YARN FORMED FROM RECYCLED COTTON AND RECYCLED PARA-ARAMID, AND FABRICS MADE THEREFROM

BACKGROUND OF THE INVENTION

The typical life cycle of denim begins with the extraction of raw materials and ends with disposal of the denim. However, the life cycle can be maintained as an ongoing circle by way of recycling of materials and components and producing sustainable products from the recycled materials. Such a closed-loop production cycle is advantageous in creating a sustainable textile industry.

Life Cycle Assessment (LCA) studies have been performed to analyze the potential environmental impact of a product such as a cotton textile from raw material extraction to endproduct disposal. This systems-based, quantitative method has been used to evaluate the environmental impact of the different life stages for a pair of denim jeans including the stages of cotton fiber production, cotton textile and garment manufacturing, and consumer use and eventual disposal. Environmental impact is generally evaluated according to several impact categories including global warming potential, primary energy demand, acidification potential, eutrophication (nitrogen and phosphorous deposit) potential, ozone depletion potential, photochemical ozone creation potential, water consumed, water used, human toxicity potential, ecotoxicity potential, abiotic resource depletion, and land occupation. Studies have identified that the textile manufacturing and the consumer use phases of the life cycle contribute to most of the impact categories.

For example, the agriculture processes associated with growing cotton, and the manufacturing of cotton fibers are harmful to the environment because these processes utilize large quantities of water, herbicides, fertilizers and pesticides, which are required for growing the cotton. Both the growing of cotton and the manufacture of cotton fibers contribute to harmful pollutants to air and water, and use significant amounts of energy and other non-renewable resources.

According to one LCA study, the manufacturing of 1000 kg of knit or woven cotton fabric produces about 8,760-9,070 kg of CO₂-e (Cotton Incorporated, National Cotton Council, PE International, “The Life Cycle Inventory & Life Cycle assessment of Cotton Fiber & Fabric, Full Report”, 2012). It was calculated that one pair of denim jeans contributes to 33.4 kg CO₂-e over its life cycle. Moreover, 15% of the calculated CO₂emissions is generated during the cotton fiber production phase while 58% of the calculated CO₂emissions is generated during the textile manufacturing phase (Levi Strauss & Co, “The Life Cycle of a Jean”, 2015).

On average about 25 billion pounds of textiles per year are generated in the U.S. and only 15% of this is donated or recycled, thus leaving about 85% of all remaining textiles ultimately destined for landfills. Each year, about 1.5 million tons of unwanted clothing ends up in landfill.

To reduce its environmental impact and to create a closed-loop production cycle, it is advantageous to produce denim and other cotton fabrics and articles from recycled cotton. Mechanical recycling of fibers involves chopping or cutting up the textile into smaller pieces followed by separating the pieces into cotton fibers before spinning the reclaimed fibers into a yarn. Unfortunately, staple cotton fibers produced from recycled cotton fabric are shorter in length compared to staple fiber from virgin cotton, thereby, compromising the strength and softness of the yarns and fabrics made thereof.

As such, there exists a need for yarns and fabrics made of recycled materials such as recycled cotton that possess substantially similar characteristics and properties as yarns and fabrics made of virgin materials such as virgin cotton.

SUMMARY OF THE INVENTION

In one aspect, provided herein is a spun yarn comprising from about 1 wt % to about 30 wt % recycled para-aramid fiber, from about 5 wt % to about 60 wt % recycled cotton fiber, and from about 10 wt % to about 94 wt % virgin cotton fiber.

In some embodiments, the recycled para-aramid fiber is from about 3 wt % to about 5 wt %. In various instances, the recycled para-aramid fiber is a poly-paraphenylene terephthalamide fiber or a derivative thereof. In some cases, the recycled para-aramid fiber comprises a plurality of staple fibers having a length substantially similar to or shorter than those of virgin para-aramid fiber.

In particular embodiments, the recycled cotton fiber is from about 5 wt % to about 15 wt % and the virgin cotton fiber is from 82 wt % to about 92 wt %. In some cases, the recycled cotton fiber comprises a plurality of staple fibers having a length substantially similar to or shorter than those of virgin cotton fiber.

In various embodiments, the spun yarn has a tensile strength substantially similar to or higher than spun yarn of about 100 wt % cotton.

In another aspect, provided herein is a core spun yarn comprising: (i) a core yarn comprising a filament yarn, and (ii) a wrap yarn comprising from about 1 wt % to about 30 wt % recycled para-aramid fiber, from about 5 wt % to about 60 wt % recycled cotton fiber, and from about 10 wt % to about 94 wt % virgin cotton fiber. In some embodiments, the core spun yarn has a tensile strength substantially similar to or higher than core spun yarn comprising cotton fiber.

In some embodiments, the filament yarn is elastomeric fiber. The elastomeric fiber may comprise an elastane fiber.

In certain embodiments, the recycled para-aramid fiber of the wrap yarn is from about 3 wt % to about 5 wt % of said wrap yarn. The recycled para-aramid fiber can be a poly-paraphenylene terephthalamide fiber. In some instances, the recycled para-aramid fiber comprises a plurality of staple fibers having a length substantially similar to or shorter than those of virgin para-aramid fiber.

In some embodiments, the recycled cotton of the wrap yarn is from about 40 wt % to about 60 wt % of said wrap yarn. In some instances, the recycled cotton fiber comprises a plurality of staple fibers having a length substantially similar to or shorter than those of virgin cotton fiber.

In some aspects, provided herein is a core spun yarn comprising: (i) a core yarn comprising about 1 wt % to about 30 wt % recycled para-aramid fiber, from about 6 wt % to about 60 wt % recycled cotton fiber, and from about 10 wt % to about 94 wt % virgin cotton fiber, and (ii) a wrap yarn comprising a filament yarn. The core spun yarn can have a tensile strength substantially similar to or higher than core spun yarn comprising cotton fiber.

In some embodiments, the filament yarn is elastomeric fiber. The elastomeric fiber may comprise an elastane fiber.

In particular embodiments, the recycled para-aramid fiber of the core yarn is from about 3 wt % to about 5 wt % of said core yarn. The recycled para-aramid fiber can be a poly-paraphenylene terephthalamide fiber. The recycled para-aramid fiber may comprise a plurality of staple fibers having a length substantially similar to or shorter than those of virgin para-aramid fiber. In several embodiments, the recycled para-aramid fiber comprises a plurality of staple fibers having a length substantially similar to or shorter than those of virgin para-aramid fiber.

In various embodiments, the recycled cotton fiber is from about 5 wt % to about 15 wt % and the virgin cotton fiber is from about 82 wt % to about 92 wt % of the core yarn. In some embodiments, the recycled cotton fiber comprises a plurality of staple fibers having a length substantially similar to or shorter than those of virgin cotton fiber.

In other aspects, provided herein is a denim fabric comprising weft yarn comprising any of the spun yarns described herein or any one of the core spun yarns described herein. In some embodiments, the denim fabric further comprises warp yarn comprising one or more textile fibers selected from the group consisting of recycled para-aramid fiber, recycled cotton fiber, and virgin cotton fiber. In certain embodiments, the denim fabric further comprises warp yarn comprising virgin cotton fiber. In some embodiments, the warp yarn comprises recycled para-aramid fiber and recycled cotton fiber. In other embodiments, the warp yarn further comprises recycled para-aramid fiber. In various embodiments, the warp yarn further comprises one or more textile fiber selected from the group consisting of polyester fiber, nylon fiber, cellulosic fiber, elastomeric fiber, and a combination thereof. In some instances, the warp yarn comprises from about 1 wt % to about 30 wt % recycled para-aramid fiber, from about 5 wt % to about 60 wt % recycled cotton fiber, and from about 10 wt % to about 94 wt % virgin cotton fiber.

In certain embodiments, the denim fabric has a higher tear strength compared to a denim fabric of about 100 wt % cotton. The tear strength can be at least about 2-fold higher compared to a denim fabric of about 100 wt % cotton.

In some instances, the denim fabric has a twill weave with a yarn count of 7-10 or lower. In other instances, the denim fabric has a twill weave with a yarn count of higher than 7-10.

In some aspects, provided herein is a denim fabric comprising warp yarn comprising any of the spun yarns described herein or any one of the core spun yarns described herein. In some embodiments, the denim fabric further comprises weft yarn comprising one or more textile fibers selected from the group consisting of recycled para-aramid fiber, recycled cotton fiber, and virgin cotton fiber. In certain embodiments, the denim fabric further comprises weft yarn comprising virgin cotton fibers. In particular embodiments, the weft yarn includes recycled para-aramid fiber and recycled cotton fiber. In various embodiments, the weft yarn further contains one or more textile fiber selected from the group consisting of polyester fiber, nylon fiber, cellulosic fiber, elastomeric fiber, and a combination thereof. In some instances, the weft yarn comprises from about 1 wt % to about 30 wt % recycled para-aramid fiber, from about 5 wt % to about 60 wt % recycled cotton fiber, and from about 10 wt % to about 94 wt % virgin cotton fiber. In other instances, the weft yarn includes virgin cotton fiber and elastomeric fiber.

In several embodiments, the denim fabric has a higher tear strength compared to a denim fabric of about 100 wt % cotton. The tear strength can be at least about 2-fold higher compared to a denim fabric of about 100 wt % cotton.

In some embodiments, the denim fabric has a twill weave with a yarn count of 7-10 or lower. In other instances, the denim fabric has a twill weave with a yarn count of higher than 7-10.

In one aspect, the present invention provides a garment comprising a denim fabric comprising a twill weave comprising warp yarn and weft yarn,

wherein the warp yarn comprises: (i) a spun yarn comprising from about 1 wt % to about 30 wt % recycled para-aramid fiber, about 5 wt % to about 60 wt % recycled cotton fiber, and about 10 wt % to about 94 wt % virgin cotton fiber; (ii) a first core spun yarn comprising a first filament yarn comprising elastomeric fiber and a first wrap yarn comprising about 1 wt % to about 30 wt % recycled para-aramid fiber, about 5 wt % to about 60 wt % recycled cotton fiber, and about 10 wt % to about 94 wt % virgin cotton fiber; (iii) a second core spun yarn comprising a second filament yarn comprising about 1 wt % to about 30 wt % recycled para-aramid fiber, about 5 wt % to about 60 wt % recycled cotton fiber, and about 10 wt % to about 94 wt % virgin cotton fiber and a second wrap yarn comprising elastomeric fiber; or (iv) a yarn comprising one or more textile fibers selected from the group consisting of recycled cotton fiber, virgin cotton fiber, polyester fiber, nylon fiber, cellulosic fiber, elastomeric fiber, and a combination thereof; and

wherein the weft yarn comprises: (i) a spun yarn comprising from about 1 wt % to about 30 wt % recycled para-aramid fiber, about 5 wt % to about 60 wt % recycled cotton fiber, and about 10 wt % to about 94 wt % virgin cotton fiber; (ii) a first core spun yarn comprising a first filament yarn comprising elastomeric fiber and a first wrap yarn comprising about 1 wt % to about 30 wt % recycled para-aramid fiber, about 5 wt % to about 60 wt % recycled cotton fiber, and about 10 wt % to about 94 wt % virgin cotton fiber; (iii) a second core spun yarn comprising a second filament yarn comprising about 1 wt % to about 30 wt % recycled para-aramid fiber, about 5 wt % to about 60 wt % recycled cotton fiber, and about 10 wt % to about 94 wt % virgin cotton fiber and a second wrap yarn comprising elastomeric fiber; or (iv) a yarn comprising one or more textile fibers selected from the group consisting of recycled cotton fiber, virgin cotton fiber, polyester fiber, nylon fiber, cellulosic fiber, elastomeric fiber, and a combination thereof.

In some embodiments, the spun yarn of the weft yarn comprises about 3 wt % to about 5 wt % recycled para-aramid fiber, about 5 wt % to about 15 wt % recycled cotton fiber, and about 82 wt % to about 92 wt % virgin cotton fiber; or the first core spun yarn of the weft yarn comprises a first filament yarn comprising elastomeric fiber and a first wrap yarn comprising about 3 wt % to about 5 wt % recycled para-aramid fiber, about 5 wt % to about 15 wt % recycled cotton fiber, and about 82 wt % to about 92 wt % virgin cotton fiber; or the second core spun yarn of the weft yarn comprises a second filament yarn comprising about 3 wt % to about 5 wt % recycled para-aramid fiber, about 5 wt % to about 15 wt % recycled cotton fiber, and about 82 wt % to about 92 wt % virgin cotton fiber and a second wrap yarn comprising elastomeric fiber; or the yarn of the weft yarn comprises a core spun yarn comprising a filament yarn comprising elastomeric fiber (e.g., elastane) and a wrap yarn comprising virgin cotton fiber.

In some embodiments, the spun yarn of the warp yarn comprises about 3 wt % to about 5 wt % recycled para-aramid fiber, about 5 wt % to about 15 wt % recycled cotton fiber, and about 82 wt % to about 92 wt % virgin cotton fiber; or the first core spun yarn of the warp yarn comprises a first filament yarn comprising elastomeric fiber and a first wrap yarn comprising about 3 wt % to about 5 wt % recycled para-aramid fiber, about 5 wt % to about 15 wt % recycled cotton fiber, and about 82 wt % to about 92 wt % virgin cotton fiber; or the second core spun yarn of the warp yarn comprises a second filament yarn comprising about 3 wt % to about 5 wt % recycled para-aramid fiber, about 5 wt % to about 15 wt % recycled cotton fiber, and about 82 wt % to about 92 wt % virgin cotton fiber and a second wrap yarn comprising elastomeric fiber; or the yarn of the warp yarn comprises a core spun yarn comprising a filament yarn comprising elastomeric fiber (e.g., elastane) and a wrap yarn comprising virgin cotton fiber.

In some embodiments, the garment is selected from the group consisting of a jacket, jeans, shorts, a shirt, overalls, a romper, a skirt, and a dress. In some cases, the garment is a pair of jeans. In some cases, the garment is a jacket.

