US3822543A - Spun-like yarn and method of manufacturing same - Google Patents

Abstract

A yarn having soft, attractive handle and a structure such that staple fibers are intertwined with each other to cohere into a substantially non-twist yarn. The yarn is manufactured by supplying a substantially non-twist strand of staple fibers to a fluid treatment zone where the staple fibers are intertwined with each other by the turbulent flow, at least part of said staple fibers to be supplied to the treatment zone having a length larger than the distance L between the fiber grasping point in the fiber feed zone and the point where the intertwinement due to the turbulent flow most effectively occurs.

Description

United States Patent Edagawa et al. 1

[ July 9, 1974 SPUN-LIKE YARN AND METHOD OF MANUFACTURING SAME Inventors: Hiroshi Edagawa; Ituo Nakamura;

Kozo Susami, all of Otsu, Japan Assignee: Toray Industries, Inc., Tokyo, Japan Filed: May 4, 1972 Appl. No.: 250,176

Foreign Application Priority Data July 12, 1971 Japan 46-51092 US.Cl 57/160, 28/1.4, 28/72.12, 57/34 B, 57/140 BY, 57/157 F Int. Cl. D02g 1/16, D02g 3/04, D02 3/36 Field ofSearch 57/157 F, 3413, 140 BY, 57/140 R, 157 R, 160, 163, 58.95; 28/1.2,

References Cited UNITED STATES PATENTS CUI'S.

3,188,790 6/1965 Hebcler 57/157 R X 3,296,785 1/ 1967 3,603,043 9/1971 Paliyenko eta1 57/157 F X 3,604,194 9/1971 Edagawa et a1 57/58.95 X 3,609,834 10/1971 Lamb et a1 28/1.4 3,665,567 5/1972 Clarkson 28/72.12 X 3,672,147 6/1972 Callieri et al.... 57/157 F 3,678,549 7/1972 Buzano 57/157 F X Primary Examiner-John W. Huckert Assistant Examiner-Charles Gorenstein ABSTRACT A yarn having soft, attractive handle and a structure such that staple fibers are intertwined with each other to cohere into a substantially non-twist yarn. The yarn is manufactured by supplying a substantially non-twist strand of staple fibers to a fluid treatment zone where the staple fibers are intertwined with each other by the turbulent flow, at least part of said staple fibers to be supplied to the treatment zone having a length larger than the distance L between the fiber grasping point in the fiber feed zone and the point where the intertwinement due to the turbulent flow most effectively oc- 10 Claims, 24 Drawing Figures PAIENTEDJuL 9:914

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saw -10 ur11 PATENTEU JUL 9 snmrmur H SPUN-LIKE YARN AND METHOD OF MANUFACTURING SAME The present invention relates to a novel non-twist high bulky yarn having a spun-like handle or feeling and a method of manufacturing the same. The novel bulked yarn has no substantial twist but a characteristic structure such that individual staple fibers are entangled with each other, which structure quite differs from conventional spun yarns and filament yarns, and is of high practical value.

Many methods for imparting high bulkiness to yarns are known wherein a raw yarn is fed into a fluid treatfluid treatment, in order to set and make permanent the loops or the slacks formed through the fluid treatment. The need of twisting is obviously disadvantageous from an industrial viewpoint.

Also a method is known wherein a spun yarn is fed into a fluid treatment zone where the staple fibers are looped or slackened. However, a spun yarn usually has a relatively hard twist and therefore, the bulkiness is not remarkably improved even when subjected to the fluidtreatment. Further, it is similarly disadvantageous that a spun yarn necessitates twisting for the preparation thereof.

It is the main object of the present invention to obviate the defects as mentioned above and to provide a substantially non-twist high bulk yarn having soft, 'ap pealing handle.

In accordance with the present invention, there is provided a yarn having a handle like spun yarn comprising staple fibers characterized by having a structure such that individual staple fibers are intertwined with eachother to cohere thereby into a thread of high bulk havingno twist on the whole. The novelyam has a characteristic structure distinguished from conventional spun yarns, i.e. it is of very high bulk, assumes the peculiar form such that many end portions of the staplefibers projecto'ut of the periphery of the yarn as relatively long fluffs, and has no twist on the whole;

The yarn of the present invention will be illustrated in detail with reference to the drawings.

