U.S. patent application number 09/867447 was filed with the patent office on 2001-10-04 for apparent space-dyed yarns and method for producing same.
Invention is credited to Belcher, Arnold L. JR., Rasnick, Lawrence E. JR..
Application Number | 20010025405 09/867447 |
Document ID | / |
Family ID | 23759612 |
Filed Date | 2001-10-04 |
United States Patent
Application |
20010025405 |
Kind Code |
A1 |
Rasnick, Lawrence E. JR. ;
et al. |
October 4, 2001 |
Apparent space-dyed yarns and method for producing same
Abstract
A process for combining single color feed yarns, either dyed or
melt pigmented, without twisting or heat-setting, to form an
apparent space-dyed yarn product. The process includes the
sequential steps of individually and simultaneously drawing two or
more pre-spun, pre-colored singles yarns, at least one of which is
differentially colored with respect to the other yarns;
individually and simultaneously texturing the two or more yarns;
individually and simultaneously entangling the two or more textured
yarns in a first air-jet entangling process to form respective two
or more entangle-sequenced yarns each having sequences of entangled
and unentangled fibers; together air-jet entangling the two or more
sequences of entangled and unentangled fiber yarns in a second
air-jet entangling process to form a final apparent space-dyed
yarn; and winding up the final apparent space-dyed yarn.
Inventors: |
Rasnick, Lawrence E. JR.;
(Bristol, VA) ; Belcher, Arnold L. JR.; (Bristol,
TN) |
Correspondence
Address: |
John C. Kerins
MILES & STOCKBRIDGE P.C.
Suite 500
1751 Pinnacle Drive
McLean
VA
22102-3833
US
|
Family ID: |
23759612 |
Appl. No.: |
09/867447 |
Filed: |
May 31, 2001 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
09867447 |
May 31, 2001 |
|
|
|
09443147 |
Nov 18, 1999 |
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Current U.S.
Class: |
28/258 ; 28/248;
428/369 |
Current CPC
Class: |
D02G 1/161 20130101;
D02J 11/00 20130101; D02G 1/20 20130101; D02J 1/08 20130101; Y10T
428/2922 20150115 |
Class at
Publication: |
28/258 ; 28/248;
428/369 |
International
Class: |
D02J 011/00 |
Claims
What is claimed is:
1. A process for producing apparent space-dyed bulked continuous
filament yarn comprising the sequential steps of: individually and
simultaneously drawing two or more pre-spun, pre-colored singles
yarns, at least one of said singles yarns being differentially
colored with respect to the other singles yarns; individually and
simultaneously texturing the two or more singles yarns;
individually and simultaneously entangling the two or more textured
singles yarns to form respective two or more entangle-sequenced
yarns each having fiber portions having sequences of entangled and
unentangled fibers; together entangling the two or more
entangle-sequenced yarns to form a final apparent space-dyed yarn;
and winding up the final apparent space-dyed yarn.
2. The process of claim 1 wherein said step of individually and
simultaneously drawing two or more pre-spun, pre-colored singles
yarns includes the step of unwinding said pre-spun, undrawn, yarns
from storage bobbins.
3. The process of claim 1 wherein the step of individually and
simultaneously entangling the two or more textured singles yarns
comprises: controlling at least one first nozzle assembly by
providing to said at least one first nozzle a first pressurized air
setting of a repeating on-off sequence; and the step of together
entangling the two or more entangle-sequenced yarns comprises:
controlling a second nozzle assembly by providing to said second
nozzle assembly a second pressurized air setting of a repeating
pressure sequence of high and low pressure, wherein said second
pressurized air setting is timed such that the second nozzle
assembly is at a high pressure when the at least one first nozzle
is on, and at a low pressure when the at least one first nozzle is
off.
4. The process of claim 1 wherein the repeating on-off sequence is
a repeating sequence of 0.3 seconds on and 0.3 seconds off.
5. The process of claim 1 wherein the repeating pressure sequence
is a repeating sequence of 0.3 seconds high pressure and 0.3
seconds low pressure.
6. The process of claim 1 wherein the step of individually and
simultaneously texturing the two or more singles yarns comprises
individually mechanically texturing said two or more singles
yarns.
7. The process of claim 1 further comprising a singles yarn feed
rate of up to 1000 m/min and an entanglement spacing arranged to
cause colors of the two or more entangled textured singles yarns to
be distinctly visibly spaced.
8. The process of claim 7, wherein said singles yarn feed rate is
400-600 m/min.
9. The process of claim 1 wherein said step of individually and
simultaneously drawing two or more pre-spun, pre-colored singles
yarns further comprises a draw ratio of about 2.9:1 to about
3.6:1.