Other objects, embodiments and advantages of the present invention are apparent in the Detailed Description below.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 depicts a front perspective view of exemplary jeans 100 comprising denim fabric comprising recycled cotton fiber and recycled para-aramid fiber in accordance with descriptions herein and shows illustrative stitch features of the jeans. Stitching 110 on the waistband can be S/N TS (single needle topstitch) with 1/16″ margin. Stitching 120 can be a side seam cord stitch with back stitch. Stitching 130 on each front pocket can be 2/N TS (two needle topstitch) with ¼″ gauge and 1/16″ margin. Stitching 140 can be S/N TS with 3/16″ margin that extends ⅜″ past the 2/N J-stitch 150 and tapers to zero (FR edge of fly can be turned back). Stitching 150 can be 2/N TS with a 1/16″ gauge. Stitching 160 can be 2/N TS with 1/16″ margin, ½″ gauge at the top that tapers to ¼″ gauge. Inside seam 180 can be S/N TS with 1/16″ margin by lockstitch. Stitching 190 at the bottom hem can be S/N TS with 5/16″ margin by chainstitch at the interior. Side seam 170 can be selvedge with busted side seams. A bartack 200 can be at the crotch point. The jean can have a felled seam at the front and back rise. The jean may have a 1″ cuff at the bottom.

FIG. 2 depicts a back perspective view of exemplary jeans 200 comprising recycled cotton fiber and recycled para-aramid fiber in accordance with descriptions herein and shows illustrative stitch features and seams of the jeans. Stitching 210 on the yoke and rise can be a 2/N felled seam with ¼″ gauge and 1/16″ margin. Stitching 220 on a back pocket can be 2/N TS with ¼″ gauge and 1/16″ margin. Stitching 230 on a back pocket can be S/N TS as interior pocket reinforcement. Stitching 250 on a back pocket can be hidden bartacks.

FIG. 3 depicts a front perspective view of exemplary denim jeans in accordance with descriptions herein and shows illustrative thread features 300 of the jeans. Threads 305, 310, 320, 330, 335, 340, 350, 355, 357, 360, and 375 can be of a primary thread color. These threads are of the same color. Threads 380, 385, and 390 can be of a second thread color; these threads are of the same color. Thread 300 can be 60 TEX (S/N, not chainstitch). Thread 310 can be 60TEX (S/N and chainstitch). Thread 320 can be 80 TEX 8-SPI. Thread 330 can be 60 TEX 8-SPI (TS and bobbin). Thread 335 can be 105 TEX 8-SPI. Thread 340 can be 80 TEX 8-SPI (and bobbin is 60 TEX). Thread 350 can be 60 TEX 10-SPI. Thread 355 can be 80 TEX 8-SPI (and bobbin is 60 TEX). Thread 357 can be 105 TEX 8-SPI. Thread 360 can be 60 TEX. Thread 375 can be 80 TEX 8-SPI (and 80TEX for interior overlock). Thread 380 can be 135 TEX 8-SPI (and bobbin is 60 TEX). Thread 385 can be 150 TEX 8-SPI (and bobbin is 60 TEX). Thread 390 can be 105 TEX 8-SPI (and bobbin is 80 TEX for chainstitch). Thread 370 can be 105 TEX 8-SPI for 1/N chainstitch (and bobbin 60 TEX). The thread for the buttonhole can be 80 TEX. In some cases, thread 370 and buttonhole thread are of the same color.

FIG. 4 depicts a back perspective view of denim jeans 400 in accordance with descriptions herein and shows illustrative thread features of the jeans. Threads 410, 415, 420, 430, 440, and 450 can be of the primary thread color. Thread 460 can be of a different color. Thread 410 for the stitching on the belt loop can be 120 TEX 8-SPI (80 TEX for interior overlock). Thread 415 can be 105 TEX 8-SPI (and bobbin is 60 TEX). Thread 420 can be 105 TEX 8-SPI (and bobbin is 60 TEX). Thread 430 can be 80 TEX 8-SPI (and bobbin is 60 TEX). Thread 440 can be 60 TEX 8-SPI. Thread 450 can be 105 TEX 8-SPI (and bobbin is 60 TEX). Thread 460 can be 80 TEX 8-SPI (and bobbin is 60 TEX).

FIG. 5A depicts a view of an exemplary back pocket 500 and shows illustrative stitch features. The exemplary back pocket comprises a quad-fold hem construction. Hidden bar tacks 520 located at the top of the pocket. Stitching 510 can be 2/N TS with ½″ gauge at the top and becomes stitching 530 with 2/N TS with ¼″ gauge at the bottom of the pocket. The triangle stitch at the bottom of the pocket can be ⅛″ on a side 540, ⅛″ on a side 550, and ¼″ on the bottom 560.

FIG. 5B depicts a cross-sectional view of the quad-fold hem construction. The quad-fold helm construction 580 of the back pocket can include a 2/N TS, 1/16″ margin, and ¼″ gauge.

FIG. 6A depicts a close-up view of an exemplary coin pocket located in a front pocket of the jeans 600. Stitching 610 can be extended stitching from the coin pocket to the bottom of the waistband.

FIG. 6B depicts a front view of an exemplary coin pocket 650. Stitching on the coin pocket can be 2/N TS with 1/16″ margin, ¼″ gauge, and ⅜″ hem. Stitching 710 can be S/N TS with a 1/16″ margin. Stitching 720 can be a topstitch that ends at the shank and at stitching 750 the width formed by the stitch can be ¼″ wide. In some embodiments, length of stitching 740 is 4″ and the length of stitching 745 is 1⅜″. Stitching 730 S/N TS with a 1/16″ margin.

FIG. 7 depicts a close-up view of a button shank or a center front (CF) shank detail 700 of the jeans.

FIG. 8A depicts a close-up view of an exemplary belt loop 800 comprising quad-fold construction. In some embodiments, a belt loop comprises a bartack at the top of the belt loop, a bartack at the bottom of the belt loop, and two rows of stitching running along the length of the belt loop. 800 represents a center back belt loop having quad-fold belt loop construction.

FIG. 8B shows a cross-sectional view of a quad-fold belt loop construction 800. The outward facing side of the belt loop is represented as 810. In some embodiments, the belt loop comprises 5 layers of fabric 820 between the stitching that runs from the top and bottom of the belt loop. The stitching can be through 2 layers of the belt loop fabric. The region between the two rows of stitching of the belt loop 835 can be about ¼ inches (¼″). The margin 830 between the edge of the belt loop and one row (e.g., a left row) of stitching of the belt loop can be about ⅛″. A similar margin can be found between the edge of the belt loop and one row (e.g., a right row) of stitching of the belt loop.

FIG. 9A depicts a front view of an illustrative denim jacket 10 comprising denim of the present invention comprising recycled cotton and recycled para-amid. FIG. 9B depicts a back view of the illustrative denim jacket 10.

FIG. 10A depicts a front view of an illustrative denim jacket 10 in accordance with descriptions herein and shows illustrative stitch features and seams of the jacket. Stitching 15 of the collar can be SN TS (single needle topstitch) with 1/16″ margin and with selvedge. Stitching 25 can be SN TS with a 1¾″ margin. Stitching 20 can be DN TS (double needle topstitch) with 1/16″ margin and ¼″ gauge. Stitching 30 can be SN after bartack. Stitching 35 can be SN TS with 1/16″ margin. In some embodiments, the shoulder seam, back yoke seam, front and back princess seams, sleeve seams, and side seams are 2N felled seams on the interior with 1/16″ margin and ¼″ gauge. In some embodiments, the jacket includes selvedge along both sides of the interior center front placket, the top edge of the interior waist band and the bottom edge of the top collar. FIG. 10B depicts a back view of an illustrative denim jacket 10 in accordance with descriptions herein and shows illustrative stitch features of the jacket. Stitching 50 can be SN TS with 3/16″ margin. Stitching 55 can be DN TS with 1/16″ margin and ¼″ gauge and with a 2N felled seam at the interior. Stitching 60 on the back waistband tab can be DN TS at the side with 1/16″ margin and ¼″ gauge. Stitching 70 on the back waistband tab can be SN TS with 1/16″ margin.

DETAILED DESCRIPTION OF THE INVENTION
I. Introduction

The present invention relates to spun yarns and core spun yarns comprising at least one recycled fiber component selected from cotton, aramid and a combination thereof. In various embodiments, the yarn comprises recycled or reclaimed para-aramid, recycled or reclaimed cotton, and virgin cotton. In some embodiments, the wrap yarn of the core spun yarns contains recycled para-aramid, recycled cotton and virgin cotton, and the core yarn contains a filament yarn such as, an elastomeric yarn. In certain embodiments, the wrap yarn of the core spun yarns comprises a filament yarn, and the core yarn contains recycled para-aramid, recycled cotton and virgin cotton. The spun yarns and core spun yarns can be knit or woven into fabrics including, but not limited to, denim.

An exemplary denim fabric of the present invention comprising recycled cotton fibers and recycled para-aramid fibers exhibits improved properties such as increased tear strength, breaking strength, abrasion resistance and a combination thereof compared to denim fabric made of 100 wt % cotton, such as 100 wt % virgin cotton. The tear strength of the denim fabric of the present invention can be at least 2-fold, at least about 3-fold, at least about 5-fold or higher compared to the tear strength of denim made of 100 wt % cotton. As will be appreciated by those of skill in the art, exemplary cotton blend fabrics other than denim formed from yarns of the invention are characterized by similar improved properties.

II. Definitions

“Fiber” and “staple fiber” are used interchangeably and refer to a fiber that can be twisted to form yarn.

“Yam” refers to an assembly of fibers spun or twisted together to form a long and continuous string or filament useful for weaving or knitting fabric materials.

“Denim” refers to a two faced “twill” (a textile weave characterized by diagonal lines on the face of the fabric) construction fabric. The front face of denim fabrics is referred to as the warp-face comprising mainly warp yarns, and the back face of denim fabrics is comprised of mainly filling or weft yarns.

The term “warp yarn” or “warp”, as used herein, refers to yarns adapted for use as the warp in fabric, and may be stronger and have a higher number of turns of twist per inch than weft yarn (e.g., filling yarn). The warp yarn is generally woven lengthwise in fabric.

The term “weft yarn” or “weft” as used herein refers to yarns adapted for use as the filling or weft in fabric, which may be finer and have fewer turns of twist per inch than warp yarn. The weft yarn is generally woven widthwise or crosswise in fabric.

“Spun yarn” refers to yarn made from staple fibers by twisting the staple fibers together to make a cohesive thread.

“Core spun yarn” or “sheath/core yarn” refers to yarn made from staple fibers twisted around a central filament core yarn.

The term “spandex” as used herein is a manufactured fiber in which the fiber-forming substance is a long chain synthetic polymer comprised of at least 85 wt % of segmented polyurethane.

The term “% by weight” or “% wt” or “wt %” as used herein and referring to components of a fabric as a percentage of the total weight of the fabric, unless otherwise specified herein.

These terms may be defined with additional language in the remaining portions of the specification.

III. Detailed Descriptions of the Embodiments
1. Recycled Cotton and Recycled Para-Aramid

Provided herein are yarns, denim fabrics and garment made from recycled cotton and recycled para-aramid.

A para-aramid fiber can be a staple fiber of poly-paraphenylene terephthalamide, p-phenylene terephthalamide, Kevlar®, Twaron®, Technora®, Armos®, Rusar®, Terlon®, or another high modulus or high strength fiber. Detailed descriptions of para-aramid fibers can be found in, for example, U.S. Pat. No. 3,819,587 and Karl K. Chang, “Aramid Fiber,” Constituents Materials, 2005, 27:41-45. Kevlar® refers to a para-aramid fiber having a very high tenacity ranging from 28 g/denier to 32 g/denier and an extremely high heat resistance.

The term “high strength fiber” can refer to a fiber having a tenacity of at least about 10 grams per dtex and a tensile modulus of at least about 150 grams per dtex. Non-limiting examples of high strength fibers include aramids and particularly para-aramids, wholly aromatic copolyamides, polyolefins, polybenzoxazole, polybenzothiazole, and combinations thereof.

In some embodiments, the recycled para-aramid fiber is produced from a post-industrial or post-consumer product containing the para-aramid fiber. In other embodiments, the recycled para-aramid fiber is produced from a secondary material, such as but not limited to, a scrap or waste material. Recycled para-aramid fiber can be produced according to any method recognized by one skilled in the art. For example, a para-aramid material can be mechanically recycled and formed into a staple fiber.

Recycled cotton and recycled para-aramid staple fibers can be produced from pre-consumer and/or post-consumer textiles, fabrics, fabric scraps (e.g., salvages and cut-offs), garments, and the like. Recycled cotton and recycled para-aramid can be produced from fabric waste using a mechanical recycling method. Such a method can include garnetting the fabric waste to generate fibers, opening the fibers, carding the opened fibers, and spinning the carded fibers into yarn. In some cases, para-aramid fabric is milled and pulped to produce recycled para-aramid staple fibers. Textiles can be recycled to produce reclaimed fibers using mechanical recycling, chemical recycling, thermal recycling, or a combination thereof.

Detailed descriptions of methods for producing recycled cotton and recycled para-aramid can be found, for example, in U.S. Pat. Nos. 5,369,861 and 5,471,720 and K.K. Leonas, “The Use of Recycled Fibers in Fashion and Home Products,” Textiles and Clothing Sustainability: Recycled and Upcycled Textiles and Fashion, Muthu, S. S. (ed.), 2017, VII, 125, pp. 55-77.

In some embodiments, a garment of the present invention comprises a denim fabric comprising at least about 40 wt % recycled content (e.g., about 40 wt %, 41 wt %, 42 wt %, 43 wt %, 44 wt %, 45 wt %, 46 wt %, 47 wt %, 48 wt %, 49 wt %, 50 wt %, 51 wt %, 52 wt %, 53 wt %, 54 wt %, 55 wt %, 56 wt %, 57 wt %, 58 wt %, 59 wt %, 60 wt %, 61 wt %, 62 wt %, 63 wt %, 64 wt %, 65 wt %, 66 wt %, 67 wt %, 68 wt %, 69 wt %, 70 wt %, 71 wt %, 72 wt %, 73 wt %, 74 wt %, 75 wt %, 76 wt %, 77 wt %, 78 wt %, 79 wt %, 80 wt %, 81 wt %, 82 wt %, 83 wt %, 84 wt %, 85 wt %, 86 wt %, 87 wt %, 88 wt %, 89 wt %, 90 wt %, or more recycled content). In some instances, the recycled content is recycled para-aramid, recycled cotton, or a combination thereof. In certain embodiments, the recycled content described herein can be obtained from postconsumer material or secondary material.

“Postconsumer material” may refer to a finished material (e.g., a finished fabric) that has completed its life-cycle as a consumer item. The term “postconsumer material” does not include waste material (e.g., waste fabric) produced during the manufacture of the consumer product.