FIGS. 1A and 1B are a diagrammatical view and a photograph of a yarn of the present invention, respectively,

FIGS. 2A and 2B are a diagrammatical view and a photograph of another yarn of the present invention, respectively,

FIG. 3 is an explanatory view of the manufacture of the yarn shown in FIGS. 1A and 1B, 7

FIG. 4 is an explanatory view of the manufacture of the yarn shown in FIGS. 2A and 2B,

FIGS. 5 and 6 are a diagrammatical view of a fluid treatment apparatus used for the manufacture of the yarn of the present invention and an enlarged diagrammatical view of a bending part of the apparatus, respectively, I

' 2 FIGS. 7, 8, 9 and 10 are diagrammatical views of other fluid treatment apparatus each used for the manufacture of the yarn of the present invention,

FIGS. 11 and 12 are diagrams showing relationships of the degree of intertwinement vs. difference in peripheral speed between feed rollers (front rollers) and delivery rollers, and of yarn strength vs. l/L ratio defined later, respectively,

FIGS. 13, 14, 15 and 16 are diagrammatical views of other fluid treatment apparatus each used for the manufacture of the yarn of the present invention further involving a second fluid treatment device,

FIGS. 17, 18, 19, 20 and 21 are diagrammatical views of other fluid treatment apparatus each used for the manufacture of yarns of the present invention involving the additional employment of a false twist system,

FIG. 22 is a diagram showing relationship of degree of intertwinement vs. the'ratio of fiber diameter (d) to mesh size (D) of a deflecting member with perforations such as a screen used as a supplementary board for the intertwinement.

With reference to FIG. 1A diagrammatically showing the appearance of the yarn of the present invention,

staple fibers 2 are intertwined with each other to cohere thereby into a single yarn l as though spun. Theyarn 1 comprisesloops 4 therein giving a very high bulk andfluffs 5 of relatively great length projecting out of the periphery thereof, which structure cannot be found in conventional spun yarns.

A method of manufacturing such a yarn will be described in detail:

The method involves the step of feeding a substantially non-twisted strand of staple fibers such as a roving or sliver from a fiber supply zone to a fluid treatment zone where individual staple fibers are intertwined with each other by a turbulent flow of fluid to cohere thereby into a single yarn, at least some of said staple fibers to'be supplied to said fluid treatment zone have a length larger than the distance L between the grasping point in the fiber feed zone and the intertwining point in the fluid treatment zone. The term intertwining point means herein the point at which the intertwinement of staple fibers most effectively occurs due to the turbulent flow in the fluid treatment zone.

In order to manufacture the yarn of the present invention, it is insufficient merely to subject a conventional non-twist strand of staple fibers to normal fluid treatment, i.e. it is necessary to employ specific conditions for intertwining the staple fibers with each other to a considerable degree. It is, therefore, fundamentally required that the fluid exerts a strong intertwining action on the staple fibers and that at least some of the staple fibers have a length larger than the abovespecified distance.

FIG. 3 illustrates the principle of the method of the present invention. With reference to FIG. 3, a roving 7 unwound from abobbin 6 is drawn, for example, approximately 20 times its original length while passing throughback rollers 8, draft means 9, andfront rollers 10, to become a non-twist strand in the form of fleece. The fleecy strand is continuously supplied from thefront rollers 10 to afluid treatment apparatus 12 through an inlet tube 11. High pressure fluid such as compressed air is introduced following the arrow through aninlet 13 into adisturbance chamber 14 and discharged through anoutlet 15. An aspirator effect is therefore produced on the inlet tube 11, whereby the fleecy strand is sucked into thedisturbance chamber 14 and discharged therefrom through theoutlet 15. In the fluid treatment zone, the individual staple fibers are actively intertwined with each other to form asingle spun yarn 16 by the turbulent flow produced in thedisturbance chamber 14 and the wide flow of fluid ejected through theoutlet 15. Thespun yarn 16 so formed is continuously wound into apackage 18 by way of a take-up roller 17.

The feed stock, i.e. a strand of staple'fibers such as a roving or sliver should comprise staple fibers lying substantially parallel at least some of which have a length L larger than the distance L between the grasping point of the pair of front rollers and the outlet of thefluid treatment nozzle 14, i.e. the point at which the intertwinement due to the turbulent flow most effectively occurs.

When all the staple fibers of the strand to be treated substantially have a length smaller than the distance L, the individual staple fiber escapes from the grasp of the front rollers before the forward end thereof reaches the outlet of the fluid treatment nozzle. Consequently, they are insufficiently intertwined with each other and some of them are scattered out from the outlet I5. It is difficult to produce a continuous yarn from such staple fibers.