10. An apparatus for making apparent space-dyed bulked continuous
filament yarn from at least two separate yarns of different color,
comprising, in a single production line separate from a yarn
spinning apparatus, a drawing device for drawing said at least two
yarns at a predetermined draw ratio; a texturing device for
individually and simultaneously texturing the at least two yarns to
obtain two or more respective textured yarns; a first set of
entanglers for individually and simultaneously entangling the at
least two respective textured yarns to obtain at least two
respective entangle-sequenced yarns each including sequences of
entangled and unentangled fibers; second stage entangler for
together entangling the at least two respective entangle-sequenced
yarns to obtain a final apparent space-dyed yarn including
sequences of entangled and unentangled fibers; and a programmable
controller operably connected to said first set of entanglers and
said second stage entangler, and being so constructed and arranged
to individually control the timing and degree of fiber entanglement
of yarn operatively processed by said each entanglers.
11. The apparatus of claim 10 wherein said programmable controller
comprises: a control for controlling said first set of entanglers
by providing to said first set of entanglers a first pressurized
air setting of a repeating on-off sequence; and a control for
controlling said second stage entangler by providing to said second
stage of entangler a second pressurized air setting of a repeating
sequence of high pressure and low pressure, wherein said second
pressurized air setting is timed such that the second stage
entangler is at a high pressure when said first set of entanglers
is on, and at a low pressure when said first set of entanglers is
off.
12. The apparatus of claim 10 wherein said texturing device is a
mechancal crimper texturing device.
13. The apparatus of claim 10 further comprises a feed rate control
for controlling a singles yarn feed rate of up to 1000 m/min.
14. The apparatus of claim 13 wherein said feed rate control
operates to control said singles yarn feed rate in a range of about
400-600 m/min.
15. A non-twisted, non-heat set, continuous filament apparent
space-dyed yarn product capable of having a pixel color effect,
comprising at least a first and a second singles yarn, said first
singles yarn having a different color than said second singles
yarn, said first and said second singles yarns being individually
textured and being individually entangled to include first spaced
apart nodes after being individually textured, and, after being
individually entangled, being together entangled to include second
spaced apart nodes to obtain said apparent space-dyed effect.
16. The continuous filament apparent space-dyed yarn product of
claim 15, wherein said texturing of said at least a first and a
second singles yarns is a mechanical crimp.
17. The continuous filament apparent space-dyed yarn product of
claim 15, wherein said first and second spaced apart nodes are
formed as a result of individually and independently programmably
controlled node position, frequency, randomness, and tightness.
18. The continuous filament apparent space-dyed yarn product of
claim 15, wherein said at least two differently colored or
colorable yarns comprise spinnable polymers.
19. The continuous filament apparent space-dyed yarn product of
claim 15, wherein said spinnable polymer is colored by melt
pigmentation.
20. The continuous filament apparent space-dyed yarn product of
claim 15, wherein said spinnable polymer is a reclaimed
polymer.
21. The continuous filament apparent space-dyed yarn product of
claim 20, wherein said reclaimed polymer is reclaimed from a member
of the group consisting of: reclaimed fiber, reclaimed fabric,
reclaimed plastic scrap, and combinations thereof.
Description
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to bulked continuous filament
(BCF) bundled yarns, and, more particularly, to bulked continuous
filament bundled yarns made from differently colored singles yarns
wherein the bundled yarns are capable of providing space-dyed
effects in tufted floor coverings.
[0003] 2. Description of Related Art
[0004] As used herein, certain terms have the meanings ascribed to
them as follows:
[0005] The terms "thread" and "filament" are intended to connote
single filament fibers, whereas "singles yarn" or "strand" is an
assembly of two or more threads or filaments.
[0006] The term "node" is intended to mean relatively compact,
tangled sections of a yarn that are separated by relatively bulky
or unentangled sections.
[0007] The term "entangling" is intended to mean the mixing of
fiber components to an extent that the individual components cohere
to one another, where "cohere" means to stick or hold together in a
visually identifiable and distinguishable mass, an example of which
is the above-mentioned "node". Entangling includes directing a flow
of fluid, such as air, against a moving plurality of strands
transversely of the direction of movement of the strands. The
resulting dislocation of the strands leads to a knot-like
intertwining and entangling of the strands. The term "air-jet
entangler" is a device which achieves an entangled yarn by
co-mingling the components of the yarn.
[0008] A "texturing process" causes a permanent departure from the
original longitudinal shape of the filament, for example, by
causing the filament to be crimped, or to have some degree of
curved or angular change along its length. One example of a
texturing process employs a chamber in which a yarn is moved at
high speed through a flow of heated gas or vapor, i.e., hot air or
steam. Alternatively, heated or unheated yarn may be moved at high
speed through a mechanical crimping process. In either arrangement,
the fiber is then bulked by collision with a surface which, for
practical purposes, may be the wad or plug formed by the yarn
itself. As a consequence, individual yarns deposit themselves in a
regularly bent configuration on an impact surface, and because of
heat-induced effects, the yarns to some degree retain this curved
or angular configuration. In the embodiment in which the fiber is
heated with air, the crimped fiber configuration is made permanent
by a cooling process, without permitting portions of the yarn to
adhere, or be connected, to each other.
