Multi-length, multi-denier, multi-cross section fiber blend yarn

Abstract

A yarn disclosed that is formed of a blend of polyester fibers customized by three parameters (1) a combination of polyester staple fibers with staple lengths of 1.5 inches, 1.25 inches, 1.0 inch and 0.75 inch; (2) a combination of polyester staple fibers with staple deniers (tex, fineness) of 1.0 dpf, 1.2 dpf, and 1.5 dpf; and (3) a combination of polyester staple fibers with at least two different staple cross sections.

1 . A yarn consisting essentially of a blend of polyester fibers customized by three parameters:
 (1) a combination of polyester staple fibers with staple lengths of 1.5 inches, 1.25 inches, 1.0 inch and 0.75 inch;   (2) a combination of polyester staple fibers with staple deniers (tex, fineness) of 1.0 dpf, 1.2 dpf, and 1.5 dpf; and   (3) a combination of polyester staple fibers with at least two different staple cross sections.   
     
     
         2 . A yarn according to  claim 1  that includes some staple fibers with circular cross sections and some with oval cross sections. 
     
     
         3 . A yarn consisting essentially of a blend of polyester fibers in the amounts of
 20% by weight staple length of 1.5 inches or greater;   54% by weight staple lengths of 1.25 inches or greater;   77% by weight staple lengths of 1 inch or greater; and   96% by weight staple lengths of 0.75 inch or greater;   with all lengths and percentages expressed to 2 significant figures.   
     
     
         4 . A yarn consisting essentially of a blend of polyester fibers that includes:
 94% by weight of fibers at least 100 mtex;   87% by weight of fibers of at least 125 mtex;   76% by weight of fibers having at least 150 mtex; and   63% of fibers having at least 175 mtex;   with all percentages expressed to 2 significant figures.   
     
     
         5 . An intimately blended bale of polyester staple fibers comprising:
 (1) a combination of staple fibers with staple lengths of 1.5 inches, 1.25 inches, 1.0 inch and 0.75, inch;   (2) a combination of staple fibers with staple deniers (tex, fineness) of 1.0 dpf, 1.2 dpf, and 1.5 dpf; and   (3) a combination of staple fibers with at least two different staple cross sections.   
     
     
         6 . An opened bale according to  claim 5 . 
     
     
         7 . A yarn spun from the opened bale of  claim 6 . 
     
     
         8 . A fabric that includes at least some yarns that consist essentially of:
 (1) a combination of polyester staple fibers with staple lengths of 1.5 inches, 1.25 inches, 1.0 inch and 0.75 inch;   (2) a combination of polyester staple fibers with staple deniers (tex, fineness) of 1.0 dpf, 1.2 dpf, and 1.5 dpf; and   (3) a combination of polyester staple fibers with at least two different staple cross sections.   
     
     
         9 . A fabric according to  claim 8  selected from the group consisting of woven fabrics, nonwoven fabrics, and knitted fabrics. 
     
     
         10 . A fabric according to  claim 8  consisting essentially of a blend of polyester fibers in the amounts of
 20% by weight staple length of 1.5 inches or greater; 
 54% by weight staple lengths of 1.25 inches or greater; 
 77% by weight staple lengths of 1 inch or greater; and 
 96% by weight staple lengths of 0.75 inch or greater; 
 with all lengths and percentages expressed to 2 significant figures. 
 
     
     
         11 . A fabric according to  claim 8  consisting essentially of a blend of polyester fibers that includes:
 94% by weight of fibers at least 100 mtex; 
 87% by weight of fibers of at least 125 mtex: 
 76% by weight of fibers having at least 150 mtex: and 
 63% of fibers having at least 175 mtex; 
 with all percentages expressed to 2 significant figures. 
 
     
     
         12 . A method of making a yarn precursor blend with selected properties of moisture management and hand, the method comprising:
 spinning continuous synthetic filament in each of at least three different deniers and at least two different cross sections;   gathering the different continuous filaments into a single tow;   using a common cutter to cut the tow into it at least four different staple lengths; and   blending the different length, different denier and different cross-sectional staple fibers into an intimately blended bale.   
     
     
         13 . A method of making a yarn precursor blend according to  claim 12  comprising
 spinning the continuous synthetic filament into staple deniers (tex, fineness) of 1.0 dpf, 1.2 dpf, and 1.5 dpf; and 
 using the common cutter to cut the tow into staple lengths of 1.5 inches, 1.25 inches, 1.0 inch and 0.75 inch. 
 
     
     
         14 . A method according to  claim 13  where in the spinning step is preceded by at least one drafting step that extends the fibers far enough past each other to reduce fiber-to-fiber cohesion to a level that minimizes snap back among the fibers. 
     
     
         12 . A method according to  claim 12  wherein the opening step produces some continuous filament with a circular cross section and some continuous filament with an oval cross section. 
     
     
         16 . A method of making a yarn with selected properties of moisture management and hand, the method comprising:
 opening an intimately blended bale of staple fibers in at least three different deniers, at least four different lengths, and at least two different cross sections, and forming the opened staple fibers into tow:   forming the toe into a roving; and   spinning the roving into yarn.   
     
     
         17 . A method of making a yarn according to  claim 16  comprising opening an intimately blended bale that consists essentially of
 (1) a combination of polyester staple fibers with staple lengths of 1.5 inches, 1.25 inches, 1.0 inch and 0.75 inch; 
 (2) a combination of polyester staple fibers with staple deniers (tex, fineness) of 1.0 dpf, 1.2 dpf, and 1.5 dpf; and 
 (3) a combination of polyester staple fibers with at least two different staple cross sections. 
 
     
     
         18 . A method according to  claim 16  comprising opening a bale that consists essentially of a blend of polyester fibers in the amounts of
 20% by weight staple length of 1.5 inches or greater; 
 54% by weight staple lengths of 1.25 inches or greater; 
 77% by weight staple lengths of 1 inch or greater; and 
 96% by weight staple lengths of 0.75 inch or greater; 
 with all lengths and percentages expressed to 2 significant figures. 
 
     
     
         19 . A method according to  claim 16  comprising opening a bale that consists essentially of a blend of polyester fibers that includes:
 94% by weight of fibers at least 100 mtex; 
 87% by weight of fibers of at least 125 mtex. 
 76% by weight of fibers having at least 150 mtex: and 
 63% of fibers having at least 175 mtex; 
 with all percentages expressed to 2 significant figures. 
 
     
     
         20 . In a reel assembly for use with a staple cutting apparatus that includes:
 a cutter reel having a pair of annular reel members spaced axially one from the other with each reel member defining an outwardly facing axial surface having a predetermined diameter and a circumferential mating engagement portion;   a plurality of cutter blades mounted in said reel members for engaging and cutting fiber; and   a cover member encircling and affixed about one of the reel members;   the improvement comprising cutter blades spaced to cut synthetic filament into discrete staple lengths of 1.5 inches, 1.25 inches, 1.0 inch and 0.75 inch.