JP2024533021A - Spun yarn and fabric made from it - Google Patents

Abstract

【assignment】
To provide a spun yarn which is low in cost, can be processed simply, has excellent anti-pilling properties, and is not affected by abrasion resistance.
SOLUTION
The present invention relates to a spun yarn and a fabric made from the same. The spun yarn contains synthetic fibers with an elastic recovery rate of 50% or more after 10 repeated stretches, and the content of the synthetic fibers is 40 wt% or more, which effectively prevents the occurrence of pilling caused by friction, and does not require the use of any anti-pilling agent, and the strength of the fibers is maintained and the abrasion resistance is not affected. The fabric made from the spun yarn can be widely used in the manufacture of sportswear, casualwear, etc.
[Selected Figure] Figure 1

Description

The present invention relates to spun yarn and fabric made using the same.

As living standards improve, people's demands for fabrics are also increasing. Knitted fabrics made from spun yarn have advantages such as a soft feel and good breathability, and are loved by many consumers. However, they have problems such as being prone to pilling and having poor abrasion resistance. For this reason, a lot of research and development is being conducted.

For example, Patent Document 1 discloses an acrylic fiber for low-pill fabrics having a breaking elongation of not more than 35% and a knot strength of not more than 1.7 g/D. It effectively suppresses pilling and improves anti-pilling properties, but affects abrasion resistance.

Patent Document 2 also discloses a fabric made of anti-pilling polyester spun yarn. Specifically, anti-pilling polyester spun yarn and cotton spun yarn are used as the warp yarns of the fabric, and anti-pilling polyester spun yarn and wool are used as the weft yarns, with the anti-pilling polyester spun yarn being obtained by adding a pilling inhibitor during the spinning process, and it is disclosed that the anti-pilling properties of the fabric are significantly improved by forming a structure similar to natural fibers on the surface of the polyester fiber. However, the method of adding a pilling inhibitor during the spinning process is complicated and expensive, and there is also the problem that it causes a decrease in fiber strength, affecting the abrasion resistance of the fabric.

Japanese Patent Application Publication No. 4-240209 China Patent Application Publication No. 102505261

The objective of the present invention is to provide a spun yarn that is low cost, has a simple processing process, has excellent anti-pilling properties, and is not affected by abrasion resistance.

Another object of the present invention is to provide a fabric made using the spun yarn.

The present invention solves these problems as follows:

(1) The spun yarn of the present invention contains synthetic fibers having an elastic recovery rate of 50% or more after 10 repeated stretches, and the content of said synthetic fibers is 40 wt% or more.

(2) The knot strength of the synthetic fiber is 2.0 to 6.0 cN/dtex.

(3) The synthetic fiber is a polyester fiber.

(4) The polyester fibers are polyethylene terephthalate fibers and/or polybutylene terephthalate fibers.

(5) The twist coefficient of the spun yarn is 2.0 to 6.0, and the fineness of the single fiber constituting the spun yarn is 0.5 to 4.0 dtex and the length is 35 to 110 mm.

(6) The spun yarn is obtained by the silo compact spinning method, the silo spinning method, or the compact spinning method.

(7) The spun yarn is obtained by a vortex spinning method.

(8) A fabric made using 40 wt% or more of the spun yarn described in any one of (1) to (7).

(9) The fabric has anti-pilling properties of grade 3 or higher in accordance with GB/T 4802.2:2008 standard, and/or abrasion resistance of 30,000 cycles or more in accordance with JIS L 1096:2010 standard, method E.

(10) The spun yarn is exposed on at least one side of the fabric, and the exposure rate is 30% or more.

The spun yarn of the present invention uses a specified amount of synthetic fibers with excellent elastic recovery, which effectively prevents the occurrence of the phenomenon in which fibers are pulled out by friction and cause pilling, does not require the use of any anti-pilling agents, maintains the strength of the fibers, does not affect abrasion resistance, and is low cost, so fabrics using it can be widely used in the manufacture of sportswear, casualwear, etc.

1 is a diagram showing the elastic recovery of a synthetic fiber monofilament after it has been stretched, where a is the length of the stretched portion and b is the length of the recovered portion.

After a synthetic fiber monofilament is stretched (especially 10% stretched), there will be stretch-recoverable and non-stretch-recoverable parts in the recovery process. The higher the proportion of stretch-recoverable parts, the better the elastic recovery of the fiber. The spun yarn of the present invention contains synthetic fibers with an elastic recovery rate of 50% or more after 10 repeated stretching, so that even if the synthetic fibers are pulled out during the friction process, most of them will return to their original state, making them less likely to pill. On the other hand, if the synthetic fibers have an elastic recovery rate of less than 50% after 10 repeated stretching, fatigue will be noticeable after repeated stretching, and the fuzz pulled out during the friction process will not return to its original state and will become pills. With subsequent repeated friction, the pills will gradually become larger and more numerous, resulting in poor anti-pilling properties of the fabric.

