Yarn formed from recycled cotton and recycled para-aramid, and fabrics made therefrom

Abstract

Described herein are spun yarns, core spun yarns, and fabrics such as denim fabrics made thereof that contain recycled cotton fibers and recycled para-aramid fibers. The combination of fibers in the yarns and fabrics provide desirable properties such as increased tear strength, breaking strength, and abrasion resistance compared to yarns and fabrics made of 100 wt % cotton.

1 . A garment comprising a denim fabric comprising a twill weave comprising a warp yarn and a weft yarn,
 wherein said warp yarn comprises:
 i) a spun yarn comprising from about 1 wt % to about 30 wt % recycled para-aramid fiber, about 5 wt % to about 15 wt % recycled cotton fiber, and about 10 wt % to about 94 wt % virgin cotton fiber; 
 ii) a first core spun yarn comprising a first filament yarn comprising elastomeric fiber and a first wrap yarn comprising about 1 wt % to about 30 wt % recycled para-aramid fiber, about 5 wt % to about 15 wt % recycled cotton fiber, and about 10 wt % to about 94 wt % virgin cotton fiber; or 
 iii) a second core spun yarn comprising a second filament yarn comprising about 1 wt % to about 30 wt % recycled para-aramid fiber, about 5 wt % to about 15 wt % recycled cotton fiber, and about 10 wt % to about 94 wt % virgin cotton fiber and a second wrap yarn comprising a second filament yarn comprising elastomeric fiber; 
   wherein said weft yarn comprises:
 i) a spun yarn comprising from about 1 wt % to about 30 wt % recycled para-aramid fiber, about 5 wt % to about 15 wt % recycled cotton fiber, and about 10 wt % to about 94 wt % virgin cotton fiber; 
 ii) a first core spun yarn comprising a first filament yarn comprising elastomeric fiber and a first wrap yarn comprising about 1 wt % to about 30 wt % recycled para-aramid fiber, about 5 wt % to about 15 wt % recycled cotton fiber, and about 10 wt % to about 94 wt % virgin cotton fiber; or 
 iii) a second core spun yarn comprising a second filament yarn comprising about 1 wt % to about 30 wt % recycled para-aramid fiber, about 5 wt % to about 15 wt % recycled cotton fiber, and about 10 wt % to about 94 wt % virgin cotton fiber and a second wrap yarn comprising a second filament yarn comprising elastomeric fiber. 
   
     
     
         2 . The garment of  claim 1 , wherein said spun yarn of said weft yarn comprises about 3 wt % to about 5 wt % recycled para-aramid fiber, about 5 wt % to about 15 wt % recycled cotton fiber, and about 82 wt % to about 92 wt % virgin cotton fiber;
 said first wrap yarn of said first core spun yarn of said weft yarn comprising about 3 wt % to about 5 wt % recycled para-aramid fiber, about 5 wt % to about 15 wt % recycled cotton fiber, and about 82 wt % to about 92 wt % virgin cotton fiber;   said second filament yarn of said second core spun yarn of said weft yarn comprises about 3 wt % to about 5 wt % recycled para-aramid fiber, about 5 wt % to about 15 wt % recycled cotton fiber, and about 82 wt % to about 92 wt % virgin cotton fiber; or   said yarn of said weft yarn comprises a core spun yarn comprising a filament yarn comprising elastomeric fiber and a wrap yarn comprising virgin cotton fiber.   
     
     
         3 . The garment of  claim 1 , wherein said spun yarn of said warp yarn comprises about 3 wt % to about 5 wt % recycled para-aramid fiber, about 5 wt % to about 15 wt % recycled cotton fiber, and about 82 wt % to about 92 wt % virgin cotton fiber;
 said first wrap yarn of said first core spun yarn of said warp yarn comprises about 3 wt % to about 5 wt % recycled para-aramid fiber, about 5 wt % to about 15 wt % recycled cotton fiber, and about 82 wt % to about 92 wt % virgin cotton fiber;   said second filament yarn of said second core spun yarn of said warp yarn comprises about 3 wt % to about 5 wt % recycled para-aramid fiber, about 5 wt % to about 15 wt % recycled cotton fiber, and about 82 wt % to about 92 wt % virgin cotton fiber; or   said yarn of said warp yarn comprises a core spun yarn comprising a filament yarn comprising elastomeric fiber and a wrap yarn comprising virgin cotton fiber.   
     
