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.

What is claimed is: 
     
         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 .