The spun yarn of the present invention may be made of 100 wt% of the synthetic fiber, or may be blended with other short fibers. Preferably, it is made of 100 wt% of the synthetic fiber. This reduces the possibility of pilling and ensures anti-pilling properties even when rubbed repeatedly. When the spun yarn of the present invention is made of a blend of the synthetic fiber and other short fibers, if the synthetic fiber content is less than 40 wt%, the content of short fibers that are easily pulled out and become fluffy and form pills is high, which has a significant effect on the anti-pilling properties of the fabric. Therefore, in the present invention, the synthetic fiber content in the spun yarn is required to be 40 wt% or more.

When the spun yarn of the present invention is made by blending the synthetic fibers with other staple fibers, the blending method is not particularly limited, but may be a method of blending raw cotton in the blending or carding process, a method of blending slivers in the drawing or gilling mixing process, or a method of spinning and twisting multiple rovings in the spinning process.

The synthetic fibers in the spun yarn of the present invention may be short fibers having the same elastic recovery rate or short fibers having different elastic recovery rates, as long as both have elastic recovery rates of 50% or more.

The knot strength of the synthetic fibers is preferably 2 to 6 cN/dtex. If the knot strength is less than 2 cN/dtex, the breaking strength of the staple fibers is relatively low, which may affect the strength of the spun yarn, and the resulting fabric tends to have reduced abrasion resistance. If the knot strength exceeds 6 cN/dtex, the strength of the spun yarn increases to a certain extent, but pilling resistance tends to decrease because pills formed during the repeated friction process are difficult to remove.

The type of synthetic fiber is not particularly limited, but examples include polyester fiber, acrylic fiber, polyamide fiber, etc., and polyester fiber is preferable. The polyester fiber is one or more of polyethylene terephthalate fiber (PET), polybutylene terephthalate fiber (PBT), and polypropylene terephthalate fiber (PTT). The fiber is obtained by using raw silk through processes such as drawing, shrinking, heat setting (130 to 170°C), and cutting.

Among them, the molecular structure of PBT fiber has an ester group and a benzene ring structure, and compared with regular PET fiber, the soft segment in the basic segment is long, the melting point is relatively low, and the main chain structure is helical, so that micro-crimping is likely to occur. The molecular structure of PTT fiber has a "trans-gauche-gauche-trans" structure, which shows an obvious "Z"-shaped structure, and also has three methylene segments in the molecular chain, so that an "odd carbon atom (methylene group) effect" occurs between the molecular chains. Such a molecular structure gives PTT fiber a deformation ability like a coil spring. Knitted fabrics are the application that can best realize the effects of the spun yarn of the present invention, but the relatively low Young's modulus of PTT fiber may affect the dimensional stability of the knitted fabric, and on the other hand, the relatively high elongation of PTT fiber makes it stretched and long when rubbed for a long time or with high intensity, and it is easy to be entangled with the surrounding fuzz, so that the anti-pilling effect tends to be deteriorated. Therefore, in the present invention, the synthetic fiber is more preferably PBT fiber.

In addition, if the fibers are easily stretched during the spinning process, problems such as deterioration in the quality and strength of the spun yarn may occur, so most preferably, the synthetic fibers have a Young's modulus of 30 cN/dtex or more and an elongation of 75% or less.

The types of the other short fibers are not particularly limited, but can be selected as necessary. Examples include natural fibers, regenerated fibers, and synthetic fibers with an elastic recovery rate of less than 50%. Natural fibers include cotton, hemp, wool, and silk, and regenerated fibers include cuprammonium fibers, rayon fibers, and acetate fibers.

