CONTINUOUS PROCESS TO PROVIDE A HEATHER YARN

PROCEDE CONTINU DE PRODUCTION DE FIL A PLUSIEURS COULEURS

English Abstract

Method to continuously merge two multifilament yarns supplied from bobbins
on a creel by merging and entangling the two yarns in a commingling air jet and
supplying directly to a warper to form a warp beam. The method includes feed rolls
upstream and downstream of the air jets providing an overfeed of the yarns to the jet of
about 2.3%.

Claims

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WE CLAIM:
1. A method to continuously produce a warp beam of merged multifilament yarn
from at least two yarns wound on individual bobbins having multifilament
synthetic yarn thereon, supplying at least two yarns from separate bobbins to a
set of feed rolls, driving said set of feed rolls at a first rate to supply the two
yarns to a commingling air jet, commingling the two yarns in the air jet to
provide a merged, commingled yarn, providing a second set of feed rolls
downstream of the air jet, driving the second set of feed rolls at a rate lower than
that of the first set of feed rolls so that the yarns are supplied to the air jet at an
overfeed of between 1 to 4%, supplying the commingled yarn from the second
set of feed rolls to a warper and forcing a warp beam of commingled yarn on the
warp beam.
2. The method of Claim 1 wherein false twisted yarns are supplied from the
bobbins.
3. The method of Claim 1 wherein the air jet is supplied air at a pressure of about
60 psi.
4. The method of Claim 3 wherein the yarn overfeed is about 2.3%.
5. The method of Claim 1 wherein the yarn overfeed is about 2.3%.

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6. The method of Claim 1 wherein the two yarns supplied are of different colors
and the commingled yarn is a heather yarn.
7. The method of Claim 6 wherein the air jet is supplied air at a pressure of about
60 psi.
8. The method of Claim 7 wherein the yarn overfeed is about 2.3%.
9. A method to continuously produce a warp beam of merged multifilament yarn
from at least two yarns each wound on a bobbin comprising: supplying a
plurality of bobbins having multifilament synthetic yarn thereon, supplying at
least two yarns each from a separate bobbin into a commingling air jet,
entangling the two yarns in the air jet and continuously supplying the entangled
yarns to a warper to wind a warp beam of entangled yarn.
10. The method of Claim 9 wherein the two yarns are dissimilar yarns thereby
providing a unique entangled yarn.
11. The method of Claim 10 wherein the two yarns are of different colors and the
entangled yarn is a heather yarn.

Description

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CONTINUOUS PROCESS TO PROVIDE A HEATHER YARN
This invention relates generally to the continuous production of a warp beam of
a multiplicity of merged or entangled yarns from a plurality of bobbins mounted in a
5 creel.
It is known to air entangle a multiplicity of yarns from a bobbin into a single yarn
and then take up the merged or entangled on another bobbin which is combined with
other bobbins and supplied to a warp beam. The supplied yarns can be yarns of the
same color or texture or can be yarns of di~l~-ll colors. These yarns normally are
10 taken up on a bobbin prior to warping and require the additional step or steps of loading
them onto a creel and then threading them up to a warper to provide a warp beam of
such yarns.
It is therefore an object of this invention to provide a continuous process of
merging a plurality of yarns from bobbins mounted on a creel and, in line, continuously
15 directing the merged yarns on a warp beam.
Other objects and advantages of the invention will become clearly apparent as
the specification proceeds to describe the invention with reference to the accompanying
drawing, in which:
Figure 1 is a side schematic view of the new and hllpl()ved process and Figure 2
2 0 is a top view taken on line 2-2 of Figure 1.
Looking now to the drawings, the reference numbers 10 and 12 represent a false
twisted single ply, 250 denier, 100 fil~ment polyester yarns that are being supplied from
bobbins 13 on a creel 14. In the prerelled form of the invention, the yarn 10 is light
grey and the yarn 1 2 is a dark grey in order to form a heather yarn 18 but it should be

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understood that other synthetic filament yarns, such as nylon, of di~erellL deniers,
numbers of filaments and colors can be used within the scope of the invention.
The yarns 10 and 12 are delivered from the creel 14 to feed rolls 20 and 21
through a comb 22 which supplies one yarn 10 and one yarn 12 to each air entanglement
5 jet 24 mounted on the air manifold 26 supplying air to each air jet 24 so that they
operate.at a pressure between 30 - 90 psi, preferably 60 psi, to entangle each pair of
yarns 10 and 12. Since the yarns 10 and 12 are di~ele"l colors, the entangled yarn 18
has a heather appearance and is basically a two ply, 250 denier, 200 fil~ment yarn. To
allow the jets 24 to provide this heather effect, the output feed rolls 30 and 32 are
1 0 supplying yarn to the warper 34 at a rate of 400 meters/minute which the input feed
rolls are supplying yarn at a rate of about 409 meters providing an overfeed of yarn of
about 2.3%. This overfeed can vary between 1 and 4 %. Prior to the output rolls 30
and 32 the entangled yarns 18 each pass through a separate space in the dent 36 to
m~int~in them separate as the feed rolls 30 and 32 feed them to the warp beam 38 of the
1 5 warper 34.
The above described process provides an entangled yarn, preferably a heather
yarn, warped and ready for use in a single continuous process from bobbins to the warp
beam çli~in~ g the intermediate steps of winding bobbins and recreeling at the warper
to form a warp beam. Furthermore, the continuous system described provides a yarn
2 0 having a heather hand and appearance especially when knit or woven into a fabric.
It is contemplated that modifications of the process can be made without
departing from the scope or spirit of the invention and it is desired to be limited only by
the scope of the claims.

Representative Drawing