[0009] Singles yarns may be combined into plied yarns in several
ways that usually involve the use of texturing of filaments
followed by air-jet entangling. For example, three separate singles
yarns can be combined into a final BCF product. The process may be
a "one-step" or "two-step" process. The one-step process begins
with forming the spun filaments making up the yarns and continues
through all subsequent steps to winding of the final product,
without interim spooling. In known two-step processes, the spun
yarns are wound up after the first step of spinning, drawing, and
texturing. The second step typically involves unwinding the yarn
from a storage spool, which includes precision tension control
before commencing the entangling step.
[0010] Both the one-step and two-step processes often employ a
number of known steps, however, various permutations of those
steps, together with uniquely selected parameter settings,
determine which of a wide variety of results are achieved, in terms
of filament and yarn configuration, and/or in terms of the
appearance and performance of the ultimate product produced using
such yarns. A specific sequence of process steps, along with a
corresponding selection of process parameters, such as temperature,
yarn tension, and other particulars, can determine a unique and
possibly unforeseeable result, in terms of yarn specifications and
functional and appearance qualities of a carpet made from the
yarn.
[0011] One particular BCF yarn product is a space-dyed yarn, which
has repeated, random or regular, intense bands of different colors
along its length, which provide unique accent styling, primarily,
but not exclusively, in tufted floor coverings, such as carpets.
Such carpet products are normally manufactured by post-coloring of
uncolored spun yarns with dyestuffs in an intermittent, regular or
random, fashion. The yarns are then (ply)twisted and heat set. An
example of such methods may be found in U.S. Pat. No. 4,153,961.
Such yarns, when fully processed into carpet face yarns, exhibit
pinpoints or larger "pixels" of different colors against a more
mixed background shading. Depending on the regularity of spacing
between colors, and the length of the different colors present in
the yarns, the carpet can also feature a wider repeat patterning of
areas of single perceived shade and areas of pinpoints of bright
colors against a background of the single perceived shade.
[0012] Such effects are, to a large extent, different from those
achieved with so-called "heather" yarns. Heather yarns, while also
containing different colors, are mixed in such a way during
processing that no one color predominates, and a single shade is
perceived in carpeting made from such yarns, except on very close
inspection. A heather appearance includes small points of
individual color, i.e., color points, randomly distributed
throughout a matrix of contrasting colors. In contrast to processes
for making space-dyed yarn products, processes for making heather
yarns are formulated to prevent the formation of any directional
carpet appearance or patterns, such as streaks and chevrons in the
finished product.
[0013] In order to eliminate the complex dyeing processes used to
manufacture "true" space-dyed yarns, attempts have been made to
utilize yarns which have been pre-colored in single colors, either
by dyeing or by melt pigmentation. Such pre-colored singles yarns
have been combined, in groups of two or more, with at least one
group being of a different color than the others, to provide final
yarns with a variety of coloring effects. The specific sequence of
the process steps is as important as the selected steps,
themselves. Such yarn products are referred to as "apparent
space-dyed yarns" as their effects in a tufted product make them
appear to be space-dyed yarns.
[0014] U.S. Pat. No. 5,804,115 discloses a one-step process for
producing an apparent space-dyed yarn, made by sequentially
spinning two or more strands having two or more colors, forming two
or more yarn fractions from the strands, independently texturing
and entangling at least one of the yarn fractions, and then
together entangling all of the yarn fractions. This arrangement
suffers from restrictions on process control flexibility, because
it is performed as a one-step process. In a one-step process,
fibers are spun at a minimum viable rate, e.g., 500 m/min., which,
at a conventional 3:1 draw ratio, results in a downstream feed rate
of 1500 m/min. At this rate, a desired level of precision in the
downstream processing, in particular, in the air-jet entangling,
cannot be attained. As a result, the space-dye effect of the yarn
product when tufted into carpet is not as pronounced or as crisp as
it otherwise might be.
[0015] The above process and products are, to varying degrees,
unsatisfactory in terms of complexity, and/or their inability to
provide the range of effects required to simulate true space-dyed
yarns. Thus, there remains a need for a process for producing a
simple, effective, product yarn series which can match all of the
effects possible using true space-dyed yarns, and to produce other
unique effects not possible by other means.