“Secondary material” may refer to fragments of a finished product that has not made it to the consumer and are not intended for the finished product. In some cases, a secondary material includes waste material (e.g., waste fabric) produced during the manufacture of a consumer product.

In particular embodiments, the recycled para-aramid fibers of the present invention can be generated from postconsumer material comprising para-aramid fibers, secondary material comprising para-aramid fibers, or a combination thereof. The recycled para-aramid fibers can be generated from substantially equal or equal percentages of postconsumer material and secondary material. In other embodiments, the recycled para-aramid fibers contain a higher percentage of postconsumer material than secondary material. In certain embodiments, the recycled para-aramid fibers contain a higher percentage of secondary material than postconsumer material. The recycled para-aramid fibers can be made from about 0 wt % to about 50 wt % of postconsumer material (e.g., about 0 wt %, about 5 wt %, about 10 wt %, about 15 wt %, about 20 wt %, about 25 wt %, about 30 wt %, about 35 wt %, about 40 wt %, about 45 wt %, or about 50 wt % of postconsumer material) and about 50 wt % or more of secondary material (e.g., about 50 wt %, about 55 wt %, about 60 wt %, about 65 wt %, about 70 wt %, about 75 wt %, about 80 wt %, about 85 wt %, about 90 wt %, about 95 wt %, or about 100 wt % of secondary material). In other cases, the recycled para-aramid fibers can be made from about 50 wt % or more of postconsumer material (e.g., about 50 wt %, about 55 wt %, about 60 wt %, about 65 wt %, about 70 wt %, about 75 wt %, about 80 wt %, about 85 wt %, about 90 wt %, about 95 wt %, or about 100 wt % of postconsumer material) and from about 0 wt % to about 50 wt % of secondary material (e.g., about 0 wt %, about 5 wt %, about 10 wt %, about 15 wt %, about 20 wt %, about 25 wt %, about 30 wt %, about 35 wt %, about 40 wt %, about 45 wt %, or about 50 wt % of secondary material). In some cases, the recycled para-aramid fibers are made only from postconsumer material comprising para-aramid. In other cases, the recycled virgin para-aramid fibers are made only from secondary material comprising virgin para-aramid.

In various embodiments, the recycled cotton fibers of the present invention can be generated from postconsumer material comprising cotton fibers, secondary material comprising cotton fibers, or a combination thereof. The recycled cotton fibers can be generated from substantially equal or equal percentages of postconsumer material and secondary material. In other embodiments, the recycled cotton fibers contain a higher percentage of postconsumer material than secondary material. In certain embodiments, the recycled cotton fibers contain a higher percentage of secondary material than postconsumer material. The recycled cotton fibers can be made from about 0 wt % to about 50 wt % of postconsumer material (e.g., about 0 wt %, about 5 wt %, about 10 wt %, about 15 wt %, about 20 wt %, about 25 wt %, about 30 wt %, about 35 wt %, about 40 wt %, about 45 wt %, or about 50 wt % of postconsumer material) and about 50 wt % or more of secondary material (e.g., about 50 wt %, about 55 wt %, about 60 wt %, about 65 wt %, about 70 wt %, about 75 wt %, about 80 wt %, about 85 wt %, about 90 wt %, about 95 wt %, or about 100 wt % of secondary material). In other cases, the recycled cotton fibers can be made from about 50 wt % or more of postconsumer material (e.g., about 50 wt %, about 55 wt %, about 60 wt %, about 65 wt %, about 70 wt %, about 75 wt %, about 80 wt %, about 85 wt %, about 90 wt %, about 95 wt %, or about 100 wt % of postconsumer material) and from about 0 wt % to about 50 wt % of secondary material (e.g., about 0 wt %, about 5 wt %, about 10 wt %, about 15 wt %, about 20 wt %, about 25 wt %, about 30 wt %, about 35 wt %, about 40 wt %, about 45 wt %, or about 50 wt % of secondary material). In some cases, the recycled cotton fibers are made only from postconsumer material comprising virgin cotton. In other cases, the recycled cotton fibers are made only from secondary material comprising virgin cotton.

The recycled cotton fiber and recycled para-aramid fiber can be manufactured into staple fibers using any method known to those skilled in the art. In some case, the staple fibers are ring spun to produce yarn.

2. Spun Yarn

An exemplary spun yarn described herein comprises a blend of from about 1 wt % to about 30 wt % recycled para-aramid fiber, from about 5 wt % to about 60 wt % recycled cotton fiber, and from about 10 wt % to about 94 wt % virgin cotton fiber. In some embodiments, the spun yarn includes a range of from about 1 wt % to about 30 wt % recycled para-aramid fiber, e.g., from about 1 wt % to about 30 wt %, from about 1 wt % to about 25 wt %, from about 1 wt % to about 20 wt %, from about 1 wt % to about 15 wt %, from about 1 wt % to about 10 wt %, from about 1 wt % to about 5 wt %, from about 3 wt % to about 5 wt %; about 1 wt %, about 2 wt %, about 3 wt %, about 4 wt %, about 5 wt %, about 6 wt %, about 7 wt %, about 8 wt %, about 9 wt %, about 10 wt %, about 11 wt %, about 12 wt %, about 13 wt %, about 14 wt %, about 15 wt %, about 16 wt %, about 17 wt %, about 18 wt %, about 19 wt %, about 20 wt %, about 21 wt %, about 22 wt %, about 23 wt %, about 24 wt %, about 25 wt %, about 26 wt %, about 27 wt %, about 28 wt %, about 29 wt %, or about 30 wt % recycled para-aramid fiber. The recycled para-aramid fiber comprises a plurality of staple fibers having a length (average length) substantially similar to or shorter than those of virgin para-aramid fiber. The length of the recycled fibers can be the same as a staple fiber from virgin para-aramid. In some cases, the recycled para-aramid fibers can be shorter (e.g., shorter by 0.001%, 0.01%, 0.05%, 0.1%, 0.2%, 0.5%, 0.8%, 1%, 1.5%, 5%, or more) than staple fibers of virgin para-aramid.

In certain embodiments, the spun yarn includes a range of from about 5 wt % to about 60 wt % recycled cotton fiber, e.g., from about 5 wt % to about 60 wt %, from about 5 wt % to about 50 wt %, from about 5 wt % to about 40 wt %, from about 5 wt % to about 30 wt %, from about 20 wt % to about 50 wt %, from about 5 wt % to about 40 wt %, from about 20 wt % to about 60 wt %, from about 20 wt % to about 55 wt %, from about 20 wt % to about 50 wt %, from about 20 wt % to about 45 wt %, from about 20 wt % to about 40 wt %, from about 40 wt % to about 60 wt %, from about 20 wt % to about 35 wt %, about 5 wt %, about 10 wt %, about 15 wt %, about 18 wt %, about 20 wt %, about 22 wt %, about 24 wt %, about 26 wt %, about 28 wt %, about 30 wt %, about 32 wt %, about 34 wt %, about 36 wt %, about 38 wt %, about 39 wt %, about 40 wt %, about 42 wt %, about 44 wt %, about 45 wt %, about 46 wt %, about 47 wt %, about 48 wt %, about 49 wt %, about 50 wt %, about 51 wt %, about 52 wt %, about 53 wt %, about 54 wt %, about 55 wt %, about 56 wt %, about 57 wt %, about 58 wt %, about 59 wt %, or about 60 wt % recycled cotton fiber.

The recycled cotton fiber can comprise a plurality of staple fibers having a length (average length) substantially similar to or shorter than those of virgin cotton fiber. The length of the recycled fibers can be the same as a staple fiber from virgin cotton. In other cases, the recycled cotton fibers can be shorter (e.g., shorter by 0.001%, 0.01%, 0.05%, 0.1%, 0.2%, 0.5%, 0.8%, 1%, 1.5%, 5%, or more) than staple fibers of virgin cotton.

In some embodiments, the spun yarn includes a range of about 10 wt % to about 94 wt % virgin cotton fiber, e.g., from about 10 wt % to about 94 wt %, from about 20 wt % to about 94 wt %, from about 30 wt % to about 94 wt %, from about 40 wt % to about 94 wt %, from about 45 wt % to about 94 wt %, from about 10 wt % to about 50 wt %, from about 20 wt % to about 75 wt %, from about 50 wt % to about 94 wt %, about 10 wt %, about 15 wt %, about 20 wt %, about 25 wt %, about 30 wt %, about 35 wt %, about 40 wt %, about 45 wt %, about 50 wt %, about 55 wt %, about 60 wt %, about 65 wt %, about 70 wt %, about 75 wt %, about 80 wt %, about 85 wt %, about 90 wt %, or about 94 wt % virgin cotton fiber. In preferred embodiments, the spun yarn includes from about 3 wt % to about 5 wt % recycled para-aramid fiber and from about 40 wt % to about 60 wt % recycled cotton fiber.

3. Core Spun Yarn

Exemplary core spun yarns described herein include a wrap yarn that is twisted around a central core yarn (e.g., a filament yarn). In some embodiments, the wrap yarn of the core spun yarn includes about 1 wt %-about 30 wt % recycled para-aramid fiber, from about 5 wt % to about 60 wt % recycled cotton fiber, and from about 10 wt % to about 94 wt % virgin cotton fiber. In preferred embodiments, the core spun yarn includes wrap yarn containing from about 3 wt % to about 5 wt % recycled para-aramid fiber and from about 40 wt % to about 60 wt % recycled cotton fiber.

An exemplary wrap yarn can contain from about 1 wt % to about 30 wt % recycled para-aramid fiber. In some embodiments, the spun yarn includes a range of from about 1 wt % to about 30 wt % recycled para-aramid fiber, e.g., from about 1 wt % to about 30 wt %, from about 1 wt % to about 25 wt %, from about 1 wt % to about 20 wt %, from about 1 wt % to about 15 wt %, from about 1 wt % to about 10 wt %, from about 1 wt % to about 5 wt %, from about 3 wt % to about 5 wt %, about 1 wt %, about 2 wt %, about 3 wt %, about 4 wt %, about 5 wt %, about 6 wt %, about 7 wt %, about 8 wt %, about 9 wt %, about 10 wt %, about 11 wt %, about 12 wt %, about 13 wt %, about 14 wt %, about 15 wt %, about 16 wt %, about 17 wt %, about 18 wt %, about 19 wt %, about 20 wt %, about 21 wt %, about 22 wt %, about 23 wt %, about 24 wt %, about 25 wt %, about 26 wt %, about 27 wt %, about 28 wt %, about 29 wt %, or about 30 wt % recycled para-aramid fiber.

In some embodiments, the recycled para-aramid fiber comprises a plurality of staple fibers having a length (average length) substantially similar to or shorter than those of virgin para-aramid fiber. The length of the recycled fibers can be the same as a staple fiber from virgin para-aramid. In some cases, the recycled para-aramid fibers can be shorter (e.g., shorter by 0.001%, 0.01%, 0.05%, 0.1%, 0.2%, 0.5%, 0.8%, 1%, 1.5%, 5%, or more) than staple fibers of virgin para-aramid.

An exemplary wrap yarn can contain from about 5 wt %-about 60 wt % recycled cotton fiber. In certain embodiments, the wrap yarn includes a range of from about 5 wt % to about 60 wt % recycled cotton fiber, e.g., from about 5 wt % to about 60 wt %, from about 5 wt % to about 50 wt %, from about 5 wt % to about 40 wt %, from about 5 wt % to about 30 wt %, from about 20 wt % to about 50 wt %, from about 5 wt % to about 40 wt %, from about 20 wt % to about 60 wt %, from about 20 wt % to about 55 wt %, from about 20 wt % to about 50 wt %, from about 20 wt % to about 45 wt %, from about 20 wt % to about 40 wt %, from about 40 wt % to about 60 wt %, from about 20 wt % to about 35 wt %, about 5 wt %, about 10 wt %, about 15 wt %, about 18 wt %, about 20 wt %, about 22 wt %, about 24 wt %, about 26 wt %, about 28 wt %, about 30 wt %, about 32 wt %, about 34 wt %, about 36 wt %, about 38 wt %, about 39 wt %, about 40 wt %, about 42 wt %, about 44 wt %, about 45 wt %, about 46 wt %, about 47 wt %, about 48 wt %, about 49 wt %, about 50 wt %, about 51 wt %, about 52 wt %, about 53 wt %, about 54 wt %, about 55 wt %, about 56 wt %, about 57 wt %, about 58 wt %, about 59 wt %, or about 60 wt % recycled cotton fiber.

The wrap yarn can contain from about 10 wt % to about 94 wt % virgin cotton fiber. In some embodiments, the wrap yarn includes a range of from about 10 wt % to about 94 wt % virgin cotton fiber, e.g., from about 10 wt % to about 94 wt %, from about 20 wt % to about 94 wt %, from about 30 wt % to about 94 wt %, from about 40 wt % to about 94 wt %, from about 45 wt % to about 94 wt %, from about 10 wt % to about 50 wt %, from about 20 wt % to about 75 wt %, from about 50 wt % to about 94 wt %, from about 10 wt %, about 15 wt %, about 20 wt %, about 25 wt %, about 30 wt %, about 35 wt %, about 40 wt %, about 45 wt %, about 50 wt %, about 55 wt %, about 60 wt %, about 65 wt %, about 70 wt %, about 75 wt %, about 80 wt %, about 85 wt %, about 90 wt %, or about 94 wt % virgin cotton fiber.

In some embodiments, the central core yarn (also referred to as filament yarn) comprises an elastomeric yarn or fiber. Non-limiting examples of an elastomeric material comprising the elastomeric yarn or fiber are an elastane, a blended elastane, spandex such a Lycra®, a blended spandex, silicone, fluoroelastomer, polyurethane, modified elastic, rubber, and the like. Mixtures of elastomeric compounds are of use as well.

In other embodiments, the core spun yarn of the present invention comprises a central core yarn containing from about 1 wt % to about 30 wt % recycled para-aramid fiber, from about 5 wt % to about 60 wt % recycled cotton fiber, and from about 10 wt % to about 94 wt % virgin cotton fiber. In preferred embodiments, the central core yarn contains from about 3 wt % to about 5 wt % recycled para-aramid fiber and from about 40 wt % to about 60 wt % recycled cotton fiber. As such, in some embodiments, the wrap yarn of the core spun yarn comprises an elastomeric yarn.

