Composite regenerated cotton and bast fiber yarn and method for making the same

Abstract

A composite bast fiber and cotton yarn is formed by blending natural bast fibers with cotton fibers which have been regenerated from waste cotton material such as trimmings and cuttings from the apparel manufacturing industry. The regenerated cotton and bast 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 natural bast fibers are up to two and one half to three time longer than the regenerated cotton fibers, so that the natural bast 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, a blend of regenerated cotton and acrylic fibers, or regenerated cotton and polyester fibers currently available.

1 . A method for making pre-dyed 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 natural bast fibers; and   (c) spinning the blended cotton fibers and bast 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 and dyed cotton fabric used to manufacture clothing, household linens and other articles of manufacture. 
     
     
         3 . A method as defined in  claim 2 , wherein the amount of cotton is less than the amount of natural bast fiber in the yarn. 
     
     
         4 . A method as defined in  claim 3 , wherein the yarn comprises 30-45% cotton fibers. 
     
     
         5 . A method as defined in  claim 2 , wherein said natural bast fibers are longer than said cotton fibers. 
     
     
         6 . A method as defined in  claim 2 , and further comprising the step of cleaning said blended cotton shoddy and bast fibers prior to said spinning step. 
     
     
         7 . A method as defined in  claim 2 , 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 for clothing, household linens, and canvas, comprising
 (a) regenerated cotton fibers from waste cotton fabric that has previously been bleached, dyed and treated; and   (b) natural bast fibers spun with said regenerated cotton fibers.   
     
     
         11 . A yarn as defined in  claim 10 , wherein the amount of cotton is less than the amount of bast in the yarn. 
     
     
         12 . A yarn as defined in  claim 11 , wherein the yarn comprises 30-45% cotton fibers. 
     
     
         13 . A yarn as defined in  claim 10 , where in said natural bast fibers are longer than said cotton fibers. 
     
     
         14 . A yarn as defined in  claim 10  and having a fine count of up to 28 s Ne.