In contrast, when at least a substantial number of the staple fibers have a length L larger than the distance L, the staple fiber is still grasp ed between the pair of front rollers when the forward end thereof reaches the outlet and consequently, strongly intertwined with other staple fibers by the turbulent flow of the fluid to form thereby a continuous spun yarn.

It is noted however that the strand containing an excess of staple fibers having the length L results in a spun yarn of reduced bulk and softness. Therefore, the ratio of the staple fiber having length L contained in the strand should preferably be within a stated range, i.e. from 5 percent to 80 percent based on the total weight of the strand.

The fluid treatment apparatus where staple fibers are intertwined with each other to form a spun yarn of the present invention is not critical. Any type of fluid treating apparatus may be used as long as it is capable of exerting a sufficient intertwining action on the staple fibers. l n particular, those of the type equipped with a jet apparatus capable of producing a strong turbulent flow such as, for example, of the type provided with two or more jet apparatus whereby two or more flows of fluid are simultaneously introduced into the fluid treatment zone as illustrated later, are preferred. Some conventional apparatus used for the production of filament yarn of high bulk by employing a fluid ejection technique may be used if the fluid treatment conditions are strictly determined.

The fluid used in the present invention may be either gas or liquid. Compressed air is most preferable because of ready availability and no baneful effect on the human body or the apparatus, and particular protection apparatus is not required. Hot air or saturated steam or super-heated steam may be preferably used when thermoplastic staple fibers are treated. Pressure of the fluid flow may be optionally varied.

Regarding the ratio in peripheral speed of the front rollers as a fiber supply source to the take-up roller, it may be varied depending upon the characteristic of staple fibers used, the material and form of staple fibers. The ratio is usually 1:1. It is however preferred to adjust suitably the ratio depending upon the particular spinning condition when a smooth treatment cannot be effected at the fixed ratio of 1:1 in the case where staple fibers having no crimp or having conventional crimp are used. The ratio may be varied in a manner such that some of the staple fibers are either strained or released during the treatment.

In a modified embodiment, a deflecting member (not shown in FIG. 3) is so arranged in front of theoutlet 15 that the member deflects the fluid flow passing out of the outlet and consequently produces a further turbulent flow and enhances the intertwining effect of staple fibers. The distance between the deflecting member and the outlet may be suitably determined depending upon the desired spun yarn and the feed stock used.

The length offluffs 5, i.e. end portions of the staple fibers projecting out from the periphery of the spun yarn may be varied by altering the distance L between the grasping point of the front rollers and the outlet of the fluid treatment nozzle or the ratio in diameter of the inlet tube Ill to the thickness of the fleecy strand. That is, the length of fluffs increases with an increase of the distance L and an increase of the ratio in diameter of 'the inlet tube to the thickness of the fleecy strand, and decreases with a decrease of these quantities. The length of fluffs may also be varied by varying the shape of crimp, surface characteristic and physical characteristic of the staple fiber and the particular additives applied to the staple fiber.

The method of the present invention can be employed in the manufacture from both a non-twist strand of staple fibers and a filament yarn as well as the strand of staple fibers alone. FIGS. 2A and 2B shows yarn manufactured from both staple fibers and filaments.

In this embodiment, as shown in FIG. 4,filaments 31 unwound from abobbin 6 are supplied throughguides 64 and atension device 63 to a pair offront rollers 10 where the filaments are joined together with afleecy strand 7 of staple fibers fed from abobbin 6 throughback rollers 8 and aprons 9 as illustrated referring to FIG. 3, and supplied into thefluid treatment nozzle 12. Alternatively,filaments 31 may be supplied into thefluid treatment nozzle 12 seperately from thefleecy I strand 7 of staple fibers.

two or more fluid jets may be applied simultaneously or in sequence to staple fibers.

FIG. 5 shows one preferable embodiment of the fluid treating apparatus, wherein two paths for fluid are provided, one (shown in the right hand) being slopewise formed at a certain angle to the other (shown in the left hand) at the one end thereof and hence the two forming a crooked path.