An exemplary central core yarn can contain from about 1 wt % to about 30 wt % recycled para-aramid fiber. In some embodiments, the central core yarn includes a range of from about 1 wt % to about 30 wt % recycled para-aramid fiber, e.g., from about 1 wt % to about 30 wt %, from about 1 wt % to about 25 wt %, from about 1 wt % to about 20 wt %, from about 1 wt % to about 15 wt %, from about 1 wt % to about 10 wt %, from about 1 wt % to about 5 wt %, from about 3 wt % to about 5 wt %, about 1 wt %, about 2 wt %, about 3 wt %, about 4 wt %, about 5 wt %, about 6 wt %, about 7 wt %, about 8 wt %, about 9 wt %, about 10 wt %, about 11 wt %, about 12 wt %, about 13 wt %, about 14 wt %, about 15 wt %, about 16 wt %, about 17 wt %, about 18 wt %, about 19 wt %, about 20 wt %, about 21 wt %, about 22 wt %, about 23 wt %, about 24 wt %, about 25 wt %, about 26 wt %, about 27 wt %, about 28 wt %, about 29 wt %, or about 30 wt % recycled para-aramid fiber. The recycled para-aramid fiber can include a plurality of staple fibers having a length (average length) substantially similar to or shorter than those of virgin para-aramid fiber.

An exemplary central core yarn can contain from about 5 wt % to about 60 wt % recycled cotton fiber. In certain embodiments, the central core yarn includes a range of from about 5 wt % to about 60 wt % recycled cotton fiber, e.g., from about 5 wt % to about 60 wt %, from about 5 wt % to about 50 wt %, from about 5 wt % to about 40 wt %, from about 5 wt % to about 30 wt %, from about 20 wt % to about 50 wt %, from about 5 wt % to about 40 wt %, from about 20 wt % to about 60 wt %, from about 20 wt % to about 55 wt %, from about 20 wt % to about 50 wt %, from about 20 wt % to about 45 wt %, from about 20 wt % to about 40 wt %, from about 40 wt % to about 60 wt %, from about 20 wt % to about 35 wt %, about 5 wt %, about 10 wt %, about 15 wt %, about 18 wt %, about 20 wt %, about 22 wt %, about 24 wt %, about 26 wt %, about 28 wt %, about 30 wt %, about 32 wt %, about 34 wt %, about 36 wt %, about 38 wt %, about 39 wt %, about 40 wt %, about 42 wt %, about 44 wt %, about 45 wt %, about 46 wt %, about 47 wt %, about 48 wt %, about 49 wt %, about 50 wt %, about 51 wt %, about 52 wt %, about 53 wt %, about 54 wt %, about 55 wt %, about 56 wt %, about 57 wt %, about 58 wt %, about 59 wt %, or about 60 wt % recycled cotton fiber.

An exemplary central core yarn can contain from about 10 wt % to about 94 wt % virgin cotton fiber. In some embodiments, the central core yarn includes a range of from about 10 wt % to about 94 wt % virgin cotton fiber, e.g., from about 10 wt % to about 94 wt %, from about 20 wt % to about 94 wt %, from about 30 wt % to about 94 wt %, from about 40 wt % to about 94 wt %, from about 45 wt % to about 94 wt %, from about 10 wt % to about 50 wt %, from about 20 wt % to about 75 wt %, from about 50 wt % to about 94 wt %, about 10 wt %, about 15 wt %, about 20 wt %, about 25 wt %, about 30 wt %, about 35 wt %, about 40 wt %, about 45 wt %, about 50 wt %, about 55 wt %, about 60 wt %, about 65 wt %, about 70 wt %, about 75 wt %, about 80 wt %, about 85 wt %, about 90 wt %, or about 94 wt % virgin cotton fiber.

The recycled cotton fiber can include a plurality of staple fibers having a length (average length) substantially similar to or shorter than those of virgin cotton fiber. The length of the recycled fibers can be the same as a staple fiber from virgin cotton. In other cases, the recycled cotton fibers can be shorter (e.g., shorter by 0.001%, 0.01%, 0.05%, 0.1%, 0.2%, 0.5%, 0.8%, 1%, 1.5%, 5%, or more) than staple fibers of virgin cotton.

The tensile strength of any one of the yarns of the present invention can be substantially similar to or higher than yarn comprising cotton fiber such as, but not limited to, about 30 wt % cotton fiber, about 35 wt %, about 40 wt %, about 45 wt %, or about 50 wt %, bout 50 wt %, about 55 wt %, about 60 wt %, about 65 wt %, about 70 wt %, about 75 wt %, about 80 wt %, about 85 wt %, about 90 wt %, about 95 wt %, or about 100 wt % cotton fiber (e.g., virgin cotton, recycled cotton, or a mixture thereof). In some embodiments, the tensile strength of any one of the yarns provided herein is substantially similar as the tensile strength of a comparable yarn comprising virgin cotton.

Tensile strength of yarn can be determined using any method recognized by those skilled in the art. Non-limiting examples include ASTM D2256 for tensile properties of yarn by the single-strand method, ASTM D2653 for tensile properties of elastomeric yarns (CRE type tensile testing machines), and ASTM D7269 for tensile testing of aramid yarns.

Useful physical properties of yarns such as, but not limited to, breaking strength, elongation at rupture, elasticity, diameter, twist, and weight can be determined utilizing art-recognized procedures. The present invention provides materials and methods for engineering a desired physical property into a yarn and, hence, into a fabric formed by the yarn. Such engineering is readily accomplished by testing a spun yarn or fabric including a particular blend of recycled and virgin fibers and determining whether more or less of a particular fiber will increase or diminish the physical property of interest.

The spun yarns and core spun yarns of the present invention can be produced by a number of spinning methods known in the art, including, but not limited to ring spinning, open end spinning, air jet spinning, and friction spinning. The yarns can be dyed according to methods known to those skilled in the art. In some embodiments, the fibers are dyed during manufacturing of the fibers. In other embodiments, the yarns are dyed after being spun.

In some cases, the spun yarns and core spun yarns can be dyed according to any method known to those skilled in the art. Detailed description of dyeing methods can be found, for example, in Paul, Roshan, ed. Denim: Manufacture, Finishing and Applications Woodhead Publishing Series in Textiles: Number 164, Cambridge: Elsevier, 2015 and Denim Book: from Cotton to Fashion, Archroma Management LLC, 2014.

The yarns described herein can be formed into any suitable type of fabric such as, but not limited to, non-woven fabrics including hydroentangled fabrics, felted fabrics, needle-punched fabrics, thermal bonded fabrics, and wet-laid fabrics and woven fabrics including plain weaves, twill weaves, denim weaves, knits, and the like.

4. Denim Containing Recycled Fibers

Exemplary denims described herein can be woven using the spun yarn containing recycled para-aramid fiber such as recycled Kevlar® as the warp yarn or the weft yarn. Optionally, spun yarn containing recycled para-aramid fiber is used as both warp yarn and weft yarn.

In some embodiments, spun yarn comprising from about 1 wt % to about 30 wt % recycled para-aramid fiber, from about 5 wt % to about 60 wt % recycled cotton fiber, and from about 10 wt % to about 94 wt % virgin cotton fiber is used as warp yarn, weft yarn, or both warp yarn and weft yarn in the denim fabric. In certain embodiments, the spun yarn comprises from about 3 wt % to about 5 wt % recycled para-aramid fiber, from about 10 wt % to about 60 wt % recycled cotton fiber, and from about 30 wt % to about 85 wt % virgin cotton fiber. In other embodiments, the warp yarn of the denim includes recycled para-aramid fiber and/or recycled cotton fiber. In certain embodiments, the weft yarn of the denim includes recycled para-aramid fiber and/or recycled cotton fiber.

In some embodiments, the denim is woven using the core spun yarn containing recycled para-aramid fiber and recycled cotton. The core spun yarn can include a wrap yarn comprising from about 1 wt % to about 30 wt % recycled para-aramid fiber, from about 5 wt % to about 60 wt % recycled cotton fiber, and from about 10 wt % to about 94 wt % virgin cotton fiber, and a core yarn comprising a filament yarn, such as an elastomeric yarn. In other embodiments, core spun yarn can include a wrap yarn comprising a filament yarn and a core yarn containing from about 1 wt % to about 30 wt % recycled para-aramid fiber, from about 5 wt % to about 60 wt % recycled cotton fiber, and from about 10 wt % to about 94 wt % virgin cotton fiber.

The core spun yarn comprising recycled para-aramid fiber can be used as the warp, the weft, or both the warp and the weft of the denim. In some embodiments, the denim fabric comprises a core spun yarn described herein as warp yarn, and optionally, the weft yarn comprises recycled cotton fiber. In other embodiments, the core spun yarn is weft yarn, and optionally, the warp yarn comprises recycled cotton fiber. In particular embodiments, any core spun yarn described herein is warp yarn and weft yarn.

In some embodiments, the denim fabric comprising warp yarn comprising recycled cotton, virgin cotton, polyester (e.g., polyethylene terephthalate (PET) or poly-1, 4-cyclohexylene-dimethylene terephthalate (PCDT)), nylon, hemp, bamboo, manufactured cellulosic yarn (e.g., rayon, viscose rayon, modal, Lyocell, Tencel, other cellulose-derived acetate yarn), elastomeric yarn, blends thereof, or any combination thereof. Cellulosic fiber can be made from any source of natural cellulose such as but not limited to cotton, bamboo, hemp, flax, wood pulp, sorghum, jute, ramie, sisal, and the like, or any type of manufactured or regenerated cellulosic fiber. Elastomeric fiber or elastomeric yarn include, such as but is not limited to, an elastane yarn, a blended elastane yarn, spandex such a Lycra®, a blended spandex yarn, and the like. In some instances, the elastomeric yarn comprises a synthetic fiber made from a polymer containing polyurethane. The synthetic fiber can provide desirable elasticity to the fabric. Denim fabric containing elastomeric yarn can have two-way or four-way strength.

In illustrative embodiments, the denim fabric contains a warp yarn that includes a spun yarn comprising from about 1 wt % to about 30 wt % recycled para-aramid fiber, about 5 wt % to about 60 wt % recycled cotton fiber, and about 10 wt % to about 94 wt % virgin cotton fiber, and a weft yarn that includes a spun yarn comprising from about 1 wt % to about 30 wt % recycled para-aramid fiber, about 5 wt % to about 60 wt % recycled cotton fiber, and about 10 wt % to about 94 wt % virgin cotton fiber. In some instances, the spun yarn comprises from about 3 wt % to about 5 wt % recycled para-aramid fiber (e.g., about 3 wt %, about 4 wt %, or about 5 wt % recycled para-aramid fiber), from about 10 wt % to about 55 wt % recycled cotton fiber (e.g., about 10 wt %, about 15 wt %, about 20 wt %, about 25 wt %, about 30 wt %, about 35 wt %, about 40 wt %, about 41 wt %, about 42 wt %, about 43 wt %, about 44 wt %, about 45 wt %, about 46 wt %, about 47 wt %, about 48 wt %, about 49 wt %, about 50 wt %, or about 55 wt % recycled cotton fiber), and from about 30 wt % to about 80 wt % virgin cotton fiber (e.g., about 30 wt %, about 35 wt %, about 40 wt %, about 41 wt %, about 42 wt %, about 43 wt %, about 44 wt %, about 45 wt %, about 46 wt %, about 47 wt %, about 48 wt %, about 49 wt %, about 50 wt %, about 51 wt %, about 52 wt %, about 53 wt %, about 54 wt %, about 55 wt %, about 56 wt %, about 57 wt %, about 58 wt %, about 59 wt %, about 60 wt %, about 65 wt %, about 70 wt %, about 75 wt %, or about 80 wt % virgin cotton fiber). In particular cases, the composition of spun yarn of the warp yarn is the same as the composition of spun yarn of the weft yarn. In other cases, the composition of spun yarn of the warp yarn is different than the composition of spun yarn of the weft yarn.

In other embodiments, the denim fabric contains a warp yarn that includes a spun yarn comprising from about 1 wt % to about 30 wt % recycled para-aramid fiber, about 5 wt % to about 60 wt % recycled cotton fiber, and about 10 wt % to about 94 wt % virgin cotton fiber, and a weft yarn that includes a core spun yarn comprising a filament yarn comprising an elastomeric yarn and a wrap yarn comprising about 1 wt % to about 30 wt % recycled para-aramid fiber, about 5 wt % to about 60 wt % recycled cotton fiber, and about 10 wt % to about 94 wt % virgin cotton fiber. In certain instances, the spun yarn comprises from about 3 wt % to about 5 wt % recycled para-aramid fiber, from about 10 wt % to about 55 wt % recycled cotton fiber, and from about 30 wt % to about 80 wt % virgin cotton fiber. In particular embodiments, core spun yarn of the weft yarn comprises a filament yarn comprising an elastomeric yarn and a wrap yarn comprising about 3 wt % to about 5 wt % recycled para-aramid fiber (e.g., about 3 wt %, about 4 wt %, or about 5 wt % recycled para-aramid fiber), from about 10 wt % to about 55 wt % recycled cotton fiber (e.g., about 10 wt %, about 15 wt %, about 20 wt %, about 25 wt %, about 30 wt %, about 35 wt %, about 40 wt %, about 41 wt %, about 42 wt %, about 43 wt %, about 44 wt %, about 45 wt %, about 46 wt %, about 47 wt %, about 48 wt %, about 49 wt %, about 50 wt %, or about 55 wt % recycled cotton fiber), and from about 30 wt % to about 80 wt % virgin cotton fiber (e.g., about 30 wt %, about 35 wt %, about 40 wt %, about 41 wt %, about 42 wt %, about 43 wt %, about 44 wt %, about 45 wt %, about 46 wt %, about 47 wt %, about 48 wt %, about 49 wt %, about 50 wt %, about 51 wt %, about 52 wt %, about 53 wt %, about 54 wt %, about 55 wt %, about 56 wt %, about 57 wt %, about 58 wt %, about 59 wt %, about 60 wt %, about 65 wt %, about 70 wt %, about 75 wt %, or about 80 wt % virgin cotton fiber).