The twist coefficient, the fineness and length of the single fibers constituting the spun yarn are also important for the spun yarn of the present invention. Taking the English twist coefficient as an example, if the twist coefficient of the spun yarn is less than 2.0, the binding force between the short fibers is low, the phenomenon of loose twisting occurs frequently, the strength of the spun yarn tends to decrease, the frequency of yarn breakage increases during the spinning process, and the fuzz and neps also tend to increase. If the twist coefficient exceeds 6.0, the twist angle of the single fiber becomes large, the strength utilization rate of the single fiber decreases, the strength of the spun yarn tends to decrease, the yarn is easily twisted and snarls occur, the occurrence rate of stoppage or fabric defects due to yarn breakage also tends to increase, and the texture of the obtained fabric tends to become hard. If the fineness of the single fiber is less than 0.5 dtex, spinning processing becomes difficult, and neps are easily generated due to the small bending rigidity of the fiber, which may affect the quality of the fabric surface. On the other hand, when the fineness of the single fiber exceeds 4.0 dtex, the number of single fibers constituting the spun yarn decreases under the same conditions, the binding force between the fibers decreases, and the fluff is easily pulled out during the friction process to form pills, and the anti-pilling properties tend to deteriorate. Also, since the bending rigidity of the single fiber is large, there is a possibility of insufficient carding, and the quality of the formed web tends to deteriorate. When the length of the single fiber is less than 35 mm, the binding force between the fibers becomes weak, and the occurrence rate of thread breakage during spinning tends to increase. Also, even if the spun yarn is made, since the fiber is relatively short, the fluff is easily pulled out during the friction process to form pills, and the anti-pilling properties tend to deteriorate. On the other hand, when the length of the single fiber exceeds 110 mm, damage and cutting are easily caused during the mixing process or carding process, the number of neps increases, and the neps are easily lumped during the friction process, and the anti-pilling properties tend to deteriorate. Therefore, in the present invention, it is preferable that the twist coefficient of the spun yarn is 2.0 to 6.0, the fineness of the single fiber that constitutes the spun yarn is 0.5 to 4.0 dtex, and the length is 35 to 110 mm.

The spinning method of the spun yarn of the present invention is not particularly limited, but examples thereof include vortex spinning, ring spinning, silo compact spinning, silo spinning, and compact spinning. In order to achieve both anti-pilling properties and texture, silo compact spinning, silo spinning, and compact spinning are preferred. Among them, silo compact spinning is a new spinning technology that combines silo spinning and compact spinning, in which two roving yarns are fed to the draft mechanism in parallel through a trumpet mouth with a predetermined interval, and when they leave the front roller, they are converged by the negative pressure airflow suction action, and then twisted to be integrated, resulting in a denser structure and significantly reduced fuzz, so silo compact spinning is more preferred. In the vortex spinning method, a high-speed air vortex generated inside a nozzle twists a fiber bundle into a yarn, and the resulting yarn has a double structure, with the core fibers arranged in parallel in an untwisted state, the sheath fibers entangled around the outer periphery of the core fibers, and both the head and tail of the fibers being twisted inside the spun yarn, resulting in a dense structure with very little fuzz, making the vortex spinning method preferable in terms of better pilling resistance.

Fabric is manufactured using 40 wt% or more of the above spun yarn as a raw material. The fabric here may be woven or knitted. When the spun yarn of the present invention is used partially, the other yarns are not particularly limited, but can be selected as necessary. For example, 100% cotton spun yarn, 100% rayon spun yarn, polyester/cotton blended yarn (the polyester fiber here is a PET fiber with an elastic recovery rate of less than 50% after repeated elongation 10 times), etc. can be mentioned. Here, the knitted fabric can be circular knitted and weft knitted, or warp knitted. Examples of the structure of the circular knitted fabric and the weft knitted fabric include, but are not limited to, flat knitted, elastic knitted, double-sided knitted, pearl knitted, tuck knitted, floating knitted, lace knitted, affixed knitted, and one-sided rib knitted. Examples of the structure of the warp knitted fabric include, but are not limited to, single denby knitted, single atlas knitted, double cord knitted, double half tricot knitted, fleece knitted, and jacquard knitted. Among them, circular knitted fabrics are more preferable in terms of anti-pilling properties. On the other hand, the number of layers may be either single layer or multi-layer, but the multi-layer structure is two layers or has more layers.

Preferably, the fabric of the present invention has an anti-pilling property of grade 3 or higher according to the GB/T 4802.2:2008 standard and/or an abrasion resistance of 30,000 cycles or more according to the JIS L 1096:2010 standard, method E.

Preferably, the spun yarn of the present invention is exposed on at least one side of the fabric, with an exposure rate of 30% or more. If the exposure rate of the spun yarn of the present invention on one side of the fabric is less than 30%, the content of yarn capable of forming pills will be high, the incidence of pilling due to friction will increase, and the anti-pilling properties of the fabric will tend to decrease.

In addition, as long as the fabric is not damaged, post-processing may involve standard dyeing, water absorption, water repellency, etc., and various other processes may be used to impart functionality, such as UV protection, antibacterial, deodorant, insect repellent, phosphorescent, reflective, or negative ion generating properties.