In FIG. 5, anon-twist strand 7 is supplied from a fiber supply source comprising rollers with aprons 9 andfront rollers 10 to afluid treatment apparatus 14 where thestrand 7 is subjected to fluid treatment, and the resultingyarn 16 is delivered by way of a pair ofdelivery rollers 27. Thefluid treatment apparatus 14 comprises a fiber inlet tube 11, a firstfluid inlet tube 13, afiber transportation tube 20, a secondfluid inlet tube 26 and a slantingtube 22. Fluid, particularly compressed air, is introduced thereinto through the first and secondfluid inlet tubes 13 and.26 at the same time. One end of the fiber transportation tube is connected tothe slantingtube 22, the longitudinal axis of which is in the direction of air flow through the secondfluid inlet tube 26. The wall of the connecting portion of thefiber transportation tube 20 and the slantingtube 22, against which wall the air flow passing through thetube 20 runs, is provided with perforations of suitable number and size extending parallel to the axis of thefiber transportation tube 20. The strand l9 (i.e., the portion of thestrand 7 in the fluid treatment zone) is subjected to the turbulent flow of air at the connecting portion where staple fibers are intertwined with each other to form thereby a single yarn. More particularly, thestrand 19 passing together with the first air flow through thefiber transportation tube 20 intersects with the second air flow from thesecond fluid inlet 26, at the connecting portion, from which staple fibers, while being drawn to the wall provided with the perforations, are transported to the outlet of thetube 22 due to the second air flow and drawn out as a non-twist spun yarn by way of thedelivery rollers 27. Preferably, a' deflectingmember 23 provided with perforations is arranged in front of the outlet of the slantingtube 22, i.e. at a point I immediately downstream from the outlet whereby the air flow and theoutput strand 16 of staple fibers at least a substantial number of which have been intertwined with each other are advantageously separated.

The intertwining effect produced at the point ofintersection 24 of both the air flows as mentioned above will be illustrated in detail referring to FIG. 6, which diagrammatically shows an enlargement of the neighbourhood of the point of intersection.

The strand ofstaple fibers 19 passing through thefiber transportation tube 20 is intertwined therein to a certain extent. It is however not yet in the condition capable of forming a single yarn. The two air flows run against each other at theintersection point 24 and produce a turbulent flow whereby staple fibers are in com plicated motion and are intertwined with each other to a greater extent. A part or a substantial part of the air flowing out of thefiber transportation tube 20 is discharged throughperforations 21 made on the wall of the slantingtube 22 into the atmosphere. The yarn indicated by the numeral 28 in this region as spun is transported. accompanying the air flow introduced from thefluid inlet tube 26, through the slantingtube 22 to the outside.

In FIG. 5, the distance L mentioned before is defined as that between the grasping point of thefront rollers 10 and theintersection point 24 of the two air flows, the latter point being the one at which the intertwinement of staple fibers most effectively occurs due to the turbulent flow.

FIG. 7 shows another preferred embodiment of the fluid treatment apparatus used in the present invention, involving two fiber supply sources; a non-twist fleecy strand of staple fibers and a filament yarn comprising a plurality of continuous filaments. Of course, filaments may be additionally supplied to the fluid treatment apparatus of the type shown in FIGS. 5 and 6, for example, onto the strand of staple fibers at the upstream or downstream of the front rollers. It is however preferable to employ such an apparatus of the type as shown in FIG. 7 in order to treat both staple fibers and filaments.

Referring to FIG. 7, a non-twist strand ofstaple fibers 7 is supplied from a pair offront rollers 10 into a first fiber inlet tube 11 in the same manner as illustrated referring to FIG. 5 and simultaneously, afilament yarn 31 is supplied from a pair offront rollers 30 to a second fiber inlet tube 11 diverging from afiber transportation tube 20. Thefluid treatment apparatus 14 is similar to that shown in FIG. 5 except: that thefiber transportation tube 20 is equipped with the filament yarn inlet and transportation tube 11' diverging therefrom at an angle of 0 and the latter tube 11' is connected to a slantingtube 22.

The intertwinement between thefilament yarn 31 andstaple fibers 7 is effected at theintersection point 34 of the fiber transportation tube: 20 and the filament inlet tube 11' by a first fluid flow introduced from aninlet 13. Since thefilaments 31 and thestaple fibers 7 are intertwined while intersecting at an angle of 0, the staple fibers sufficiently pierce the filament yarn. Further, a turbulent flow occurs as the first fluid accompanied with the intertwined fibers runs against the wall of the slantingtube 22, and therefore, enhances the intertwining effect on the fibers. Therefore, this embodiment is obviously preferred to that shown in FIG. 5 in the case where both a strand of staple fibers and a filament yarn are treated. In addition, a second fluid flow from afluid inlet tube 26 enhances still more the intertwining effect. The distance L mentioned above is defined as that between the grasping point of thefront rollers 10 and theintersection point 34 herein.