SUMMARY OF THE INVENTION
[0016] The present invention provides a process for combining a
plurality of single color feed yarns, either dyed or melt
pigmented, without twisting or heat-setting, to form an apparent
space-dyed yarn product which closely approaches the aesthetic and
design requirements of a true space-dyed yarn. Advantageously, the
process preferably uses melt pigmented, also known as
solution-dyed, singles yarns, which have been found to offer
superior end-use performance, e.g., low color fade, and resistance
to harsh cleaning methods.
[0017] The present invention includes a process for making apparent
space-dyed bulked continuous filament yarn employing the sequential
steps of: (a) individually and simultaneously drawing two or more
pre-spun, pre-colored singles yarns, at least one of which is
differentially colored with respect to the other yarns; (b)
individually and simultaneously texturing the two or more yarns;
(c) individually and simultaneously air-jet entangling the two or
more textured yarns in a first air-jet entangling process to form
respective two or more entangle-sequenced yarns each having fiber
portions having segments of entangled and unentangled fibers; (d)
together air-jet entangling the two or more segments of entangled
and unentangled fiber yarns in a second air-jet entangling process
to form a final apparent space-dyed yarn; and (e) winding up the
final apparent space-dyed yarn.
[0018] The texturing step involves mechanically crimping the yarn
by moving the yarn at high speed through frictional rolls pressed
together, thereby forming a rectilinear, two dimensional zig-zag
pattern. Alternatively, the yarn may be moved through a flow of
heated gas or vapor, i.e., hot air or steam, to form a curvilinear
profile, after which the yarn is bulked by collision with a surface
which, for practical purposes, may be the wad or plug formed by the
strand itself.
[0019] The first air-jet entangling step includes, for each singles
yarn, a respective, individual entangler, which is arranged to
provide pre-determined patterns of on-off cycles of pressurized air
through jets, which results in segments of entangled and
unentangled fibers in the respective singles yarn. Each individual
jet in the first entangling process operates on the same, or
optionally, on a different timing sequence as the other jets, and
the sequences themselves may be even or uneven, i.e., the time-on
interval may be the same as, or different than, the time-off
interval.
[0020] The second airjet entangling step employs a further
entangler, and the entangling which is carried out on the final,
combined yarn, is also programmably controlled, and operates under
the same, or, optionally, a different, timing sequence as that of
the first set of air-jet entanglers.
[0021] According to the present invention, the timing sequence
control of the first and second air-jet entangling processes
preferably is electronically programmed in such a manner as to
controllably entangle the drawn and textured singles yarns in an
intermittent, regular or random, fashion. This makes possible the
manufacture of a wide range of color effects in the final yarn
product. This method for processing multicolored yarn produces a
yarn which effectively duplicates all effects possible with
traditional space-dyed yarns, and does so with a limited palette of
colors. Moreover, the process of the invention offers unique
styling possibilities not available by any other means.
[0022] Other aspects of the yarn processing sequence, including
drawing, texturing and winding, utilize equipment and techniques
for such processes which are known to those skilled in the art.
[0023] Therefore, it is a principal object of the present invention
to provide an apparatus and process to produce a yarn product that
can duplicate all effects possible with true space-dyed yarns.
[0024] A further principal object of the present invention is to
provide a process for making apparent space-dyed yarn that features
sequences of "heather" type mixed color, along with sequences where
selected colors are each separately visible on turning the yarn,
whereby, when tufted into a carpet, the perceived color effect is
comparable to that provided by true space-dyed yarns in such carpet
products.
[0025] It is a further object to provide a process for making
apparent space-dyed yarn which can be used to provide a broad range
of potential effects, using only a limited palette of colors.
[0026] Still another object of the present invention is to provide
a process for making apparent space-dyed yarn that offers unique
styling possibilities not available by other processing means.
[0027] Another object of the present invention is to provide a
process for making apparent space-dyed yarn which uses melt
pigmented singles yarns.
[0028] Another object of the present invention is to provide a
process for making a ready-to-tuft apparent space-dyed yarn that
does not include the steps of twisting or heat-setting.
[0029] Another object of the present invention is to provide a
process for making apparent space-dyed yarn wherein the process
involves selectable control of node position Nov. 10, 1999,
frequency, randomness, and tightness.
[0030] Other objects and benefits of the present invention will
become apparent from the following written description and
accompanying figures.
BRIEF DESCRIPTION OF THE DRAWINGS
[0031] The above and other features of the present invention and
the attendant advantages will be readily apparent to those having
ordinary skill in the art and the invention will be more easily
understood from the following detailed description of the preferred
embodiments of the present invention, taken in conjunction with the
accompanying drawings, in which like reference numerals refer to
like parts throughout the several views.
[0032] FIG. 1 is a block diagram representing a two-step process
according to a preferred embodiment of the present invention.