The present invention will be described in detail below with reference to examples and comparative examples, but the present invention is not limited to these. Each parameter according to the present invention was measured by the following method.

(1) Elastic recovery rate and blend ratio of synthetic fibers A. Sampling If necessary, perform sampling according to the following <1> or <2>:
<1> Five spun yarns each having a length of 5 cm were directly prepared and untwisted, and the short fibers having a length of 30 mm or more were used as samples, and the number of samples was recorded as X.
<2> Determine the type of yarn constituting the fabric in accordance with JIS L 1030-1:2012, disassemble the spun yarn containing synthetic fibers, prepare five spun yarns with a length of 5 cm, untwist them, and take the short fibers with a length of 30 mm or more as samples. Record the number of samples as X.
B. Testing Facilities
An extension and recovery test was performed using an RTC-1225 A-type tensile tester (manufactured by INTEC CO., LTD.) equipped with an Orientec printer (AR-6600-7) by selecting the EXTENSION CYCLE TEST program, setting the grip interval to 20 mm, elongation to 10%, and tensile speed to 20 mm/min.
C. Measurement and Calculation In a straight and unstretched state, one sample prepared in step A was fixed to the upper and lower grips of the tester, the test start button was pressed, the sample was stretched to 10% elongation and then recovered, and the first curve was automatically drawn at the same time, and after one minute, the origin of the drawing was adjusted so that the needle was at the origin of the millimeter coordinate paper, and the measurement procedure of the stretch recovery was repeated to draw a second curve. A total of 10 measurements were made, and 10 curves were obtained. As shown in Figure 1, on the millimeter coordinate paper, a is the length of the stretched part, b is the length of the recovered part, and the transverse length of the longest curve was recorded as a + b. The elastic recovery rate of a single fiber after 10 repeated stretches was calculated according to the following formula:
Elastic recovery rate (%) = [b/(a+b)] x 100.

All samples were measured in the same manner, the elastic recovery of each single fiber sample was recorded, and the average of the data with an elastic recovery of 50% or more was calculated, and this average was regarded as the elastic recovery of the synthetic fiber of the present invention after 10 repeated stretchings. The number of fibers with an elastic recovery of 50% or more was counted and recorded as f1, and the synthetic fiber blend ratio was calculated by the following formula.
Mixing rate (%) = (f1/X) x 100.

(2) Spun Yarn Blend Ratio One complete structure was marked in the fabric, and one sample was taken along the edge of the complete structure. (If the size of one complete structure is less than 5 cm x 5 cm, one sample of 5 cm x 5 cm should be taken.) All yarns were extracted, weighed, and recorded as m. In accordance with the JIS L 1030-1:2012 standard, the type of yarn constituting the fabric was identified, and spun yarns containing synthetic fibers were picked up. Based on the method for measuring the elastic recovery rate of synthetic fibers, it was determined whether the spun yarns contained synthetic fibers with an elastic recovery rate of 50% or more. The weight of the spun yarns containing synthetic fibers with an elastic recovery rate of 50% or more was measured and recorded as m1, and the blend ratio of spun yarns in the fabric was calculated using the following formula.
Mixing rate (%) = (m1/m) x 100.

(3) Knot strength: Measured in accordance with JIS L 1015:2010 standard.

(4) Pilling resistance: Measured in accordance with GB/T 4802.2:2008 standard.

(5) Abrasion resistance Measured in accordance with JIS L 1096:2010 standard (Method E).

In the first measurement, the number of frictions is set to 20,000 times, and the wear condition of the fabric is checked after 20,000 frictions. If the fabric is damaged, the measurement is stopped and the wear resistance is judged to be 10,000 times. If the fabric is not damaged (woven fabric: two or more broken threads, knitted fabric: damaged areas), the measurement is continued. For continued measurement, the number of frictions is set to 10,000 times, and the wear condition of the fabric is checked after 10,000 frictions. If the fabric is damaged, the measurement is stopped and the wear resistance is judged to be 20,000 times. If the fabric does not have two or more broken threads, the measurement is continued. For continued measurement, the number of frictions is set to 10,000 times, and the wear condition of the fabric is observed after 10,000 frictions. If the fabric is damaged, the measurement is stopped and the wear resistance is judged to be 30,000 times. The wear condition of the fabric is checked every 10,000 times until damage occurs. If the total number of friction cycles reaches 100,000, check the wear condition of the fabric after 100,000 friction cycles. If the fabric is damaged, the wear resistance is judged to be 90,000 cycles. If the fabric is not damaged, the wear resistance is judged to be 100,000 cycles or more.

