Improving pilling resistance in fabrics using cellulose acetate staple fibers

Abstract

A method of making a pilling-resistant fabric is provided. In one instance, the method comprises (a) blending a cellulose acetate (CA) staple fiber with a non-CA staple fiber to form a blended yarn comprising 20 to 80 wt % of the CA staple fiber and (b) forming a pilling-resistant fabric comprising the blended yarn. In another instance, the method comprises (a) providing a first yarn comprising at least 20 wt % of a CA staple fiber and (b) forming a pilling-resistant fabric comprising the first yarn and a second yarn comprising a non-CA staple fiber. The CA staple fiber has (i) a round or closed-C cross-sectional shape, (ii) a cut length of 20 to 80 mm, (iii) a crimp frequency of 4 to 24 crimps per inch (CPI), and (iv) a denier per filament (DPF) of 0.5 to 4.0. The pilling-resistant fabric has a higher pilling resistance rating than a fabric made without the CA staple fiber.

1 . A method of making a pilling-resistant fabric, the method comprising:
 (a) blending a cellulose acetate (CA) staple fiber with a non-CA staple fiber to form a blended yarn comprising 20 to 80 wt % of the CA staple fiber, based on the total weight of the blended yarn; and   (b) forming a pilling-resistant fabric comprising the blended yarn;   wherein the pilling-resistant fabric has a higher pilling resistance rating than a fabric made without the CA staple fiber; and   wherein the CA staple fiber has:   (i) a round or closed-C cross-sectional shape;   (ii) a cut length of 20 to 80 mm;   (iii) a crimp frequency of 4 to 24 crimps per inch (CPI); and   (iv) a denier per filament (DPF) of 0.5 to 4.0.   
     
     
         2 . A method of making a pilling-resistant fabric, the method comprising:
 (a) providing a first yarn comprising at least 20 wt % of a cellulose acetate (CA) staple fiber, based on the total weight of the first yarn; and   (b) forming a pilling-resistant fabric comprising the first yarn and a second yarn comprising a non-CA staple fiber;   wherein the pilling-resistant fabric has a higher pilling resistance rating than a fabric made without the CA staple fiber; and   wherein the CA staple fiber has:   (i) a round or closed-C cross-sectional shape;   (ii) a cut length of 20 to 80 mm;   (iii) a crimp frequency of 4 to 24 crimps per inch (CPI); and   (iv) a denier per filament (DPF) of 0.5 to 4.0.   
     
     
         3 . (canceled) 
     
     
         4 . (canceled) 
     
     
         5 . The method according to  claim 1 , wherein the blended yarn or the first yarn comprises 20 to 75 wt % of the CA staple fiber. 
     
     
         6 . The method according to  claim 1 , wherein the first yarn comprises from 75 to 100 wt % of the CA staple fiber. 
     
     
         7 . The method according to  claim 1 , wherein the pilling-resistant fabric comprises at least 10 wt %, of the blended yarn. 
     
     
         8 . The method according to  claim 1 , wherein the non-CA staple fiber comprises nylon, wool, silk, acrylic, bamboo, linen, hemp, cotton, lyocell, modal, polyester, viscose, spandex, or combinations thereof. 
     
     
         9 . The method according to  claim 1 , wherein the CA staple fiber has a cut length of 30 to 60 mm. 
     
     
         10 . The method according to  claim 1 , wherein the CA staple fiber has a crimp frequency of 5 to 20 CPI. 
     
     
         11 . The method according to  claim 1 , wherein the CA staple fiber has a DPF of 0.5 to 2.3. 
     
     
         12 . The method according to  claim 1 , wherein the blended yarn or the first yarn comprises 30 to 80 wt % of the CA staple fiber, and
 wherein the CA staple fiber has:   (i) a round cross-sectional shape;   (ii) a cut length of 34 to 51 mm;   (iii) a crimp frequency of 9 to 17 CPI; and   (iv) a DPF of 0.9 to 4.0.   
     
     
         13 . The method according to  claim 1 , wherein step (b) comprises weaving or knitting. 
     
     
         14 . The method according to  claim 1 , wherein the pilling-resistant fabric has a pilling resistance rating of at least 0.5 higher than the rating of a fabric made without the CA staple fiber measured according to ASTM D4970/D4970M-16e3 at 1000 rubs. 
     
     
         15 . The method according to  claim 1 , wherein the pilling-resistant fabric has a pilling resistance rating of at least 4 according to ASTM D4970/D4970M-16e3 at 1000 rubs. 
     
     
         16 . The method according to  claim 1 , wherein the pilling-resistant fabric has a pilling resistance rating of at least 0.5 higher than the rating of a fabric made without the CA staple fiber according to ASTM D3512/D3512M-2016 after 30 minutes. 
     
     
         17 . The method according to  claim 1 , wherein the pilling-resistant fabric has a pilling resistance rating of at least 4 according to ASTM D3512/D3512M-2016 after 30 minutes. 
     
     
         18 . (canceled) 
     
     
         19 . (canceled) 
     
     
         20 . (canceled)