[0033] FIG. 2 schematically illustrates an apparatus employing
texturing by mechanical crimping according to a preferred
embodiment of the present invention
[0034] FIG. 3 schematically illustrates an apparatus employing
texturing by air-jet crimping according to an alternative preferred
embodiment of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0035] FIG. 1 is a block diagram representing a two-step process
100, for producing apparent space-dyed yarn according to a
preferred embodiment of the present invention. The process includes
processing steps for two individual singles yarns 110, 111,
although it will readily be recognized that more than two singles
yarns will generally be employed in the process. Since each singles
yarn is produced and further processed by the same processing
steps, it is sufficient to illustrate the processing of two
yarns.
[0036] In process 100, singles yarns 110, 111 are individually spun
in a known manner, preferably in a known solution-dyed melt
spinning process, according to any desired spinning schedule. The
yarns produced are wound on a storage bobbin or package in an
undrawn state. In a second discrete stage or step of the process,
singles yarns 110, 111, are individually and simultaneously, but in
separate and substantially parallel relationship, processed through
sub-steps 116-120, and 117-121, respectively. Process 100 is
referred to as a two-step process because the spinning sub-step 112
to storage 114 constitutes a first step. The tension/draw sub-step
116, 117 begins a second, discrete stage or step by drawing a
singles yarn from a storage bobbin. Thereafter, the drawn yarns are
processed through texturing sub-step 118, 119 and an entangling
sub-step 120, 121. The singles yarns 110, 111 are combined at the
second entangling sub-step 122, thereby forming an apparent
space-dyed yarn, which is then wound up in sub-step 124.
[0037] FIG. 2 is a schematic representation of a preferred
apparatus of the present invention for performing the second stage
or step of the two-stage process 100, illustrated in FIG. 1. Feed
yarns A, B, and C represent, as a non-limiting example, two or more
pre-spun, pre-colored singles yarns, at least one of which is
differentially colored with respect to the other yarns. These
singles yarns may preferably be produced in a conventional melt
spinning process for producing solution dyed yarns. The yarns, at
the commencement of this second stage, are preferably in an undrawn
state. The yarns are guided from respective storage bobbins, which
preferably comprise tubes upon which undrawn yarn is wound, the
bobbins being positioned in a rack 2, and are passed to one or more
pretensioning and draw zones, which are configured according to any
known method, and which draw the yarn to a desired specification.
For example, singles yarns A, B, and C are individually and
simultaneously, but in separate and substantially parallel
relationship, guided by a grooved roller (not shown) into
pretensioning zone 40, which includes a multi-grooved pretensioning
godet 4. Optionally, a series of guide pins (not shown), each
possibly grooved, may also be used. The pretensioning godet 4
prevents slippage of the singles yarns A, B, and C on the draw
rolls and stabilizes yarn movement.
[0038] Each singles yarn A, B, and C is supplied to draw zone 42,
preferably in the same, separate, substantially parallel
relationship as existed in pretensioning zone 40. Draw zone 42 can
include any known arrangement of components, for example, two sets
of duos having temperature and tensioning presets. For example, the
first set of duos 6 heats each yarn. The second set of duos 8 moves
faster than the first set, and heats and draws the singles yarns A,
B, and C. By adjusting the relative speeds of the duos 6, 8, the
draw ratio of the yarns is established.
[0039] Because the drawer step is not directly coupled to the
spinning step in this process, there is fair greater flexibility in
establishing a desired draw ratio. In traditional processes in
which the fiber is spun, drawn and textured in a single first step
prior to being wound and stored, the draw ratio is generally
limited to a maximum of 3.0:1, primarily due to melt coloration and
additive effects on the process. In the process of the present
invention, the range of draw ratios attainable is in the range of
about 2.9:1 to about 3.6:1. As a result, the present process
permits the production of a much wider range of sizes of the
singles yarns, and permits the physical properties of the yarn,
such as tenacity and deformation recovery, to be produced in a much
broader range.
[0040] After exiting the stretching duos 8, the yarns A, B, and C
are subsequently cooled and individually and simultaneously
textured. This is accomplished by guiding the yarns to individual,
respective, texturing zones 10, 10', and 10". Texturing zones 10,
10', and 10" can employ any suitable equipment known in the art.
Although the texturing devices shown in FIG. 2 are singular
mechanical crimping devices, it should be understood that each
texturing device may include a multi-position assembly having
several different mechanical crimping devices, one of which would
be selected for a specific process. In the present exemplary
arrangement, because all of the texturing zones 10, 10', and 10"
operate identically and share identical features, only the features
of texturing device 10 are identified with reference numerals in
FIG. 2 and are discussed herein.