(6) Exposure rate of spun yarn on one side of fabric Two complete structures are determined on one side of the fabric. First, in accordance with JIS L 1030-1:2012, all types of yarns in one complete structure are identified, and spun yarns containing synthetic fibers are picked up. Based on the measurement method of the elastic recovery rate of the synthetic fibers, it is determined whether there is a synthetic fiber with an elastic recovery rate of 50% or more in the spun yarn, and the specific position of the spun yarn in the complete structure is clarified. Next, a digital microscope (manufactured by Keyence Corporation) is used to take a photo of the other complete structure, and the photo is printed on A4 size paper (if a photo of the complete structure cannot be taken even at the lowest magnification of the digital microscope, a photo is taken using a digital camera), and the excess part is cut off with scissors, leaving only one complete structure, whose weight is measured and recorded as G. According to the specific position of the spun yarn in the complete structure, the relevant part is cut out from the paper, weighed, and recorded as g1, and the exposure rate of the spun yarn is calculated according to the following formula.
Exposure rate (%) = (g1/G) x 100.

(7) Bending resistance: Measured in accordance with JIS L 1096:2010 (Method A). The smaller the value, the higher the flexibility.

Example 1
Using PBT raw cotton (manufactured by Toray Industries, Inc.) with a fineness of 1.67 dtex, fiber length of 38 mm, and knot strength of 3.1 cN/dtex as the raw material, the yarn was successively subjected to a blending cotton process, a carding process, a drawing process, a roving process, a silo compact process, and a yarn winding process, in which the drawing process: two-times drawing, draft ratio of 8, and quantitative weight of 16 g/5 m, the roving process: draft ratio of 9, twist coefficient of 0.6, and quantitative weight of 3.5 g/10 m, and the silo compact process: spindle rotation speed of 12,500 rpm, draft ratio of 49, twist coefficient of 3.7, and air pressure of 2,300 Pa, to obtain a spun yarn of the present invention with a PBT content of 100 wt % and English count of 40.

The obtained spun yarn was used in a circular knitting machine to knit a plain knit structure under conditions of weft density 45 welts/inch x warp density 62 courses/inch to obtain a green fabric, which was then subjected to scouring (90°C x 20 minutes) → dyeing (disperse dye DK9Z3, manufactured by Zhejiang Longsheng Dye Chemical Co., Ltd., 120°C x 30 minutes) → post-processing (moisture absorption and desiccation processing agent HS-TC-18, manufactured by Zhuhai Huadahaohong Chemical Co., Ltd., usage amount 10 owf%, bath processing 80°C x 20 minutes) → drying (150°C x 1 minute) → setting (170°C x 1 minute) to obtain the knitted fabric of the present invention. See Table 1 for specific parameters.

Example 2
The same procedure as in Example 1 was followed except that PTT raw cotton (manufactured by Shanghai Defu Lun Chemical Fiber Co., Ltd.) with a fineness of 1.67 dtex, fiber length of 38 mm, and knot strength of 3.2 cN/dtex was used as the raw material, to obtain a spun yarn and knitted fabric of the present invention with a PTT content of 100 wt % and a British count of 40. See Table 1 for specific parameters.

Example 3
A spun yarn and knitted fabric of the present invention having a PBT content of 100 wt % and a British count of 40 were obtained in the same manner as in Example 1, except that PBT raw cotton (manufactured by Toray Industries, Inc.) with a fineness of 1.70 dtex, fiber length of 38 mm, and knot strength of 5.5 cN/dtex was used as the raw material. See Table 1 for specific parameters.

Example 4
A spun yarn and knitted fabric of the present invention having a PBT content of 100 wt % and a British count of 40 were obtained in the same manner as in Example 1, except that PBT raw cotton (manufactured by Toray Industries, Inc.) with a fineness of 1.70 dtex, fiber length of 38 mm, and knot strength of 6.5 cN/dtex was used as the raw material. See Table 1 for specific parameters.

Example 5
A spun yarn and a knitted fabric of the present invention having a PBT content of 100 wt % and a British count of 40 were obtained in the same manner as in Example 1, except that PBT raw cotton (manufactured by Toray Industries, Inc.) with a fineness of 1.65 dtex, fiber length of 38 mm, and knot strength of 2.0 cN/dtex was used as the raw material. See Table 1 for specific parameters.

Example 6
A spun yarn and a knitted fabric of the present invention having a PBT content of 100 wt % and a British count of 40 were obtained in the same manner as in Example 1, except that PBT raw cotton (manufactured by Toray Industries, Inc.) with a fineness of 1.65 dtex, fiber length of 38 mm, and knot strength of 1.5 cN/dtex was used as the raw material. See Table 1 for specific parameters.

