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Abstract:
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Microdenier fibers have been, and are still today, the
focal point of a great deal of attention. The expectation is
that microdenier fibers will continue to grow in popularity.
They are known to enhance the appeal of the end products
produced with them.
Unfortunately, manufacturing difficulties caused by the
different characteristics of microdenier fibers (namely more
fibers and more pliable fibers) have prevented yarn
manufacturers from being able to meet the large demand. It
has been proven that difficulties have been encountered in
carding (these fibers tend to nep and load on the cylinder).
This research was undertaken to determine if blending
microdenier fibers with conventional fibers could improve the
processability of fine denier fibers, and at the same time
improve the aesthetics of rotor and air-jet yarns.
To accomplish this work, six different denier conditions
were produced (4 mixed and 2 pure) by intimate blending. All
conditions were spun on a MJS spinning frame and an Autocoro
open-end spinning frame, producing 30/1 yarn.
The experimental yarns were knitted, and the fabrics were
commercially dyed. The results of the tests conducted were
analyzed through variance analysis of a factorial design, and
comparisons of individual means. Fabrics containing each fiber variant were also subjected to a paired comparisons
analysis for appearance and hand.
The levels of the independent variables in the design
were as follows:
Polyester denier: 50/50 blend of 0.50/1.20 dpf polyester
staple (avg. dpf 0.70)
20/80 blend of 0.50/1.20 dpf polyester
staple (avg. dpf 0.93)
20/80 blend of 1.20/0.90 dpf polyester
staple (avg. dpf 0.93)
50/50 blend of 0.90/1.20 dpf polyester
staple (avg. dpf 1.03)
100% 0.90 denier polyester staple
100% 1.20 denier polyester staple
Yarn composition: 100% polyester and 65/35
polyester/cotton
Testing was conducted at the Institute, and at a member
company. The following general results were noted.
1. Although the stock processed well at carding, tests
revealed some damage did occur to the 0.50 denier fibers.
However, the damage was not as severe as in previous
studies. Cardability of the microdenier fibers was
improved by blending deniers.
2. The rotor system overcame the problems associated with
the damaged fibers.
3. The rotor system benefitted from the presence of
microdenier fiber.
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