[0041] Typically, but not by way of limitation, texturing zone 10
includes a pair of warming rolls 12, a pair of mechanical crimper
rolls 14, and a stuffer box 16. The warming rolls 12 both pinch and
heat the yarn passing between them, thereby frictionally pulling
the yarn from draw zone 42. Warming rolls 12 each have an outer
surface maintained at a temperature sufficient to soften the yarn
as it passes between the rolls 12 at a preferred feed rate. A pair
of crimper rolls 14 are pressed together so as to frictionally pull
the yarn passing between them from the warming rolls 12. The outer
surface of each crimper roll 14 is configured to permanently deform
the yarn into a two dimensional zig-zag pattern.
[0042] Stuffer box 16 is configured to receive the yarn output from
the pair of crimper rolls 14 and to accumulate the yarn, thereby
providing a buffer between the texturing zone 10 and the succeeding
entangling step, which advantageously enables a respective singles
yarn to be subsequently processed at a carefully regulated yarn
tension and speed.
[0043] Respective tensioning rolls 20 pull the textured singles
yarns (now designated by reference numerals A', B', and C',
corresponding to singles yarns A, B, and C), from opening 18 of
respective stuffer box 16. Advantageously, a specific feed rate and
tension establishing an over-feed condition, with respect to the
first air-jet entangling nozzle 30, 30', 30", is established by a
cooperative relationship between tensioning rolls 20 located
upstream of the nozzle 30, 30', 30" and tensioning rolls 24 located
downstream of the nozzle 30, 30', 30". A feed rate of up to 1000
m/min is contemplated at this stage of the process, and, more
preferably, a feed rate of 400-600 m/min. is employed. The feed
rate of up to 1000 m/min provided by controller 25, in combination
with the timing of the programmably controlled air-jet entangler,
achieves the desired degree of relatively wide entanglement
spacing, while at the same time, resulting in a singles yarn that
remains structurally stable throughout the process of making
apparent space-dyed yarns. A yarn tension of 50-60 grams is
preferably established at the input 22 of the first air-jet
entangling nozzle 30, 30', 30", while a 200 gram tension is set at
the output 32 of the first air-jet entangling nozzle.
[0044] The singles yarns A', B', and C' are individually and
simultaneously subjected to intensive entangling nozzles 30, 30',
and 30", thereby forming respective entangle-sequenced yarns A", B"
and C". Each of the entangled yarns has sequences of entangled and
unentangled filaments. Each individual entangling nozzle is
connected to a programmable controller 34, which has electrical
connections P1, P2, and P3, which are connected to corresponding
connections P1', P2', and P3' at respective electronic regulators
36, 37 connected to respective entangling nozzles. Preferably, and
not by way of limitation, controller 34 is arranged to provide a
predetermined sequence of on-off cycles of pressurized air through
the entangling nozzles, which results in sequences of entangled and
unentangled fibers in the respective singles yarn. Each individual
jet in the first entangling process may operate on the same, or,
optionally, on a different timing sequence as the other jets, and
the sequences themselves may be even or uneven, i.e., the time-on
interval may be the same as, or different than, the time-off
interval. Preferably, the on-off cycles of pressurized air are set
to 0.3 seconds on, and 0.3 seconds off.
[0045] The entangle-sequenced yarns A", B" and C" are physically
brought together to form a combined yarn feed D. This may
preferably be accomplished by a pretensioning feed roller 38. The
combined yarn feed D is guided to the throat 40 of a yarn passage
42 within a single second air-jet entangling nozzle 44. Pressurized
air is introduced through passage 46, which is in fluid
communication with yarn passage 42, and the pressurized air impacts
yarn feed D, resulting in entanglement of the singles yarns A, B,
C.
[0046] The second air-jet entangling nozzle 44 is also programmably
controlled, and operates under the same, or optionally, a
different, timing sequence as that of the first set of air-jet
entangling nozzles 30, 30', and 30". Electrical connection P4 at
controller 34 is connected to connection P4' at entangling nozzle
44. Preferably, the air pressure fed to the second air-jet
entangling nozzle 44 is regulated between a first high pressure and
a second low pressure, each having a duration of 0.3 seconds.
Preferably, the first and second air-jet entangling nozzles are
timed such that the second air-jet entangling nozzle 44 is at a
high pressure when the first air-jet entangling nozzles 30, 30',
30" are on, and at a low pressure when the first air-jet entangling
nozzles 30, 30', 30" are off.
[0047] The second air-jet entangling nozzle 44 subjects the
combined yarn feed D to entangling, thereby forming a final
apparent space-dyed yarn D', having sequences of entangled and
unentangled portions of the previously sequentially entangled
singles yarns. The feed rate, in combination with the timing of the
air-jet entangler, determines the degree of entanglement spacing in
the final apparent space-dyed yarn D', and an optimal setting of
timing and feed rate causes colors of two or more entangled
textured singles yarns to be distinctly, visibly spaced. For a
given air-jet entangler pulse rate, too slow a feed rate results in
more entangling and a loss of color contrast in the final apparent
space-dyed yarn D'. As the feed rate becomes increasingly fast, the
color contrast becomes increasingly visibly distinct, but at some
point, the widely spaced pattern of entanglement results in a final
yarn D' having undesirable properties, such as, for example, poor
strength and aesthetic appearance. Therefore, a feed rate of up to
1000 m/min, and preferably 400-600 m/min., with an appropriate
air-jet entangler timing sequence, such as, for example, the
above-described timing sequence, has been found to achieve
desirable properties in the final yarn D'. In the last step, yarn
D' is advanced by a feed roller 48 and is guided to a package
winding fixture 50.