     
         4 . The garment of  claim 1 , wherein the garment is selected from the group consisting of a jacket, jeans, shorts, a shirt, overalls, a romper, a skirt, and a dress. 
     
     
         5 - 6 . (canceled) 
     
     
         7 . The garment of  claim 1 , wherein the recycled para-aramid fiber comprises a plurality of staple fibers having an average length comparable to or shorter than an average length of virgin cotton fiber. 
     
     
         8 . The garment of  claim 1 , wherein the recycled cotton fiber comprises a plurality of staple fibers having an average length comparable to or shorter than an average length of virgin cotton fiber. 
     
     
         9 . The garment of  claim 1 , wherein said weft yarn comprises said spun yarn and wherein said spun yarn comprises about 1 wt % to about 5 wt % recycled para-aramid fiber, about 5 wt % to about 15 wt % recycled cotton fiber, and about 20 wt % to about 94 wt % virgin cotton fiber. 
     
     
         10 . The garment of  claim 1 , wherein said weft yarn comprises said first core spun and wherein said first wrap yarn of said first core spun yarn of said weft yarn comprises about 1 wt % to about 5 wt % recycled para-aramid fiber, about 5 wt % to about 15 wt % recycled cotton fiber, and about 20 wt % to about 94 wt % virgin cotton fiber. 
     
     
         11 . The garment of  claim 1 , wherein said weft yarn comprises said second core spun and wherein said second filament yarn of said second core spun yarn of said weft yarn comprises about 1 wt % to about 5 wt % recycled para-aramid fiber, about 5 wt % to about 15 wt % recycled cotton fiber, and about 20 wt % to about 94 wt % virgin cotton fiber. 
     
     
         12 . The garment of  claim 1 , wherein said warp yarn comprises said spun yarn and wherein said spun yarn comprises about 1 wt % to about 5 wt % recycled para-aramid fiber, about 5 wt % to about 15 wt % recycled cotton fiber, and about 20 wt % to about 94 wt % virgin cotton fiber. 
     
     
         13 . The garment of  claim 1 , wherein said warp yarn comprises said first core spun yarn and wherein said first wrap yarn of said first core spun yarn of said warp yarn comprises about 1 wt % to about 5 wt % recycled para-aramid fiber, about 5 wt % to about 15 wt % recycled cotton fiber, and about 20 wt % to about 94 wt % virgin cotton fiber. 
     
     
         14 . The garment of  claim 1 , wherein said warp yarn comprises said second core spun yarn and wherein said second filament yarn and of said second core spun yarn of said warp yarn comprises about 1 wt % to about 5 wt % recycled para-aramid fiber, about 5 wt % to about 15 wt % recycled cotton fiber, and about 20 wt % to about 94 wt % virgin cotton fiber. 
     
     
         15 . The garment of  claim 1 , wherein the warp yarn further comprises one or more textile fibers selected from the group consisting of recycled cotton fiber, virgin cotton fiber, polyester fiber, nylon fiber, cellulosic fiber, elastomeric fiber, and a combination thereof. 
     
     
         16 . The garment of  claim 1 , wherein the weft yarn further comprises one or more textile fibers selected from the group consisting of recycled cotton fiber, virgin cotton fiber, polyester fiber, nylon fiber, cellulosic fiber, elastomeric fiber, and a combination thereof. 
     
     
         17 . The garment of  claim 1 , wherein said weft yarn is characterized by a tear strength of at least twice the tear strength of a weft yarn comprising 100% virgin cotton.