In particular embodiments, the denim fabric contains a warp yarn that includes a spun yarn comprising from about 1 wt % to about 30 wt % recycled para-aramid fiber, about 5 wt % to about 60 wt % recycled cotton fiber, and about 10 wt % to about 94 wt % virgin cotton fiber, and a weft yarn that includes a core spun yarn comprising a filament yarn comprising about 1 wt % to about 30 wt % recycled para-aramid fiber, about 5 wt % to about 60 wt % recycled cotton fiber, and about 10 wt % to about 94 wt % virgin cotton fiber and a wrap yarn comprising an elastomeric yarn. In certain instances, the spun yarn of the warp yarn comprises from about 3 wt % to about 5 wt % recycled para-aramid fiber, from about 10 wt % to about 60 wt % recycled cotton fiber, and from about 30 wt % to about 85 wt % virgin cotton fiber. In various instances, core spun yarn of the weft yarn comprises a filament yarn comprising about 3 wt % to about 5 wt % recycled para-aramid fiber (e.g., about 3 wt %, about 4 wt %, or about 5 wt % recycled para-aramid fiber), from about 10 wt % to about 55 wt % recycled cotton fiber (e.g., about 10 wt %, about 15 wt %, about 20 wt %, about 25 wt %, about 30 wt %, about 35 wt %, about 40 wt %, about 41 wt %, about 42 wt %, about 43 wt %, about 44 wt %, about 45 wt %, about 46 wt %, about 47 wt %, about 48 wt %, about 49 wt %, about 50 wt %, or about 55 wt % recycled cotton fiber), and from about 30 wt % to about 80 wt % virgin cotton fiber (e.g., about 30 wt %, about 35 wt %, about 40 wt %, about 41 wt %, about 42 wt %, about 43 wt %, about 44 wt %, about 45 wt %, about 46 wt %, about 47 wt %, about 48 wt %, about 49 wt %, about 50 wt %, about 51 wt %, about 52 wt %, about 53 wt %, about 54 wt %, about 55 wt %, about 56 wt %, about 57 wt %, about 58 wt %, about 59 wt %, about 60 wt %, about 65 wt %, about 70 wt %, about 75 wt %, or about 80 wt % virgin cotton fiber), and a wrap yarn comprising an elastomeric fiber (e.g., elastane yarn).

In various embodiments, the denim fabric contains a warp yarn that includes a spun yarn comprising from about 1 wt % to about 30 wt % recycled para-aramid fiber, about 5 wt % to about 60 wt % recycled cotton fiber, and about 10 wt % to about 94 wt % virgin cotton fiber, and a weft yarn that includes a yarn comprising one or more textile fibers selected from the group consisting of recycled cotton fiber, virgin cotton fiber, polyester fiber, nylon fiber, cellulosic fiber, elastomeric fiber, and a combination thereof. In certain instances, the spun yarn of the warp yarn comprises from about 3 wt % to about 5 wt % recycled para-aramid fiber, from about 10 wt % to about 60 wt % recycled cotton fiber, and from about 30 wt % to about 85 wt % virgin cotton fiber. In some instances, the weft yarn includes recycled cotton fiber, and virgin cotton fiber such as but not limited to, 50 wt % recycled cotton fiber, and 50 wt % virgin cotton fiber. In other instances, the weft yarn includes recycled cotton fiber, virgin cotton fiber, and an elastomeric fiber. In other instances, the weft yarn includes recycled cotton fiber, virgin cotton fiber, and polyester fiber.

In some embodiments, the denim fabric contains warp yarn that includes a core spun yarn comprising a filament yarn comprising an elastomeric yarn and a wrap yarn comprising about 1 wt % to about 30 wt % recycled para-aramid fiber, about 5 wt % to about 60 wt % recycled cotton fiber, and about 10 wt % to about 94 wt % virgin cotton fiber; and weft yarn that includes a spun yarn comprising from about 1 wt % to about 30 wt % recycled para-aramid fiber, about 5 wt % to about 60 wt % recycled cotton fiber, and about 10 wt % to about 94 wt % virgin cotton fiber. In some instances, core spun yarn of the warp yarn includes a filament yarn containing an elastomeric yarn and a wrap yarn containing about 3 wt % to about 5 wt % recycled para-aramid fiber, about 10 wt % to about 60 wt % recycled cotton fiber, and about 30 wt % to about 85 wt % virgin cotton fiber, and the spun yarn of the weft yarn includes from about 3 wt % to about 5 wt % recycled para-aramid fiber, from about 10 wt % to about 60 wt % recycled cotton fiber, and from about 30 wt % to about 85 wt % virgin cotton fiber and.

In other embodiments, the denim fabric contains warp yarn that includes a core spun yarn comprising a filament yarn comprising an elastomeric yarn and a wrap yarn comprising about 1 wt % to about 30 wt % recycled para-aramid fiber, about 5 wt % to about 60 wt % recycled cotton fiber, and about 10 wt % to about 94 wt % virgin cotton fiber; and weft yarn that includes a core spun yarn comprising a filament yarn comprising an elastomeric yarn and a wrap yarn comprising about 1 wt % to about 30 wt % recycled para-aramid fiber, about 5 wt % to about 60 wt % recycled cotton fiber, and about 10 wt % to about 94 wt % virgin cotton fiber. In some instances, core spun yarn of the warp yarn and the weft yarn includes a filament yarn containing about 3 wt % to about 5 wt % recycled para-aramid fiber, about 10 wt % to about 60 wt % recycled cotton fiber, and about 30 wt % to about 85 wt % virgin cotton fiber. In some cases the composition of the warp yarn and the weft yarn are the same. In other cases, the composition of the warp yarn and the weft yarn are different.

In certain embodiments, the denim fabric contains warp yarn that includes a core spun yarn comprising a filament yarn comprising an elastomeric yarn and a wrap yarn comprising about 1 wt % to about 30 wt % recycled para-aramid fiber, about 5 wt % to about 60 wt % recycled cotton fiber, and about 10 wt % to about 94 wt % virgin cotton fiber; and a weft yarn that includes a core spun yarn comprising a filament yarn comprising about 1 wt % to about 30 wt % recycled para-aramid fiber, about 5 wt % to about 60 wt % recycled cotton fiber, and about 10 wt % to about 94 wt % virgin cotton fiber and a wrap yarn comprising an elastomeric yarn.

In some instances, core spun yarn of the warp yarn contains a filament yarn including an elastomeric yarn and a wrap yarn including about 3 wt % to about 5 wt % recycled para-aramid fiber, about 10 wt % to about 60 wt % recycled cotton fiber, and about 30 wt % to about 85 wt % virgin cotton fiber, and core spun yarn of the weft yarn includes a filament yarn containing about 3 wt % to about 5 wt % recycled para-aramid fiber, about 10 wt % to about 60 wt % recycled cotton fiber, and about 30 wt % to about 85 wt % virgin cotton fiber, and a wrap yarn containing an elastomeric fiber.

In various embodiments, the denim fabric contains warp yarn that includes a core spun yarn comprising a filament yarn comprising an elastomeric yarn and a wrap yarn comprising about 1 wt % to about 30 wt % recycled para-aramid fiber, about 5 wt % to about 60 wt % recycled cotton fiber, and about 10 wt % to about 94 wt % virgin cotton fiber; and a weft yarn that includes a yarn comprising one or more textile fibers selected from the group consisting of recycled cotton fiber, virgin cotton fiber, polyester fiber, nylon fiber, cellulosic fiber, elastomeric fiber, and a combination thereof. The core spun yarn may be a filament yarn containing an elastomeric yarn and a wrap yarn containing about 3 wt % to about 5 wt % recycled para-aramid fiber, about 10 wt % to about 60 wt % recycled cotton fiber, and about 30 wt % to about 85 wt % virgin cotton fiber. In some instances, the weft yarn includes recycled cotton fiber, and virgin cotton fiber such as but not limited to, 50 wt % recycled cotton fiber, and 50 wt % virgin cotton fiber. In other instances, the weft yarn includes recycled cotton fiber, virgin cotton fiber, and an elastomeric fiber. In other instances, the weft yarn includes recycled cotton fiber, virgin cotton fiber, and polyester fiber.

In some embodiments, the denim fabric contains a warp yarn that includes a core spun yarn comprising a filament yarn comprising about 1 wt % to about 30 wt % recycled para-aramid fiber, about 5 wt % to about 60 wt % recycled cotton fiber, and about 10 wt % to about 94 wt % virgin cotton fiber and a wrap yarn comprising an elastomeric yarn; and a weft yarn that includes a spun yarn comprising from about 1 wt % to about 30 wt % recycled para-aramid fiber, about 5 wt % to about 60 wt % recycled cotton fiber, and about 10 wt % to about 94 wt % virgin cotton fiber. In some instances, the spun yarn of the weft yarn comprises from about 3 wt % to about 5 wt % recycled para-aramid fiber, from about 10 wt % to about 60 wt % recycled cotton fiber, and from about 30 wt % to about 85 wt % virgin cotton fiber. The core spun yarn of the warp yarn may be a filament yarn containing about 3 wt % to about 5 wt % recycled para-aramid fiber, about 10 wt % to about 60 wt % recycled cotton fiber, and about 30 wt % to about 85 wt % virgin cotton fiber, and a wrap yarn containing an elastomeric yarn.

In other embodiments, the denim fabric contains a warp yarn that includes a core spun yarn comprising a filament yarn comprising about 1 wt % to about 30 wt % recycled para-aramid fiber, about 5 wt % to about 60 wt % recycled cotton fiber, and about 10 wt % to about 94 wt % virgin cotton fiber and a wrap yarn comprising an elastomeric yarn; and a weft yarn that includes a core spun yarn comprising a filament yarn comprising an elastomeric yarn and a wrap yarn comprising about 1 wt % to about 30 wt % recycled para-aramid fiber, about 5 wt % to about 60 wt % recycled cotton fiber, and about 10 wt % to about 94 wt % virgin cotton fiber. The core spun yarn of the warp yarn may be a filament yarn containing about 3 wt % to about 5 wt % recycled para-aramid fiber, about 10 wt % to about 60 wt % recycled cotton fiber, and about 30 wt % to about 85 wt % virgin cotton fiber, and a wrap yarn containing an elastomeric yarn. The core spun yarn of the weft yarn may be a filament yarn containing an elastomeric yarn, and a wrap yarn containing about 3 wt % to about 5 wt % recycled para-aramid fiber, about 10 wt % to about 60 wt % recycled cotton fiber, and about 30 wt % to about 85 wt % virgin cotton fiber.

In certain embodiments, the denim fabric contains a warp yarn that includes a core spun yarn comprising a filament yarn comprising about 1 wt % to about 30 wt % recycled para-aramid fiber, about 5 wt % to about 60 wt % recycled cotton fiber, and about 10 wt % to about 94 wt % virgin cotton fiber and a wrap yarn comprising an elastomeric yarn; and a weft yarn that includes a core spun yarn comprising a filament yarn comprising about 1 wt % to about 30 wt % recycled para-aramid fiber, about 5 wt % to about 60 wt % recycled cotton fiber, and about 10 wt % to about 94 wt % virgin cotton fiber and a wrap yarn comprising an elastomeric yarn. The core spun yarn of the warp yarn and the weft yarn may be a filament yarn containing about 3 wt % to about 5 wt % recycled para-aramid fiber, about 10 wt % to about 60 wt % recycled cotton fiber, and about 30 wt % to about 85 wt % virgin cotton fiber, and a wrap yarn containing an elastomeric yarn. In some cases, the compositions of the warp yarn and the weft yarn are the same. In other cases, the compositions of the warp yarn and the weft yarn are different.

In various embodiments, the denim fabric contains a warp yarn that includes a core spun yarn comprising a filament yarn comprising about 1 wt % to about 30 wt % recycled para-aramid fiber, about 5 wt % to about 60 wt % recycled cotton fiber, and about 10 wt % to about 94 wt % virgin cotton fiber and a wrap yarn comprising an elastomeric yarn; and a weft yarn that includes a yarn comprising one or more textile fibers selected from the group consisting of recycled cotton fiber, virgin cotton fiber, polyester fiber, nylon fiber, cellulosic fiber, elastomeric fiber, and a combination thereof. The core spun yarn of the warp yarn may include a filament yarn containing about 3 wt % to about 5 wt % recycled para-aramid fiber, about 10 wt % to about 60 wt % recycled cotton fiber, and about 30 wt % to about 85 wt % virgin cotton fiber, and a wrap yarn containing an elastomeric yarn. In some instances, the weft yarn includes recycled cotton fiber, and virgin cotton fiber such as but not limited to, 50 wt % recycled cotton fiber and 50 wt % virgin cotton fiber. In other instances, the weft yarn includes recycled cotton fiber, virgin cotton fiber, and an elastomeric fiber. In other instances, the weft yarn includes recycled cotton fiber, virgin cotton fiber, and polyester fiber.

In some embodiments, the denim fabric contains a warp yarn comprising a yarn comprising one or more textile fibers selected from the group consisting of recycled cotton fiber, virgin cotton fiber, polyester fiber, nylon fiber, cellulosic fiber, elastomeric fiber, and a combination thereof; and a weft yarn that includes a spun yarn comprising from about 1 wt % to about 30 wt % recycled para-aramid fiber, about 5 wt % to about 60 wt % recycled cotton fiber, and about 10 wt % to about 94 wt % virgin cotton fiber. In some instances, the warp yarn includes recycled cotton fiber, and virgin cotton fiber such as but not limited to, 50 wt % recycled cotton fiber, and 50 wt % virgin cotton fiber. In other instances, the weft yarn includes recycled cotton fiber, virgin cotton fiber, and an elastomeric fiber. In other instances, the weft yarn includes recycled cotton fiber, virgin cotton fiber, and polyester fiber.

In other embodiments, the denim fabric contains a warp yarn comprising a yarn comprising one or more textile fibers selected from the group consisting of recycled cotton fiber, virgin cotton fiber, polyester fiber, nylon fiber, cellulosic fiber, elastomeric fiber, and a combination thereof; and a weft yarn that includes a core spun yarn comprising a filament yarn comprising an elastomeric yarn and a wrap yarn comprising about 1 wt % to about 30 wt % recycled para-aramid fiber, about 5 wt % to about 60 wt % recycled cotton fiber, and about 10 wt % to about 94 wt % virgin cotton fiber. The core spun yarn of the weft yarn may be a filament yarn containing an elastomeric yarn and a wrap yarn containing about 3 wt % to about 5 wt % recycled para-aramid fiber, about 10 wt % to about 60 wt % recycled cotton fiber, and about 30 wt % to about 85 wt % virgin cotton fiber.