[0048] FIG. 3 is a schematic representation of apparatus according
to an alternative embodiment of the present invention, in which the
mechanical crimping device 10 shown in FIG. 2 is replaced by an
airjet texturing device 60. In FIG. 3, feed yarns A, B, and C
represent, as a non-limiting example, two or more pre-spun,
pre-colored singles yarns, at least one of which is differentially
colored with respect to the other yarns. The yarns are guided from
respective storage bobbins, which preferably comprise tubes upon
which undrawn yarn is wound, located in a rack 62 and passed to one
or more pretensioning and draw zones, which are configured
according to any known method, and which draw the yarn to a desired
specification. For example, singles yarns A, B, and C are
individually and simultaneously, but in separate and substantially
parallel relationship, guided by a grooved roller (not shown) into
pretensioning zone 64, which includes a multi-grooved pretensioning
godet 66. Optionally, a series of guide pins (not shown), each
possibly grooved, may also be used. The pretensioning godet 66
prevents slippage of the singles yarns A, B, and C on the draw
rolls and stabilizes yarn movement.
[0049] Each singles yarn A, B, and C is supplied to draw zone 68,
preferably in the same, separate, substantially parallel
relationship as existed in pretensioning zone 64. Draw zone 68 can
include any known arrangement of components, for example, two sets
of duos having temperature and tensioning presets. For example, the
first set of duos 70 heats each yarn. The second set of duos 72
moves faster than the first set, and heats and draws the singles
yarns A, B, and C. By adjusting the relative speeds of the duos 70,
72, the draw ratio of the yarns is established. As was the case
with the previous embodiment, draw ratios of up to 3.6:1 may
advantageously be selected for use.
[0050] After exiting the stretching duo 72, the yarns A, B, and C
are individually and simultaneously texturized. This is
accomplished by guiding the yarns to individual, respective,
air-jet texturing devices 60, 60', and 60".
[0051] The air-jet texturing devices shown in FIG. 3 are singular
devices, however, it should be understood that each texturing
device may include a multi-position manifold assembly having
several different texturing devices, one of which would be selected
for a specific process. In the present exemplary arrangement,
because all of the air-jet texturing devices 60, 60', and 60"
operate identically and share identical features, only the features
of texturing device 60 are identified with reference numerals in
FIG. 3 and are discussed herein. Typically, but not by way of
limitation, texturing device 60 includes an entrance portion 74 and
a yarn channel 76. The entrance portion 74 is supplied with a flow
of heated gas or vapor, such as hot air or steam. The embodiment
illustrated in FIG. 3 employs pressurized air provided from a
source thereof by way of a conduit 78. The pressurized air is
heated by a heater 80. The heated air is then blown into yarn
channel 76 by way of an annular channel 82 and injection channels
84, which are angled relative to the yarn channel 76 such that the
air injected into the yarn channel travels parallel to the
direction of yarn travel. This directed flow of pressurized air
operates to advance the singles yarns A, B, and C from the
stretching duo 72 into and through the yarn channel 76.
[0052] Yarn channel 76 is connected to a chamber 86, within which
the yarn is piled up, thereby forming a plug or wad. As is typical
of known chambers, movement of singles yarn A into chamber 86
causes the yarn to collide initially with end wall 88, and
subsequently with itself, thus forming bends and similar shapes,
called crimps. Because the singles yarn has been exposed to heated
air, the yarn is softened, these crimps will be substantially
permanent. The yarn plug or wad is subjected to heated airflow,
and, at a relatively slow rate, singles yarn A is pressed out of
chamber 86.
[0053] The textured singles yarns (now designated by reference
numerals A', B', and C', corresponding to singles yarns A, B, and
C) exit the respective chambers 86 through respective openings 90
and are then cooled by any known method, for example, by guiding
the yarns across the porous surfaces of rotating cooling drums 92.
The cooling drums 92 may be any suitable configuration presently
known in the art. For example, a vacuum drawn in the interior of
the cooling drum 92 can be used to cause ambient air to flow
through the yarn which contacts the porous outer surface of the
drum 92.