Example 7
A spun yarn and knitted fabric of the present invention having a PBT content of 100 wt% and a British count of 40 were obtained in the same manner as in Example 1, except that PBT raw cotton (manufactured by Toray Industries, Inc.) with a fineness of 0.50 dtex, fiber length of 35 mm, and knot strength of 3.1 cN/dtex was used as the raw material and the twist coefficient of the Silo Compact was changed to 4.2. See Table 1 for specific parameters.

Example 8
A spun yarn and knitted fabric of the present invention having a PBT content of 100 wt% and a British count of 40 were obtained in the same manner as in Example 1, except that PBT raw cotton (manufactured by Toray Industries, Inc.) with a fineness of 4.00 dtex, fiber length of 110 mm, and knot strength of 3.1 cN/dtex was used as the raw material and the twist factor of the Silo Compact was changed to 3.0. See Table 1 for specific parameters.

Example 9
A spun yarn and knitted fabric of the present invention with a PBT content of 100 wt% and a British count of 40 were obtained in the same manner as in Example 1, except that PBT raw cotton (manufactured by Toray Industries, Inc.) with a fineness of 1.67 dtex, fiber length of 38 mm, and knot strength of 3.1 cN/dtex was used as the raw material and the twist coefficient of the Silo Compact was changed to 6.0. See Table 1 for specific parameters.

Example 10
A spun yarn and knitted fabric of the present invention having a PBT content of 100 wt% and a British count of 40 were obtained in the same manner as in Example 1, except that PBT raw cotton (manufactured by Toray Industries, Inc.) with a fineness of 1.67 dtex, fiber length of 38 mm, and knot strength of 3.1 cN/dtex was used as the raw material and the twist factor of the Silo Compact was changed to 2.0. See Table 1 for specific parameters.

Example 11
A sliver made of PBT raw cotton (manufactured by Toray Industries, Inc.) with a fineness of 1.67 dtex, fiber length of 38 mm, and knot strength of 3.1 cN/dtex was designated as sliver A, a sliver made of Brazilian cotton/American cotton (weight ratio of 50:50) was designated as sliver B, and the weight ratio of sliver A to sliver B was 65:35, and drawing was performed three times in the same manner as in Example 1 to obtain a spun yarn and knitted fabric of the present invention with a PBT content of 65 wt % and English count of 40. See Table 1 for specific parameters.

Example 12
A sliver made of PBT raw cotton (manufactured by Toray Industries, Inc.) with a fineness of 1.56 dtex, fiber length of 38 mm and knot strength of 3.9 cN/dtex was designated as sliver A, a sliver made of Brazilian cotton/American cotton (weight ratio of 50:50) was designated as sliver B, and the weight ratio of sliver A to sliver B was 45:55, and drawing was performed three times in the same manner as in Example 1 to obtain a spun yarn and knitted fabric of the present invention with a PBT content of 45 wt% and English count of 40. See Table 1 for specific parameters.

Example 13
Using PBT raw cotton (manufactured by Toray Industries, Inc.) with a fineness of 1.67 dtex, fiber length of 38 mm, and knot strength of 3.1 cN/dtex as the raw material, the yarn was successively subjected to a blending process, a carding process, a drawing process, a roving process, a ring process, and a winding process, and the same procedures as in Example 1 were carried out except that the roving process had a draft ratio of 8 and a fixed amount of 4 g/10 m, and the ring process had a draft ratio of 28, to obtain a spun yarn and knitted fabric of the present invention with a PBT content of 100 wt% and an English count of 40. See Table 1 for specific parameters.

Example 14
Using PBT raw cotton (manufactured by Toray Industries, Inc.) with a fineness of 1.67 dtex, fiber length of 38 mm, and knot strength of 3.1 cN/dtex as the raw material, the yarn was successively subjected to a blending process, a carding process, a drawing process, a roving process, a silo process, and a yarn winding process, and the same procedures as in Example 1 were carried out except that the draft ratio in the silo process was 49 times, to obtain a spun yarn and knitted fabric of the present invention with a PBT content of 100 wt% and an English count of 40. See Table 1 for specific parameters.

Example 15
Using PBT raw cotton (manufactured by Toray Industries, Inc.) with a fineness of 1.67 dtex, fiber length of 38 mm, and knot strength of 3.1 cN/dtex as the raw material, the yarn was successively subjected to a blending process, a carding process, a drawing process, a roving process, a compacting process, and a winding process, and the same procedures as in Example 1 were carried out except that the roving process had a draft ratio of 8 and a fixed amount of 4 g/10 m, and the compacting process had a draft ratio of 28, to obtain a spun yarn and knitted fabric of the present invention with a PBT content of 100 wt% and an English count of 40. See Table 1 for specific parameters.