In certain embodiments, the denim fabric contains a warp yarn comprising a yarn comprising one or more textile fibers selected from the group consisting of recycled cotton fiber, virgin cotton fiber, polyester fiber, nylon fiber, cellulosic fiber, elastomeric fiber, and a combination thereof, and a weft yarn that includes a core spun yarn comprising a filament yarn comprising about 1 wt % to about 30 wt % recycled para-aramid fiber, about 5 wt % to about 60 wt % recycled cotton fiber, and about 10 wt % to about 94 wt % virgin cotton fiber and a wrap yarn comprising an elastomeric yarn. The core spun yarn of the weft yarn may be a filament yarn containing about 3 wt % to about 5 wt % recycled para-aramid fiber, about 10 wt % to about 60 wt % recycled cotton fiber, and about 30 wt % to about 85 wt % virgin cotton fiber, and a wrap yarn containing an elastomeric yarn.

Tear strength of a fabric, e.g., a denim fabric, of the present invention can be desirably higher than the tear strength of a similar fabric, e.g., a denim fabric, made of 100 wt % cotton, such as virgin cotton or recycled cotton. In some embodiments, the tear strength of the fabric is at least 2-fold higher, e.g., at least about 2-fold higher, at least about 2.5-fold higher, at least about 3-fold higher, at least about 3.5-fold higher, at least about 4-fold higher, at least about 4.5-fold higher, or more compared to a similar fabric made from 100 wt % cotton. Any method for measuring tear strength of a fabric can be used. Non-limiting examples include ASTM D1424 for tearing strength of fabrics by falling-pendulum apparatus, ASTM D2261 for tearing strength of textile fabrics, and ASTM D5587 for tearing strength of fabrics by trapezoid procedure.

In some embodiments, breaking strength of the fabric, e.g., the denim, comprising recycled para-aramid fibers and recycled cotton is higher than the breaking strength of an identical fabric, e.g., denim, made of 100 wt % cotton. In some embodiments, the breaking strength of the fabric is at least 1.5-fold higher, e.g., at least about 1.5-fold higher, at least about 2-fold higher, at least about 2.5-fold higher, at least about 3-fold higher, at least about 3.5-fold higher, at least about 4-fold higher, at least about 4.5-fold higher, or more compared to a similar fabric made from 100 wt % cotton. Non-limiting examples of methods for testing breaking strength include ASTM D5034 for breaking strength and elongation of textile fabrics (grab method) and ASTM D5035 for breaking force and elongation of textile fabrics (strip method).

In certain embodiments, abrasion resistance of the fabric, e.g., denim, described herein is higher than the abrasion resistance of an otherwise identical fabric made of 100 wt % cotton. In some embodiments, the abrasion resistance of the fabric is at least 1.5-fold higher, e.g., at least about 1.5-fold higher, at least about 2-fold higher, at least about 2.5-fold higher, at least about 3-fold higher, at least about 3.5-fold higher, at least about 4-fold higher, at least about 4.5-fold higher, or more. Examples of methods for determining abrasion resistance include ASTM D4158 for abrasion resistance of textile fabrics (uniform abrasion), ASTM D4157 for abrasion resistance of textile fabrics (oscillatory cylinder method), and ASTM D4966 for abrasion resistance of textile fabrics (Martindale abrasion tester method).

The denim of the present invention can contain up to 90 wt % recycled content (e.g., recycled material). In some embodiments, the denim includes up to 90 wt % recycled content comprising at least 1 wt % to about 90 wt % postconsumer material. In other embodiments, the denim includes up to 90 wt % recycled content comprising at least 1 wt % to about 90 wt % secondary material.

In particular embodiments, the denim includes about 3 wt %-about 5 wt % recycled para-aramid content from a postconsumer product containing para-aramid. In some embodiments, the denim includes 3 wt %-about 5 wt % recycled para-aramid content from a secondary material containing para-aramid. In some instances, the denim includes about 48 wt %-about 50 wt % recycled cotton content from a postconsumer product containing cotton, e.g., virgin cotton. In other instances, the denim includes about 48 wt %-about 50 wt % recycled cotton content from a secondary material containing cotton, e.g., virgin cotton. In particular instances, the denim includes about 48 wt %-about 50 wt % recycled cotton content from a postconsumer product containing cotton and a secondary material containing cotton. The weft yarn can include cotton fibers from postconsumer products and secondary materials.

In one embodiment, warp yarn of the denim includes about 3 wt %-about 5 wt % recycled para-aramid content from a postconsumer product containing para-aramid. In certain embodiments, warp yarn of denim includes 3 wt %-about 5 wt % recycled para-aramid content from a secondary material containing para-aramid. In some instances, warp yarn of the denim includes about 48 wt %-about 50 wt % recycled cotton content from a postconsumer product containing cotton, e.g., virgin cotton. In other instances, warp yarn of the denim includes about 48 wt %-about 50 wt % recycled cotton content from a secondary material containing cotton, e.g., virgin cotton. The warp yarn can include cotton fibers from postconsumer products and secondary materials.

In another embodiment, weft yarn of the denim includes about 3 wt %-about 5 wt % recycled para-aramid content from a postconsumer product containing para-aramid. In some embodiments, weft yarn of denim includes 3 wt %-about 5 wt % recycled para-aramid content from a secondary material containing para-aramid. In some instances, weft yarn of the denim includes about 45 wt %-about 50 wt % recycled cotton content from a postconsumer product containing cotton, e.g., virgin cotton. In other instances, weft yarn of the denim includes about 45 wt %-about 50 wt % recycled cotton content from a secondary material containing cotton, e.g., virgin cotton.

In some aspects, warp yarn or weft yarn of the denim includes 50 wt % of virgin cotton and 50 wt % recycled cotton from a postconsumer product. In other embodiments, warp yarn or weft yarn of the denim includes 50 wt % of virgin cotton and 50 wt % recycled cotton from a secondary material. In yet other embodiments, a percentage of the recycled cotton is produced from a postconsumer product and a percentage of the recycled cotton is produced from a secondary material.

5. Descriptions of Exemplary Embodiments

Provided herein is a garment comprising denim comprising recycled cotton and recycled para-aramid. The garment can be any worn by a person such as, but not limited to, a jacket, shirt, shorts, jeans, skirt, dress, overalls, romper, hat, cap, and the like. In some embodiments, the garment is a pair of jeans. In other embodiments, the garment is a denim jacket.

As illustrated in FIGS. 1, 2, 3, and 4, in certain embodiments, the garment comprises any of the yarns and denim fabrics described herein is a pair of jeans. In some embodiments, jeans of the present invention comprise any of the denim fabrics described herein. In some embodiments, the jeans of the present invention is represented in FIGS. 1, 2, 3, and 4.

In some embodiments, the denim fabric of the jeans includes warp yarn containing about 1 wt % to about 30 wt % recycled para-aramid fiber, about 5 wt % to about 60 wt % recycled cotton fiber, and about 10 wt % to about 94 wt % virgin cotton fiber, or 3 wt % to about 5 wt % recycled para-aramid fiber, about 10 wt % to about 60 wt % recycled cotton fiber, and about 30 wt % to about 85 wt % virgin cotton fiber. In other embodiments, the denim fabric of the jeans includes weft yarn containing about 1 wt % to about 30 wt % recycled para-aramid fiber, about 5 wt % to about 60 wt % recycled cotton fiber, and about 10 wt % to about 94 wt % virgin cotton fiber, or 3 wt % to about 5 wt % recycled para-aramid fiber, about 10 wt % to about 60 wt % recycled cotton fiber, and about 30 wt % to about 85 wt % virgin cotton fiber. In some cases, the warp and/or weft yarn includes 3 wt % recycled para-aramid fiber and 97 wt % cotton (e.g., virgin cotton, recycled cotton, or a mixture thereof).

In certain embodiments, the denim fabric of the jeans includes warp yarn or weft yarn that does not contain recycled para-aramid fiber and includes up to about 50 wt % recycled cotton fiber, e.g., about 5 wt %-50 wt %, about 15 wt %-50 wt %, about 20 wt %-50 wt %, about 25 wt %-50 wt %, about 30 wt %-50 wt %, about 30 wt %-50 wt %, about 40 wt %-50 wt %, about 10 wt %, about 15 wt %, about 20 wt %, about 25 wt %, about 30 wt %, about 35 wt %, about 40 wt %, about 45 wt %, about 46 wt %, about 47 wt %, about 48 wt %, about 49 wt %, or about 50 wt % recycled cotton fiber. In particular embodiments, the denim fabric of the jeans includes warp yarn or weft yarn that does not contain recycled para-aramid fiber and has up to about 50 wt % virgin cotton fiber, e.g., about 5 wt %-50 wt %, about 15 wt %-50 wt %, about 20 wt %-50 wt %, about 25 wt %-50 wt %, about 30 wt %-50 wt %, about 30 wt %-50 wt %, about 40 wt %-50 wt %, about 10 wt %, about 15 wt %, about 20 wt %, about 25 wt %, about 30 wt %, about 35 wt %, about 40 wt %, about 45 wt %, about 46 wt %, about 47 wt %, about 48 wt %, about 49 wt %, or about 50 wt % virgin cotton fiber.

In some embodiments, the warp yarn or weft yarn that does not include recycled para-aramid fiber may include at least 5 wt % recycled cotton fiber, e.g., about 5 wt %-100 wt %, about 50 wt %-100 wt %, about 50 wt %-90 wt %, about 60 wt %-90 wt %, about 60 wt %-85 wt %, about 70 wt %-90 wt %, about 70 wt %-85 wt %, about 80 wt %-100 wt %, about 5 wt %, about 10 wt %, about 15 wt %, about 50 wt %, about 51 wt %, about 52 wt %, about 53 wt %, about 54 wt %, about 55 wt %, about 60 wt %, about 65 wt %, about 70 wt %, about 75 wt %, about 80 wt %, about 85 wt %, about 90 wt %, about 91 wt %, about 92 wt %, about 93 wt %, about 94 wt %, about 95 wt %, about 96 wt %, about 97 wt %, about 98 wt %, about 99 wt %, or about 100 wt % recycled cotton fiber. In certain embodiments, the warp yarn or weft yarn that does not include recycled para-aramid fiber may include at least 50 wt % virgin cotton fiber, e.g., about 50 wt %-100 wt %, about 50 wt %-90 wt %, about 60 wt %-90 wt %, about 60 wt %-85 wt %, about 70 wt %-90 wt %, about 70 wt %-85 wt %, about 80 wt %-100 wt %, about 50 wt %, about 51 wt %, about 52 wt %, about 53 wt %, about 54 wt %, about 55 wt %, about 60 wt %, about 65 wt %, about 70 wt %, about 75 wt %, about 80 wt %, about 85 wt %, about 90 wt %, about 91 wt %, about 92 wt %, about 93 wt %, about 94 wt %, about 95 wt %, about 96 wt %, about 97 wt %, about 98 wt %, about 99 wt %, or about 100 wt % virgin cotton fiber.

In various embodiments, the fabric of the jeans is stretch denim. As such, the warp yarn or weft yarn may not include recycled para-aramid fiber and includes about 1 wt %-about 10 wt % elastomeric yarn (e.g., elastane), about 45 wt %-about 99 wt % about recycled cotton, and optionally, about 1 wt %-about 49 wt % virgin cotton. In some embodiments, warp yarn of the jeans includes 3 wt % elastane, 47 wt % virgin cotton, and 50 wt % recycled cotton. In some embodiments, warp yarn includes 50 wt % virgin cotton and 50 wt % recycled cotton.

In various embodiments, the pair of jeans is made of a denim fabric having a twill weave of 3×1, 2×1, or 1×1. In some instances, the denim has a yarn count of 7 (ring spun) to 10 (ring spun).

As illustrated in FIGS. 9A, 9B, 10A, and 10B, in some embodiments, the garment comprises any of the yarns and denim fabrics described herein is a jacket. In some embodiments, the denim jacket of the present invention is represented in FIGS. 9A, 9B, 10A, and 10B.

In various embodiments, denim jacket is made of a denim fabric having a twill weave of 3×1, 2×1, or 1×1. In some instances, the denim has a yarn count of 7 (ring spun) to 10 (ring spun).

In one aspect, the present invention provides a spun yarn comprising a mixture of aramid and cotton in which either or both of the components at least partially comprise recycled aramid and/or recycled cotton. In an exemplary embodiment, the spun yarn includes from about 1 wt % to about 30 wt % recycled para-aramid fiber, from about 5 wt % to about 60 wt % recycled cotton fiber, and from about 10 wt % to about 94 wt % virgin cotton fiber. In another embodiment, the spun yarn includes from about 3 wt % to about 5 wt % recycled para-aramid fiber, from about 5 wt % to about 15 wt % recycled cotton fiber, and from about 82 wt % to about 92 wt % virgin cotton fiber. In some instances, the recycled para-aramid fiber is a poly-paraphenylene terephthalamide fiber or a derivative thereof. In some embodiments, the recycled para-aramid fiber is about 3 wt %. In some embodiments, the recycled cotton is from about 5 wt % to about 15 wt % of the yarn.

In some embodiments, the spun yarn has a tensile strength substantially similar to or higher than spun yarn of about 100 wt % cotton, such as virgin cotton, recycled cotton, or a blend thereof. In other embodiments, the spun yarn has a tensile strength higher than spun yarn of recycled cotton fiber, such as but not limited to, about 70 wt %, about 80 wt %, about 90 wt %, about 95 wt %, or 100 wt % recycled cotton fiber. In yet other embodiments, the spun yarn has a tensile strength higher than spun yarn of virgin cotton fiber, such as but not limited to, about 70 wt %, about 80 wt %, about 90 wt %, about 95 wt %, or 100 wt % virgin cotton fiber. In some instances, the tensile strength is higher by 0.5%, about 1%, about 2%, about 3%, about 4%, about 5%, about 6%, about 7%, about 8%, about 9%, about 10%, or more.

In some embodiments, the recycled para-aramid fiber comprises a plurality of staple fibers having a length substantially similar to or shorter than those of virgin para-aramid fiber. In some instances, the length of the staple recycled para-aramid fibers is shorter by about 0.001%. about 0.01%, about 0.1%, about 0.5%, about 1%, about 2%, about 3%, about 4%, about 5%, about 6%, about 7%, about 8%, about 9%, about 10%, or more. The length of the staple recycled para-aramid fibers is shorter by about 1%, about 0.9%, about 0.8%, about 0.7%, about 0.6%, about 0.5%, about 0.4%, about 0.3%, about 0.2%, about 0.1%, about 0.05%, about 0.01%, about 0.005%, or less.

