Grindstaff, Teddy H.;

Polyester fiber process

Spun textile yarns from new polyester staple fiber, and downstream textile articles, such as fabrics and garments, made from such, and blends thereof, wherein the staple fiber is of intentionally mixed denier, the higher denier being about twice the lower denier. Such staple fiber and precursor tows are preferably made by spinning filaments of different deniers, and collecting them in the same filament bundle on the same spinning machine, from orifices/capillaries of different diameters and/or throughputs.

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I claim:

1. A process for preparing a blend of polyester staple fiber of low and uniform shrinkage and of intentionally different deniers, wherein bundles of filaments of deniers that differ by the desired ratio and having substantially the same natural draw ratio are prepared by cospinning each bundle from the same spinneret through capillaries at differing throughputs at the same spinning position, whereby these filaments of different deniers are collected and mixed together in the same bundle, and such bundles are processed to reduce their shrinkage, and then converted into staple fiber.

2. A process according to claim 1 for preparing an intimate blend of polyester staple fiber of larger denier and of smaller denier, the larger denier being about twice the smaller denier, and of cut length about 1 to about 3 inches and of average denier up to about 3, such as is suitable for conversion into spun yarn.

3. A process for preparing a blend of polyester staple fiber of low and uniform shrinkage of intentionally different deniers, wherein bundles of filaments of deniers that differ by the desired ratio and having substantially the same natural draw ratio are prepared by spinning through capillaries at differing throughputs on the same spinning machine, and these filaments of different deniers are collected together into the same tow, and such tow is processed to reduce the filament shrinkage, and is then converted into staple fiber.

4. A process according to claim 2 for preparing an intimate blend of polyester staple fiber of larger denier and of smaller denier, the larger denier being about twice the smaller denier, and of cut length about 1 to about 3 inches and of average denier up to about 3, such as is suitable for conversion into spun yarn.