Composite cotton and polyester yarn and method for making same

Abstract

A composite polyester and cotton yarn is formed by blending polyester fibers with cotton fibers which have been regenerated from waste cotton material such as trimmings and cuttings from the apparel manufacturing industry. The fibers are cleaned and blended, then carded to align the fibers into strands. Depending on the size and texture of the desired yarn, the fibers are stretched and drawn into slivers prior to spinning to join the fibers together. The polyester fibers are preferably recycled polyethylene terephthalate fibers which are up to three time longer than the regenerated cotton fibers, so that the polyethylene terephthalate fibers overlap and braid onto the regenerated cotton fibers during spinning. The resultant yarn is stronger and more absorbent than yarns made solely out of regenerated cotton fibers. The yarn is suitable for producing woven or knit fabric for the production of colorful and functional clothing and home textiles without the need for further bleaching or dyeing.

1 . A method for making eco-friendly yarn, comprising the steps of
 (a) garnetting waste cotton fabric to produce cotton shoddy fibers therefrom;   (b) blending the cotton shoddy fibers with polyester fibers; and   (c) spinning the blended cotton fibers and polyester fibers to form a yarn.   
   
   
       2 . A method as defined in  claim 1 , wherein said waste cotton fabric comprises cuttings and trimmings of previously bleached, dyed and treated cotton fabric used to manufacture clothing, household linens and other articles of manufacture. 
   
   
       3 . A method as defined in  claim 2 , wherein said polyester fibers are recycled polyethylene terephthalate fibers. 
   
   
       4 . A method as defined in  claim 3 , wherein the amount of regenerated cotton is more than the amount of polyester in the yarn. 
   
   
       5 . A method as defined in  claim 4 , wherein the yarn comprises 65-70% regenerated cotton fibers. 
   
   
       6 . A method as defined in  claim 3 , and further comprising the step of cleaning said blended cotton and recycled polyester fibers prior to said spinning step. 
   
   
       7 . A method as defined in  claim 3 , wherein said fibers are carded to align said fibers into strands prior to said spinning step. 
   
   
       8 . A method as defined in  claim 7 , and further comprising the step of forming said fibers into smaller strands. 
   
   
       9 . A method as defined in  claim 8 , wherein said forming step comprises drawing said carded fibers into slivers and subsequently roving said slivers into smaller strands. 
   
   
       10 . A yarn for making fabric, comprising
 (a) regenerated cotton fibers from waste cotton fabric that has previously been bleached, dyed and treated; and   (b) polyester fibers spun with said regenerated cotton fibers.   
   
   
       11 . A yarn as defined in  claim 10 , wherein the amount of cotton is more than the amount of polyester on the yarn. 
   
   
       12 . A yarn as defined in  claim 11 , wherein the yarn comprises 65-70% regenerated cotton fibers. 
   
   
       13 . A yarn as defined in  claim 10 , where in said polyester fibers are recycled polyethylene terephthalate fibers.