In some embodiments, the recycled cotton fiber comprises a plurality of staple fibers having a length substantially similar to or shorter than those of virgin cotton fiber. In some instances, the length of the staple recycled cotton fibers is shorter by 0.5%, about 1%, about 2%, about 3%, about 4%, about 5%, about 6%, about 7%, about 8%, about 9%, about 10%, or more. The length of the staple recycled cotton fibers is shorter by about 1%, about 0.9%, about 0.8%, about 0.7%, about 0.6%, about 0.5%, about 0.4%, about 0.3%, about 0.2%, about 0.1%, about 0.05%, about 0.01%, about 0.005%, or less. The length (average length) of staple recycled cotton fibers and staple virgin cotton fibers.

In certain aspects, the present invention provides a denim fabric comprising weft yarns comprising any of the spun yarns described herein. In some embodiments, the warp yarns of the denim fabric comprise recycled cotton fibers. In certain embodiments, the warp yarns of the denim fabric comprise para-aramid cotton fibers. Such denim fabric desirably has a higher tear strength compared to a denim fabric of about 100 wt % cotton. In some instances, tear strength of the denim fabric is at least about 2-fold, at least about 3-fold, at least about 5-fold or higher compared to a denim fabric of about 100 wt % cotton.

In some embodiments, denim fabric comprising any of the spun yarns described herein has a twill weave of 3×1, 2×1, or 1×1. In some cases, the denim fabric has a yarn count of 7-10 (e.g., 7 (ring spun)×10 (ring spun)) or lower. In other cases, the denim fabric has a yarn count higher than 7-10 (e.g., 7 (ring spun)×10 (ring spun)).

In some aspects, the present invention provides a core spun yarn comprising (i) a core yarn comprising a filament yarn, and (ii) a wrap yarn comprising from about 1 wt % to about 30 wt % recycled para-aramid fiber, from about 5 wt % to about 60 wt % recycled cotton fiber, and from about 10 wt % to about 94 wt % virgin cotton fiber. In some instances, the wrap yarn comprises from about 3 wt % to about 5 wt % recycled para-aramid fiber, from about 5 wt % to about 15 wt % recycled cotton fiber, and from about 82 wt % to about 92 wt % virgin cotton fiber. In some embodiments, the filament yarn comprises elastomeric yarn or fiber. In certain embodiments, the elastomeric fiber comprises an elastane fiber. In some embodiments, the recycled para-aramid fiber is from about 3 wt % to about 5 wt % of said wrap yarn. In some embodiments, the recycled para-aramid fiber is a poly-paraphenylene terephthalamide fiber.

In some embodiments, the core spun yarn has a tensile strength substantially similar to or higher than core yarn comprising recycled cotton fiber, such as but not limited to, about 30 wt %, about 35 wt %, about 40 wt %, about 45 wt %, about 50 wt %, about 55 wt %, about 60 wt %, about 65 wt %, about 70 wt %, about 80 wt %, about 90 wt %, about 95 wt %, or 100 wt % recycled cotton fiber. In some instances, the tensile strength is higher by about 0.5%, about 1%, about 2%, about 3%, about 4%, about 5%, about 6%, about 7%, about 8%, about 9%, about 10%, or more. In some embodiments, the recycled para-aramid fiber of the wrap yarn fiber comprises a plurality of staple fibers having a length substantially similar to or shorter than those of virgin para-aramid fiber. In some instances, the length of the staple recycled para-aramid fiber is shorter by about 0.5%, about 1%, about 2%, about 3%, about 4%, about 5%, about 6%, about 7%, about 8%, about 9%, about 10%, or more. In certain embodiments, the recycled cotton fiber of the wrap yarn comprises a plurality of staple fibers having a length substantially similar to or shorter than those of virgin cotton fiber. In some instances, the length of the staple recycled cotton fiber is shorter by about 0.5%, about 1%, about 2%, about 3%, about 4%, about 5%, about 6%, about 7%, about 8%, about 9%, about 10%, or more.

In other aspects, the present invention provides a core spun yarn comprising (i) a core yarn comprising from about 1 wt % to about 30 wt % recycled para-aramid fiber, about 5 wt % to about 60 wt % recycled cotton fiber, and from about 10 wt % to about 94 wt % virgin cotton fiber, and (ii) a wrap yarn comprising a filament yarn. In some embodiments, the filament yarn comprises elastomeric fiber. In some embodiments, the elastomeric fiber comprises an elastane fiber.

In some embodiments, the recycled para-aramid fiber is from about 3 wt % to about 5 wt % of said core yarn. The recycled para-aramid fiber can be a poly-paraphenylene terephthalamide fiber. In some embodiments, the recycled cotton is from about 10 wt % to about 60 wt % of said core yarn. In other embodiments, the recycled cotton is from about 5 wt % to about 15 wt % of said core yarn.

In some embodiments, the core spun yarn has a tensile strength substantially similar to or higher than core yarn comprising recycled cotton fiber, such as but not limited to, about 30 wt %, about 35 wt %, about 40 wt %, about 45 wt %, about 50 wt %, about 55 wt %, about 60 wt %, about 65 wt %, about 70 wt %, about 80 wt %, about 90 wt %, about 95 wt %, or 100 wt % recycled cotton fiber. In some instances, the tensile strength is higher by 0.5%, about 1%, about 2%, about 3%, about 4%, about 5%, about 6%, about 7%, about 8%, about 9%, about 10%, or more. In some embodiments, the recycled para-aramid fiber of the core yarn comprises a plurality of staple fibers having a length substantially similar to or shorter than those of virgin para-aramid fiber. In some instances, the length of the staple recycled para-aramid fiber is shorter by about 0.5%, about 1%, about 2%, about 3%, about 4%, about 5%, about 6%, about 7%, about 8%, about 9%, about 10%, or more. In certain embodiments, the recycled cotton fiber of the core yarn comprises a plurality of staple fibers having a length substantially similar to or shorter than those of virgin cotton fiber. In some instances, the length of the staple recycled cotton fiber is shorter by about 0.5%, about 1%, about 2%, about 3%, about 4%, about 5%, about 6%, about 7%, about 8%, about 9%, about 10%, or more.

In some aspects, the present invention provides a denim fabric comprising weft yarns comprising any of core spun yarns described herein. In some embodiments, the warp yarns of the denim fabric comprise recycled cotton fibers. In certain embodiments, the warp yarns of the denim fabric comprise para-aramid cotton fibers. The denim fabric can have a higher tear strength compared to a denim fabric of from about 100 wt % cotton (e.g., virgin cotton, recycled cotton, or a blend thereof). In some instances, tear strength of the denim fabric is at least about 1-fold higher, about 2-fold higher, at least about 3-fold, at least about 5-fold or higher compared to a denim fabric of about 100 wt % cotton (e.g., virgin cotton, recycled cotton, or a blend thereof).

In an exemplary embodiment, the denim jacket of the present invention contains denim fabric with warp yarn comprising 50 wt % recycled cotton fiber and 50 wt % virgin cotton fiber and weft yarn comprising 50 wt % recycled cotton fiber, 47 wt % virgin cotton fiber, and 3 wt % recycled para-aramid fiber.

In another exemplary embodiment, the jeans of the present invention contain denim fabric with warp yarn comprising about 5 wt %-about 15 wt % recycled cotton fiber, about 82 wt %-about 92 wt % virgin cotton fiber, and about 1 wt %-about 5 wt % recycled para-aramid fiber, and weft yarn comprising 5 wt %-about 15 wt % recycled cotton fiber, about 82 wt %-about 92 wt % virgin cotton fiber, and about 1 wt %-about 5 wt % recycled para-aramid fiber. In some instances, the warp yarn comprises about 3 wt % recycled para-aramid fiber. In particular instances, the weft yarn comprises about 3 wt % recycled para-aramid fiber.

In an exemplary embodiment, the jeans of the present invention contain denim fabric comprising about 5 wt %-about 15 wt % recycled cotton fiber, about 82 wt %-about 92 wt % virgin cotton fiber, and about 1 wt %-about 5 wt % recycled para-aramid fiber. In some embodiments, the jeans contain denim fabric comprising about 5 wt %-about 15 wt % recycled cotton fiber, about 82 wt %-about 92 wt % virgin cotton fiber, and about 3 wt % recycled para-aramid fiber.

In some embodiments of the invention provided herein is a jacket containing denim fabric comprising about 5 wt %-about 15 wt % recycled cotton fiber, about 82 wt %-about 92 wt % virgin cotton fiber, and about 3 wt % recycled para-aramid fiber.

In some embodiments, the jeans of the present invention contain denim fabric comprising weft yarn comprising about 2 wt %-about 30 wt % elastomeric yarn and about 70%-about 98 wt % cotton. In various embodiments, the weft yarn comprises a core spun yarn comprising elastomeric fiber and a wrap yarn comprising cotton fiber. In some cases, the cotton of such weft yarn comprises more virgin cotton than recycled cotton. In certain cases, the cotton content of the weft yarn does not include recycled cotton. In other cases, the cotton content of the weft yarn contains about 1 wt %-about 15 wt % recycled cotton and about 55 wt %-about 97 wt % virgin cotton. In some embodiments, the warp yarn of such denim fabric comprises about 5 wt %-about 15 wt % recycled cotton fiber, about 82 wt %-about 92 wt % virgin cotton fiber, and about 1 wt %-about 5 wt % recycled para-aramid fiber. In some instances, the amount of recycled para-aramid fiber is about 3 wt %.

Additional embodiments of the invention are provided below.

1. A spun yarn comprising from about 1 wt % to about 30 wt % recycled para-aramid fiber, from about 5 wt % to about 60 wt % recycled cotton fiber, and from about 10 wt % to about 94 wt % virgin cotton fiber.

2. The spun yarn of claim 1, wherein the recycled para-aramid fiber is from about 3 wt % to about 5 wt %.

3. The spun yarn of claim 1 or 2, wherein said recycled para-aramid fiber is a poly-paraphenylene terephthalamide fiber.

4. The spun yarn of any one of claims 1 to 3, wherein the recycled cotton fiber is from about 5 wt % to about 15 wt % and the virgin cotton fiber is from 82 wt % to about 92 wt %.

5. The spun yarn of any one of claims 1 to 4, wherein the spun yarn has a tensile strength substantially similar to or higher than spun yarn of about 100 wt % cotton.

6. The spun yarn of any one of claims 1 to 5, wherein the recycled para-aramid fiber comprises a plurality of staple fibers having a length substantially similar to or shorter than those of virgin para-aramid fiber.

7. The spun yarn of any one of claims 1 to 6, wherein the recycled cotton fiber comprises a plurality of staple fibers having a length substantially similar to or shorter than those of virgin cotton fiber.

8. A core spun yarn comprising (i) a core yarn comprising a filament yarn, and (ii) a wrap yarn comprising from about 1 wt % to about 30 wt % recycled para-aramid fiber, from about 5 wt % to about 60 wt % recycled cotton fiber, and from about 10 wt % to about 94 wt % virgin cotton fiber.

9. The core spun yarn of claim 8, wherein the filament yarn is elastomeric fiber.

10. The core spun yarn of claim 9, wherein the elastomeric fiber comprises an elastane fiber.

11. The core spun yarn of any one of claims 8 to 10, wherein the recycled para-aramid fiber is from about 3 wt % to about 5 wt % of the wrap yarn.

12. The spun yarn of any one of claims 8 to 11, wherein the recycled para-aramid fiber is a poly-paraphenylene terephthalamide fiber.

13. The core spun yarn of any one of claims 8 to 12, wherein the recycled cotton fiber is from about 5 wt % to about 15 wt % and the virgin cotton fiber is from about 82 wt % to about 92 wt % of the wrap yarn.

14. The core spun yarn of any one of claims 8 to 13, wherein the recycled para-aramid fiber comprises a plurality of staple fibers having a length substantially similar to or shorter than those of virgin para-aramid fiber.

15. The core spun yarn of any one of claims 8 to 14, wherein the recycled cotton fiber comprises a plurality of staple fibers having a length substantially similar to or shorter than those of virgin cotton fiber.

16. The core spun yarn of any one of claims 8 to 15, wherein the core spun yarn has a tensile strength substantially similar to or higher than core spun yarn comprising cotton fiber.

17. A core spun yarn comprising (i) a core yarn comprising about 1 wt % to about 30 wt % recycled para-aramid fiber, from about 5 wt % to about 60 wt % recycled cotton fiber, and from about 10 wt % to about 94 wt % virgin cotton fiber, and (ii) a wrap yarn comprising a filament yarn.

18. The core spun yarn of claim 17, wherein the filament yarn is elastomeric fiber.

19. The core spun yarn of claim 18, wherein the elastomeric fiber comprises an elastane fiber.

20. The core spun yarn of any one of claims 17 to 19, wherein the recycled para-aramid fiber is from about 3 wt % to about 5 wt % of the core yarn.

21. The spun yarn of any one of claims 17 to 20, wherein the recycled para-aramid fiber is a poly-paraphenylene terephthalamide fiber.

22. The core spun yarn of any one of claims 17 to 21, wherein the recycled cotton fiber is from about 5 wt % to about 15 wt % and the virgin cotton fiber is from about 82 wt % to about 92 wt % of the core yarn.

23. The core spun yarn of any one of claims 17 to 22, wherein the recycled para-aramid fiber comprises a plurality of staple fibers having a length substantially similar to or shorter than those of virgin para-aramid fiber.

24. The core spun yarn of any one of claims 17 to 23, wherein the recycled cotton fiber comprises a plurality of staple fibers having a length substantially similar to or shorter than those of virgin cotton fiber.

25. The core spun yarn of any one of claims 17 to 24, wherein the core spun yarn has a tensile strength substantially similar to or higher than core spun yarn comprising cotton fiber.

26. A denim fabric comprising weft yarn comprising the spun yarn of any one of claims 1 to 7 or the core spun yarn of any one of claims 8 to 25.

27. The denim fabric of claim 26, further comprising warp yarn comprising one or more textile fibers selected from the group consisting of recycled para-aramid fiber, recycled cotton fiber, and virgin cotton fiber.

28. The denim fabric of claim 27, wherein said warp yarn comprises virgin cotton fiber.

29. The denim fabric of claim 27 or 28, wherein said warp yarn comprises recycled para-aramid fiber and recycled cotton fiber.

