot 20 on the blade support pin 17 supports the blade 21 to cut the tow as the cutter drum rotates. Rotation is driven using the drive hub 22 in a manner well understood by those of ordinary skill in the art.

As shown, the cutter reel is based on US Patent No. 4,497,231 (the contents of which are incorporated herein by reference in their entirety).

In the drawings and specification, preferred embodiments of the present invention have been illustrated, and although specific terms have been employed, they are used in a generic and descriptive sense only and not for the purpose of limitation, the scope of the invention is in the claims definition.

Claims (20)

1. A yarn consisting essentially of a blend of polyester fibers tailored to the following three parameters: (1) A combination of polyester staple fibers with staple fiber lengths of 1.5 inches, 1.25 inches, 1.0 inches, and 0.75 inches; (2) Combinations of polyester staple fibers having a staple fiber denier (tex, fineness) of 1.0 dpf, 1.2 dpf, and 1.5 dpf; and (3) A combination of polyester staple fibers having at least two different staple fiber cross sections. 2. The yarn of claim 1 comprising some staple fibers having a circular cross-section and some staple fibers having an oval cross-section. 3. A yarn consisting essentially of a blend of polyester fibers in the following amounts: 20% by weight polyester fibers having a staple fiber length of 1.5 inches or more; 54% by weight polyester fibers having a staple fiber length of 1.25 inches or more; 77% by weight polyester fibers having a staple fiber length of 1 inch or greater; and 96% by weight polyester fibers having a staple fiber length of 0.75 inches or more; where all lengths and percentages are expressed to 2 significant figures. 4. A yarn consisting essentially of a blend of polyester fibers, the blend comprising: 94% by weight of fibers having at least 100 mTex; 87% by weight of fibers having at least 125 mTex; 76% by weight of fibers having at least 150 mTex; and 63% of fibers with at least 175 mTex; where all percentages are expressed to 2 significant figures. 5. An intimately blended package of polyester staple fibers, the package comprising: (1) A combination of staple fibers with staple lengths of 1.5 inches, 1.25 inches, 1.0 inches, and 0.75 inches; (2) Combinations of staple fibers having short fiber denier (tex, fineness) of 1.0 dpf, 1.2 dpf, and 1.5 dpf; and (3) A combination of short fibers having at least two different short fiber cross sections. 6. An opened bag according to claim 5. 7. A yarn spun from the open bale of claim 6. 8. A fabric comprising at least some yarns consisting essentially of: (1) A combination of polyester staple fibers with staple fiber lengths of 1.5 inches, 1.25 inches, 1.0 inches, and 0.75 inches; (2) Combinations of polyester staple fibers having a staple fiber denier (tex, fineness) of 1.0 dpf, 1.2 dpf, and 1.5 dpf; and (3) A combination of polyester staple fibers having at least two different staple fiber cross sections. 9. The fabric of claim 8 selected from the group consisting of woven fabrics, non-woven fabrics, and knitted fabrics. 10. The fabric of claim 8 consisting essentially of a blend of polyester fibers in the following amounts: 20% by weight polyester fibers having a staple fiber length of 1.5 inches or more; 54% by weight polyester fibers having a staple fiber length of 1.25 inches or more; 77% by weight polyester fibers having a staple fiber length of 1 inch or greater; and 96% by weight polyester fibers having a staple fiber length of 0.75 inches or more; where all lengths and percentages are expressed to 2 significant figures. 11. The fabric of claim 8 consisting essentially of a blend of polyester fibers comprising: 94% by weight of fibers having at least 100 mTex; 87% by weight of fibers having at least 125 mTex; 76% by weight of fibers having at least 150 mTex; and 63% of fibers with at least 175 mTex; where all percentages are expressed to 2 significant figures. 12. A method of making a yarn precursor blend having selected moisture management and hand properties, the method comprising: spinning continuous synthetic filaments at each of at least three different deniers and at least two different cross sections; Gathering these different continuous filaments into a single tow; using a common cutter to cut the tow into at least four different staple fiber lengths; and These staple fibers of different lengths, different deniers, and different cross-sections are blended into an intimately blended package. 13. The method of making a yarn precursor blend according to claim 12, the method comprising Spinning these continuous synthetic filaments into staple denier (tex, fineness) of 1.0 dpf, 1.2 dpf and 1.5 dpf; and The tow was cut into staple fiber lengths of 1.5 inches, 1.25 inches, 1.0 inches and 0.75 inches using the common cutter. 14. The method of claim 13, wherein the spinning step is preceded by at least one drafting step that extends the fibers far enough past each other to reduce cohesion between the fibers to a The level at which snapbacks between the fibers are minimized. 15. The method of claim 12, wherein the opening step produces some continuous filaments having a circular cross-section and some continuous filaments having an oval cross-section. 16. A method of making a yarn having selected moisture management and hand properties, the method comprising: opening an intimately blended package of staple fibers of at least three different deniers, at least four different lengths, and at least two different cross-sections, and forming the opened staple fibers into a tow; forming the tow into a roving; and The roving is spun into yarn. 17. A method of making a yarn according to claim 16, said method comprising opening an intimately blended package consisting essentially of: (1) A combination of polyester staple fibers with staple fiber lengths of 1.5 inches, 1.25 inches, 1.0 inches, and 0.75 inches; (2) Combinations of polyester staple fibers having a staple fiber denier (tex, fineness) of 1.0 dpf, 1.2 dpf, and 1.5 dpf; and (3) A combination of polyester staple fibers having at least two different staple fiber cross sections. 18. The method of claim 16, comprising opening a package consisting essentially of a blend of polyester fibers in an amount of: 20% by weight polyester fibers having a staple fiber length of 1.5 inches or more; 54% by weight polyester fibers having a staple fiber length of 1.25 inches or more; 77% by weight polyester fibers having a staple fiber length of 1 inch or greater; and 96% by weight polyester fibers having a staple fiber length of 0.75 inches or more; where all lengths and percentages are expressed to 2 significant figures. 19. The method of claim 16, comprising opening a bag consisting essentially of a blend of polyester fibers, the blend comprising: 94% by weight of fibers having at least 100 mTex; 87% by weight of fibers having at least 125 mTex; 76% by weight of fibers having at least 150 mTex; and 63% of fibers with at least 175 mTex; where all percentages are expressed to 2 significant figures. 20. A spool assembly for use with staple fiber cutting equipment, the spool assembly comprising: a cutter spool having a pair of annular spool members axially spaced apart from each other, wherein each spool member defines an outwardly facing axial surface having a predetermined diameter and a circumferential mating engagement portion; a plurality of cutter blades mounted in the spool member for engaging and cutting fibers; and a cover member surrounding one of the spool members and secured around one of the spool members; Improvements included spacing the cutter blades to cut the synthetic filaments into discrete staple fiber lengths of 1.5 inches, 1.25 inches, 1.0 inches, and 0.75 inches.

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