[0054] After cooling, the singles yarns A', B', and C' are
individually and simultaneously subjected to intensive entangling
by a plurality of first air-jet entangling nozzles 94, 94', and
94", thereby forming respective entangle-sequenced yarns A", B" and
C". Each of the entangled yarns has sequences of entangled and
unentangled fibers. Each individual entangling nozzle is connected
to a programmable controller 96, which has electrical connections
P1, P2, and P3, which are connected to corresponding connections
P1', P2', and P3', at respective entangling nozzles. Controller 96
is arranged to provide a pre-determined sequence of on-off cycles
of pressurized air through the entangling nozzles, which results in
sequences of entangled and unentangled fibers in the respective
singles yarn. Each individual jet in the first entangling process
may operate on the same, or, optionally, on a different timing
sequence as the other jets, and the sequences themselves may be
even or uneven, i.e., the time-on interval may be the same as, or
different than, the time-off interval.
[0055] The entangle-sequenced yarns A", B" and C" are combined
together to form a combined yarn feed D. This may preferably be
accomplished by a pretensioning feed roller 98. The combined yarn
feed D is guided to the throat 100 of a yarn passage 102 within a
single second air-jet entangling nozzle 104. Pressurized air is
introduced through passage 106, which is in fluid communication
with yarn passage 104, and the pressurized air impacts yarn feed D,
resulting in entanglement of the yarns making up yarn feed D.
[0056] The second air-jet entangling step is also programmably
controlled, and operates under the same, or optionally, a
different, timing sequence as that of the first set of air-jet
entanglers 94, 94', and 94". Electrical connection P4 at controller
96 is connected to connection P4' at entangling nozzle 104. The
second air-jet entangling nozzle 104 subjects the combined yarn
feed D to entangling, thereby forming a final apparent space-dyed
yarn D', having sequences of entangled and unentangled portions of
the previously sequentially entangled fibers. Finally, the apparent
space-dyed yarn D' is advanced by a feed roller 108 and is guided
to a package winding fixture 110.
COMPARATIVE EXAMPLE A
[0057] Five storage bobbins or packages of 1850/30Y (1850 denier,
30 filament, Y cross-section) sulfonated Nylon 66 yarn, each
solution dyed to a different color, were set up to be drawn,
textured and entangled in a discrete process. The yarns were taken
form the bobbins, and were individually drawn, over a standard
Godet apparatus, to provide five 600/30Y singles yarns. The drawn
yarns were then individually and simultaneously mechanically
textured and momentarily accumulated in a stuffer box. The textured
singles yarns were then fed to individual airjet entanglers
simultaneously, where each jet was programmed to provide the same
sequence of 0.3 sec. on /0.3 sec. off, resulting in evenly spaced,
long, sequences or sections of entangled and unentangled singles
yarn. The singles yarns were then entangled together in a second
entanglement stage using a single air-jet entangler programmed to
the same time sequence as those utilized in the first entanglement
stage. In this second entanglement, the jet was on when the first
jets were off, and off when the first jets were on. The resultant
yarn was then wound up. The wind-up speed was 600 m/min, with a
final yarn tension of 125 g. The resulting yarn exhibited highly
visible color pop when tufted into a carpet sample. The tufted
patterns achieved in this example have the same aesthetically
pleasing appearance as exhibited by known space dyed yarns.
[0058] Singles yarns for use in the final apparent space-dyed yarns
may be based on any spinnable polymer, and preferably
melt-spinnable polymers such as polyamides, polyesters, and
polyolefins. Representative polymers which would be particularly
well suited for use in this invention include Nylon 6, Nylon 66,
PET, PBT, PTT, PP, and copolymers and blends thereof. Singles yarns
used in forming the apparent space-dyed yarns in the present
invention are continuous filament yarns, preferably partially
oriented yarns (POY), preferably in their as-spun condition. It is
to be noted that polymer of any of the above-noted types obtained
from reclaimed or recycled spun fibers, fabric or plastic scrap, or
mixtures or combinations thereof, can advantageously be used in
this process.
[0059] The polymeric singles yarns may be colored using methods
known to those skilled in the art, either with dyes or with
pigments. Melt pigmentation employing inorganic and/or organic
pigments may be the preferred method of coloration for most
applications. Additives may be included in the polymeric singles
yarns, including, but not limited to, antioxidants, delustrants,
antimicrobials, UV stabilizers, stainblockers, and process aids. In
addition, while the specific example given is directed to the use
of filaments of a trilobal "Y" cross-section the invention is
plainly suitable for use with filaments of any other
cross-section.
[0060] While this invention has been described in conjunction with
specific embodiments thereof, it is evident that many alternative
modifications and variations will be apparent to those skilled in
the art. Accordingly, the preferred embodiments of the invention as
set forth herein are intended to be illustrative, not limiting.
Various changes may be made without departing from the true spirit
and scope of the invention as defined in the following claims.
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