30. The denim fabric of any one of claims 27 to 29, wherein the warp yarn further comprises one or more textile fibers selected from the group consisting of polyester fiber, nylon fiber, cellulosic fiber, elastomeric fiber, and a combination thereof.

31. The denim fabric of claim 28, wherein said warp yarn comprises from about 1 wt % to about 30 wt % recycled para-aramid fiber, from about 5 wt % to about 60 wt % recycled cotton fiber, and from about 10 wt % to about 94 wt % virgin cotton fiber.

32. The denim fabric of any one of claims 26 to 29, wherein the denim fabric has a higher tear strength compared to a denim fabric of about 100 wt % cotton.

33. The denim fabric of claim 32, wherein the tear strength is at least about 2-fold higher compared to a denim fabric of about 100 wt % cotton.

34. The denim fabric of any one of claims 26 to 33, having a twill weave with a yarn count of 7-10 or lower.

35. The denim fabric of any one of claims 26 to 33, having a twill weave with a yarn count of higher than 7-10.

36. A denim fabric comprising warp yarn comprising the spun yarn of any one of claims 1 to 7 or the core spun yarn of any one of claims 8 to 25.

37. The denim fabric of claim 36, further comprising weft yarn comprising one or more textile fibers selected from the group consisting of recycled para-aramid fiber, recycled cotton fiber, and virgin cotton fiber.

38. The denim fabric of claim 37, wherein the weft yarn comprises virgin cotton fiber.

39. The denim fabric of claim 37 or 38, wherein the weft yarn comprises recycled para-aramid fiber and recycled cotton fiber.

40. The denim fabric of any one of claims 37 to 39, wherein the weft yarn further comprises one or more textile fibers selected from the group consisting of polyester fiber, nylon fiber, cellulosic fiber, elastomeric fiber, and a combination thereof.

41. The denim fabric of claim 39, wherein the weft yarn comprises from about 1 wt % to about 30 wt % recycled para-aramid fiber, from about 5 wt % to about 60 wt % recycled cotton fiber, and from about 10 wt % to about 94 wt % virgin cotton fiber.

42. The denim fabric of claim 40, wherein said weft yarn comprises virgin cotton fiber and elastomeric fiber.

43. The denim fabric of any one of claims 36 to 42, wherein the denim fabric has a higher tear strength compared to a denim fabric of 100 wt % cotton.

44. The denim fabric of claim 43, wherein the tear strength is at least 2-fold higher compared to a denim fabric of 100 wt % cotton.

45. The denim fabric of any one of claims 36 to 44, having a twill weave with a yarn count of 7-10 or lower.

46. The denim fabric of any one of claims 36 to 44, having a twill weave with a yarn count of higher than 7-10.

47. A garment comprising a denim fabric comprising a twill weave comprising warp yarn and weft yarn, wherein the warp yarn comprises: (i) a spun yarn comprising from about 1 wt % to about 30 wt % recycled para-aramid fiber, about 5 wt % to about 60 wt % recycled cotton fiber, and about 10 wt % to about 94 wt % virgin cotton fiber; (ii) a first core spun yarn comprising a first filament yarn comprising elastomeric fiber and a first wrap yarn comprising about 1 wt % to about 30 wt % recycled para-aramid fiber, about 5 wt % to about 60 wt % recycled cotton fiber, and about 10 wt % to about 94 wt % virgin cotton fiber; (iii) a second core spun yarn comprising a second filament yarn comprising about 1 wt % to about 30 wt % recycled para-aramid fiber, about 5 wt % to about 60 wt % recycled cotton fiber, and about 10 wt % to about 94 wt % virgin cotton fiber and a second wrap yarn comprising a second filament yarn comprising elastomeric fiber; or (iv) a yarn comprising one or more textile fibers selected from the group consisting of recycled cotton fiber, virgin cotton fiber, polyester fiber, nylon fiber, cellulosic fiber, elastomeric fiber, and a combination thereof, and wherein the weft yarn comprises: (i) a spun yarn comprising from about 1 wt % to about 30 wt % recycled para-aramid fiber, about 5 wt % to about 60 wt % recycled cotton fiber, and about 10 wt % to about 94 wt % virgin cotton fiber; (ii) a first core spun yarn comprising a first filament yarn comprising elastomeric fiber and a first wrap yarn comprising about 1 wt % to about 30 wt % recycled para-aramid fiber, about 5 wt % to about 60 wt % recycled cotton fiber, and about 10 wt % to about 94 wt % virgin cotton fiber; (iii) a second core spun yarn comprising a second filament yarn comprising about 1 wt % to about 30 wt % recycled para-aramid fiber, about 5 wt % to about 60 wt % recycled cotton fiber, and about 10 wt % to about 94 wt % virgin cotton fiber and a second wrap yarn comprising a second filament yarn comprising elastomeric fiber; or (iv) a yarn comprising one or more textile fibers selected from the group consisting of recycled cotton fiber, virgin cotton fiber, polyester fiber, nylon fiber, cellulosic fiber, elastomeric fiber, and a combination thereof.

48. The garment of claim 47, wherein the spun yarn of the weft yarn comprises about 3 wt % to about 5 wt % recycled para-aramid fiber, about 5 wt % to about 15 wt % recycled cotton fiber, and about 82 wt % to about 92 wt % virgin cotton fiber; the first wrap yarn of said first core spun yarn of the weft yarn comprising about 3 wt % to about 5 wt % recycled para-aramid fiber, about 5 wt % to about 15 wt % recycled cotton fiber, and about 82 wt % to about 92 wt % virgin cotton fiber; the second filament yarn of said second core spun yarn of the weft yarn comprises about 3 wt % to about 5 wt % recycled para-aramid fiber, about 5 wt % to about 15 wt % recycled cotton fiber, and about 82 wt % to about 92 wt % virgin cotton fiber; or said yarn of the weft yarn comprises a core spun yarn comprising a filament yarn comprising elastomeric fiber and a wrap yarn comprising virgin cotton fiber.

49. The garment of claim 47 or 48, wherein the spun yarn of the warp yarn comprises about 3 wt % to about 5 wt % recycled para-aramid fiber, about 5 wt % to about 15 wt % recycled cotton fiber, and about 82 wt % to about 92 wt % virgin cotton fiber; the first wrap yarn of the first core spun yarn of the warp yarn comprises about 3 wt % to about 5 wt % recycled para-aramid fiber, about 5 wt % to about 15 wt % recycled cotton fiber, and about 82 wt % to about 92 wt % virgin cotton fiber; said second filament yarn of the second core spun yarn of the warp yarn comprises about 3 wt % to about 5 wt % recycled para-aramid fiber, about 5 wt % to about 15 wt % recycled cotton fiber, and about 82 wt % to about 92 wt % virgin cotton fiber; or the yarn of said warp yarn comprises a core spun yarn comprising a filament yarn comprising elastomeric fiber and a wrap yarn comprising virgin cotton fiber.

50. The garment of any one of claims 47 to 49, wherein the garment is selected from the group consisting of a jacket, jeans, shorts, a shirt, overalls, a romper, a skirt, and a dress.

All cited references are herein expressly incorporated by reference in their entirety.

EXAMPLES
Example 1: Denim Fabrics Made of Recycled Cotton and Recycled Para-Aramid

This example illustrates that denim fabrics containing recycled cotton and 3% recycled para-aramid have increased breaking strength, tear strength, and abrasion resistance compared to denim fabric containing 100 wt % virgin cotton.

In the study, the breaking strength and tear strength of denim samples were tested. The denim samples were treated using one of the following conditions: (A) rinse wash; (B) edge damage (delicate)+bioenzyme treatment for 20 minutes; (C) whiskering and shaving+bioenzyme treatment for 40 minutes; and (D) whiskering and shaving+bioenzyme treatment for 60 minutes+chlorine bleach treatment.

Breaking strength was evaluated using a standard test method (ASTM D 5034) for determining breaking strength of textile fabrics (grab method). Briefly, a rectangular shaped fabric is loaded into the clamps or grips of the standard test equipment with the longer dimension parallel to the direction to be tested. Then, the clamps or grips were separated at a specified rate until the end of the test which is when the fabric breaks or ruptures. The breaking force or strength represents the average force required to break or rupture the sample.

Breaking strength was evaluated using a standard test method (ASTM D 1424) for tear strength of fabrics by falling-pendulum type apparatus. Briefly, the test method was useful for determining the force needed to produce a single-rip tear starting from a cut in a fabric and using a falling-pendulum type (Elmendorf-type) apparatus. The tear strength represents the force required to propagate a tear to a preset length after its initial cut. In some cases, the initial cut or slit was centrally located in the test fabric and held between two clamps or grips.

Table 1 shows the breaking strength and tear strength of denim samples containing 97% recycled cotton and 3% recycled para-aramid. These samples were treated according to conditions A-D.

TABLE 1

Breaking Strength and Tear Strength of 97% Recycled

Cotton and 3% Recycled Para-Aramid Denim

Condition A
Condition B
Condition C
Condition D

Breaking strength (ASTM D 5034, Grab Method)

Warp (lbf)
236
203
172
167

Weft (lbf)
223
211
201
155

Tear strength (ASTM D 14244, Falling-Pendulum Method)

Warp (lbf)
19.3
17.8
10.5
9.2

Weft (lbf)
24.3
23.6
23.0
14.2

Table 2 shows the breaking strength and tear strength of denim samples containing 100 wt % virgin cotton. These samples were treated according to conditions A-D.

TABLE 2

Breaking Strength and Tear Strength

of 100 wt % Virgin Cotton Denim

Condition A
Condition B
Condition C
Condition D

Breaking strength (ASTM D 5034, Grab Method)

Warp (lbf)
260
233
156
136

Weft (lbf)
180
155
130
134

Tear strength (ASTM D 14244, Falling-Pendulum Method)

Warp (lbf)
17.4
16.4
14.4
9.3

Weft (lbf)
12.8
10.8
9.5
8.4

The denim sample containing recycled cotton and recycled para-aramid exhibited an at least two-fold increase in tear strength. For instance, the tear strength of weft yarns treated under condition B was 10.8 lbf for the 100 wt % virgin cotton denim and 23.6 lbf for the denim containing recycled para-aramid (Tables 1 and 2). Also, the tear strength of weft yarns treated under condition C was 9.5 lbf for the 100 wt % virgin cotton denim and 23.0 lbf for the denim containing recycled para-aramid (Tables 1 and 2). The break strength of the weft yarn of the denim containing recycled para-aramid was higher than the virgin cotton denim. Break strength of the warp yarn was also higher for most conditions test.

Denim made of core spun yarn comprising 3% recycled para-aramid, recycled cotton, and spandex was also tested.

Table 3 shows the breaking strength and tear strength of denim samples containing 3% para-aramid, recycled cotton, and an elastic material (e.g., elastane or spandex). These samples were treated according to conditions A-D.

TABLE 3

Breaking Strength and Tear Strength of Denim Containing

Stretch Cotton and 3% Recycled Para-Aramid.

Condition A
Condition B
Condition C
Condition D

Breaking strength (ASTM D 5034, Grab Method)

Warp (lbf)
264
237
179
142

Weft (lbf)
133
123
114
85.1

Tear strength (ASTM D 14244, Falling-Pendulum Method)

Warp (lbf)
22.7
22.0
15.6
15.8

Weft (lbf)
22.2
20.6
18.0
9.3

Table 4 shows the breaking strength and tear strength of denim samples containing recycled cotton, and an elastic material (e.g., elastane or spandex). These samples were treated according to conditions A-D.

TABLE 4

Breaking Strength and Tear Strength

of Denim Containing Stretch Cotton.

Condition A
Condition B
Condition C
Condition D

Breaking strength (ASTM D 5034, Grab Method)

Warp (lbf)
260
237
190
145

Weft (lbf)
99.9
89.2
78.3
89.0

Tear strength (ASTM D 14244, Falling-Pendulum Method)

Warp (lbf)
22.0
21.4
10.3
10.5

Weft (lbf)
9.8
8.3
7.8
7.2

The results in Tables 3 and 4 show that the denim containing the recycled para-aramid and stretch cotton exhibited increased breaking strength and tear strength of the warp yarn and weft yarn compared to denim containing 100 wt % virgin cotton.

The abrasion resistance of the denim samples was also tested. As described above, the denim samples were treated using one of the following conditions A-D. Abrasion resistance was evaluated using a standard test method (ASTM D 4966-2010) abrasion resistance of textile fabrics (Martindale abrasion tester method) with modifications. The pressing load was 9 kPa. The abradant was abrasive paper (P3000C-Cw). The endpoint was set at the point when a complete breakdown occurs of a minimum of two yarns. The test method was used for determining the resistance to abrasion upon subjecting the test fabric to rubbing motion in a straight line until it forms another straight line in the opposite direction under preset conditions of pressure (pressing load) and abrasive action. Abrasion resistance can be represented in terms of a number of cycles on a particular machine.

Table 5 shows abrasion resistance of selvedge denim samples of 97% recycled cotton and 3% para-aramid. These samples were treated according to conditions A-D, as described above.

TABLE 5

Abrasion Resistance of 97% Recycled Cotton

and 3% Recycled Para-aramid Denim.

Abrasion resistance (ASTM D 4966-2010)

Condi-
Condi-
Condi-
Condi-

tion A
tion B
tion C
tion D

Abrasion resistance (cycles
1200
1200
1100
950

Table 6 shows abrasion resistance of selvedge denim samples of 100 wt % virgin cotton. These samples were treated according to conditions A-D, as described above.

TABLE 6

Abrasion Resistance of Selvage Denim

Containing 100 wt % Virgin Cotton.

Abrasion resistance (ASTM D 4966-2010)

Condi-
Condi-
Condi-
Condi-

tion A
tion B
tion C
tion D

Abrasion resistance (cycles)
1150
950
1000
900

The results in Tables 5 and 6 show that selvedge denim containing recycled para-aramid has higher abrasion resistance compared to selvedge denim containing virgin cotton.

While exemplary embodiments of the present invention have been shown and described herein, it will be obvious to those skilled in the art that such embodiments are provided by way of example only. Numerous variations, changes, and substitutions will now occur to those skilled in the art without departing from the invention. It should be understood that various alternatives to the embodiments of the invention described herein may be employed in practicing the invention. It is intended that the following claims define the scope of the invention and that methods and structures within the scope of these claims and their equivalents be covered thereby.

YARN FORMED FROM RECYCLED COTTON AND RECYCLED PARA-ARAMID, AND FABRICS MADE THEREFROM

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