Example 16
Using PBT raw cotton (manufactured by Toray Industries, Inc.) with a fineness of 1.67 dtex, fiber length of 38 mm, and knot strength of 3.1 cN/dtex as the raw material, the yarn was successively subjected to a mixed fiber combing process, a carding process, a drawing process, and an air whirlpool spinning process, in which the drawing process was performed in three steps, with a draft ratio of 8 and a fixed amount of 11 g/5 m, and the air whirlpool spinning process was performed in total with a draft ratio of 150 and a speed of 300 m/min, in the same manner as in Example 1, to obtain a spun yarn and knitted fabric of the present invention with a PBT content of 100 wt% and an English count of 40. See Table 1 for specific parameters.

Example 17
The spun yarn obtained in Example 1 was interwoven with cotton yarn of English count 30 in a ratio of 1:1, and the dyeing process was the same as in Example 1 except that the PBT fiber was first dyed (disperse dye DK9Z3, manufactured by Zhejiang Longsheng Dye Chemical Co., Ltd., 120°C x 30 minutes), and then the cotton fiber was dyed (active dye RK901, manufactured by Wuxi Advanced Chemical Co., Ltd., 60°C x 60 minutes), to obtain a knitted fabric of the present invention. See Table 1 for specific parameters.

Example 18
The knitted fabric of the present invention was obtained in the same manner as in Example 17, except that the spun yarn obtained in Example 1 and cotton yarn having a British count of 30 were interwoven in a ratio of 1:2. See Table 1 for specific parameters.

Example 19
The same procedure as in Example 1 was followed except that PET raw cotton (manufactured by Toray Industries, Inc.) with a fineness of 1.56 dtex, fiber length of 38 mm, and knot strength of 4.5 cN/dtex was used as the raw material, to obtain a spun yarn and knitted fabric of the present invention with a PBT content of 100 wt % and a British count of 40. See Table 1 for specific parameters.

Example 20
A spun yarn and knitted fabric of the present invention having a PBT content of 100 wt % and an English count of 40 were obtained in the same manner as in Example 11, except that PBT raw cotton (manufactured by Toray Industries, Inc.) with a fineness of 1.67 dtex, fiber length of 38 mm, and knot strength of 3.1 cN/dtex was used as the raw material and the twist factor of the Silo Compact was changed to 1.8. See Table 1 for specific parameters.

Example 21
PET raw cotton (manufactured by Toray Industries, Inc.) with a fineness of 1.56 dtex, fiber length of 38 mm, and knot strength of 4.5 cN/dtex was used as raw material A, and PBT raw cotton (manufactured by Toray Industries, Inc.) with a fineness of 1.67 dtex, fiber length of 38 mm, and knot strength of 3.1 cN/dtex was used as raw material B. Raw materials A and B were sequentially subjected to a mixed cotton process, a carding process, a drawing process, a roving process, a ring process, and a winding process in a weight ratio of 65:35, and the process was the same as in Example 1 except that the drawing process was drawn three times, to obtain a spun yarn and knitted fabric of the present invention with a PET content of 65 wt% and a PBT content of 35 wt%, and a British count of 40. See Table 1 for specific parameters.

Comparative Example 1
A spun yarn and a knitted fabric having a PET content of 100 wt% and a count of 40 were obtained in the same manner as in Example 1, except that PET raw cotton (manufactured by Sino-Petroleum Chemical Co., Ltd.) with a fineness of 1.56 dtex, fiber length of 38 mm, and knot strength of 4.5 cN/dtex was used as the raw material. See Table 1 for specific parameters.

Comparative Example 2
A sliver made of PBT raw cotton (manufactured by Toray Industries, Inc.) with a fineness of 1.56 dtex, fiber length of 38 mm and knot strength of 3.9 cN/dtex was designated as sliver A, a sliver made of Brazilian cotton/American cotton (weight ratio of 50:50) was designated as sliver B, and the weight ratio of sliver A to sliver B was 35:65, and drawing was performed three times in the same manner as in Example 1 to obtain a spun yarn and knitted fabric of the present invention with a PET content of 35 wt% and English count of 40. See Table 1 for specific parameters.

According to the above table,
(1) From Example 1 and Example 2, it was found that, under the same conditions, the spun yarn made of PBT staple fiber having an elastic recovery of 80% and a knot strength of 3.1 cN/dtex was superior to the spun yarn made of PTT staple fiber having an elastic recovery of 82% and a knot strength of 3.2 cN/dtex in both pilling resistance and abrasion resistance of the fabric obtained using the former, but the bending resistance value was slightly higher than that of the latter, i.e., the flexibility was slightly inferior to that of the latter.

(2) From Examples 3 and 4, it was found that under the same conditions, the spun yarn made of PBT staple fibers with a knot strength of 5.5 cN/dtex had better anti-pilling properties than the spun yarn made of PBT staple fibers with a knot strength of 6.5 cN/dtex, but the abrasion resistance and flexibility (bending resistance) of the respective fabrics were at the same level.

(3) From Examples 5 and 6, it was found that under the same conditions, the abrasion resistance of the fabric obtained using a spun yarn made of PBT staple fibers with a knot strength of 2.0 cN/dtex was superior to that of a spun yarn made of PBT staple fibers with a knot strength of 1.5 cN/dtex, but the anti-pilling properties and flexibility (bending resistance) of the respective fabrics were at the same level.

(4) From Example 1 and Example 15, it was found that under the same conditions, the yarn obtained by the silo compact spinning method was superior to the yarn obtained by the compact spinning method in both pilling resistance and abrasion resistance of the fabric obtained using the former, but the bending resistance value was slightly higher than that of the latter, i.e., the flexibility was slightly inferior to that of the latter.

(5) From Example 1 and Example 16, it was found that, under the same conditions, the yarn obtained by the silo compact spinning method was inferior to the yarn obtained by the vortex spinning method in terms of the pilling resistance of the fabric obtained by the former, but the texture was superior to that of the latter, and the abrasion resistance of each fabric was at the same level.

(6) From Examples 17 and 18, it was found that under the same conditions, the knitted fabric with an exposed PBT spun yarn rate of 40% was superior to the knitted fabric with an exposed PBT spun yarn rate of 28% in both pilling resistance and abrasion resistance, but the bending resistance value was slightly lower than that of the latter, i.e., the flexibility was slightly superior to the latter.

(7) From Examples 10 and 20, it was found that under the same conditions, the fabric obtained using a spun yarn with a twist factor of 2.0 had better pilling resistance and abrasion resistance than the fabric obtained using a spun yarn with a twist factor of 1.8, but the bending resistance value was slightly higher than that of the latter, i.e., the flexibility was slightly inferior to that of the latter.

(8) From Comparative Example 1 and Example 19, it was found that under the same conditions, the anti-pilling properties of the fabric obtained using spun yarn made of PET staple fibers with an elastic recovery rate of 40% was only second-class, and the abrasion resistance was also inferior to that of the fabric made of PET staple fibers with an elastic recovery rate of 55%.

(9) From Comparative Example 2 and Example 12, it was found that under the same conditions, the spun yarn containing 35 wt% synthetic fiber (elastic recovery rate 65%) had a second-class anti-pilling property and abrasion resistance of only 20,000 times compared with the spun yarn containing 45 wt% synthetic fiber (elastic recovery rate 65%).

Claims (10)

A spun yarn containing synthetic fibers with an elastic recovery rate of 50% or more after repeated stretching 10 times, the synthetic fiber content being 40 wt% or more. The spun yarn according to claim 1, characterized in that the knot strength of the synthetic fiber is 2 to 6 cN/dtex. The spun yarn according to claim 1 or 2, characterized in that the synthetic fiber is a polyester fiber. The spun yarn according to claim 3, characterized in that the polyester-based fiber is a polyethylene terephthalate fiber and/or a polybutylene terephthalate fiber. The spun yarn according to claim 1 or 2, characterized in that the twist coefficient of the spun yarn is 2.0 to 6.0, the fineness of the single fiber constituting the spun yarn is 0.5 to 4.0 dtex, and the fiber length is 35 to 110 mm. The spun yarn according to claim 1 or 2, characterized in that the spun yarn is obtained by the silo compact spinning method, the silo spinning method or the compact spinning method. The spun yarn according to claim 1 or 2, characterized in that the spun yarn is obtained by a vortex spinning method. A fabric made using 40 wt% or more of the spun yarn described in any one of claims 1 to 7. The fabric according to claim 8, characterized in that the fabric has anti-pilling properties of grade 3 or higher according to the GB/T 4802.2:2008 standard, and/or abrasion resistance of 30,000 cycles or more according to JIS L 1096:2010 standard, method E. The fabric according to claim 8, characterized in that the spun yarn is exposed on at least one side of the fabric, and the exposure rate is 30% or more.

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