FIG. 8 shows a preferred embodiment similar to that of FIG. 7 except that two fluid flows are separately introduced into theapparatus 14 in the neighbourhoods of the two fiber supply sources, respectively. The two fluid flows from twofiber transportation tubes 20 and 20 impinge on each other at theintersection point 34 of the twotubes 20 and 20' and consequently, produce a very complicated fluid stream whereby individual staple fibers and filaments are strongly intertwined will each other to form a complete whole, a spun yarn with no twist.

The above-illustrated embodiments involve the use of two fluid flows separately directed to a strand of staple fibers. However, as a modified embodiment of the method involving the use of two or more fluid flows, the following type is enumerated wherein one fluid flow is directed to a strand of staple fibers twice in sequence, i.e. the strand once having passed out of the path of the fluid flow is turned back thereinto? That is, a strand of staple fibers is introduced into a fluid treatment apparatus having a fiber inlet tube and a fiber transportation tube and then, withdrawn from the apparatus to the vicinity thereof and again, turned back to the fiber transportation tube through which the strand passes countercurrentwise over a stated range, and finally withdrawn from a fiber outlet tube.

Referring to FIG. 9, a strand ofstaple fibers 7 is drawn throughback rollers 8, a drafting element 9 andfront rollers 10 into a fleece composed of staple fibers lying substantially parallel and then, introduced into a fluid treatment zone in which afluid treating apparatus 14, a deflectingmember 23, aguide roller 35 and, adelivery roller 27 are arranged.

The fluid treatment apparatus I4 comprises a fiber inlet tube 11 and afiber transportation tube 20 with which a slantingfiber transportation tube 22 is connected at a certain angle. The deflectingmember 23 with perforations such as a screen is provided in front of one end of the slantingtube 22 in order to separate the intertwined fiber and the fluid. Afiber outlet tube 26 is provided at the other end of the slantingtube 22. In this arrangement, the distance L mentioned hereinbefore is defined as that between the grasping point of thefront rollers 10 and the deflectingmember 23. The distance between the deflectingmember 23 and the intersecting point of the twofiber transportation tubes 20 and 22 is herein referred to as l.

Thestrand 7 sucked into thefiber transportation tube 20 runs against the deflectingmember 23 and I then, is turned back to thetube 22 through which the strand passes countercurrently over a length of l, and withdrawn from theoutlet 26 by way of theguide roller 35.

It has been found in the practice of the abovementioned method that the difference V V between the speed of the fluid flow (V and the take-up speed (V of the yarn as spun, both in the course of yarn-formation over the range of l, and the ratio of l/L seriously affect the intertwining effect. Experimental results regarding these important factors are shown in FIGS. 11 and 12.

FIG. 11 shows the relationship between the difference in speed, V V (expressed in m/min) and degree of intertwinement (expressed in number of cycles). On this experiment, both a strand of staple fibers and a filament yarn were simultaneously introduced into the apparatus shown in FIG. 9, and the degree of intertwinement between the stple fibers and between the staple fibers and the filaments was determined. The degree ofintertwinement is determined in the following manner: One end ofa yarn as spun is secured in one of the clamps and a pre-tensioning load of IO mg/d is applied to the other end. The yarn is rubbed with a 1 mm diameter piano wire strung in the direction perpendicular to the single yarn by making the wire reciprocate. The number of cycles is-noted when all the staple fibers fall out from the filaments. FIG. 12 shows the relationship between the ratio UL and tensile strength of yarn (g/d). In this experiment, only a strand of staple fibers was treated with air using the apparatus shown in FIG. 9, and the tensile strength of yarn was determined as a measure of the degree of intertwinement.

As evident from FIGS. 11 and 12, a desired effect can be produced when the difference in speed, V V is larger than 0.75 X m/min and the ratio l/L is larger than 0.25.

Referring to FIG. 10 illustrative of another modified embodiment of the method of the present invention, a

strand 7 of staple fibers supplied fromfront rollers 10 having perforations whereby spinning stability can be ensured.

Further, it has now been found that the following method produces still more complicated turbulent flow and far enhances the intertwining effect; plural fluid flows are blown against a strand of staple fibers from the periphery thereof, while the staple fibers are suspended in the other fluid flow and intertwined with each other, in a manner such that the plural fluid flows are directed at a certain angle, e.g. perpendicular to and envelops the latter fluid flow. I

Several preferred embodiments of the method are il lustrated with reference to FIGS. 13 I6.

Referring to FIG. 13, thefluid treatment apparatus 14 is provided with a secondfluid treatment apparatus 42 at the intermediate portion of thefiber transportation tube 20, thelatter apparatus 42 comprising acompressed air inlet 43 andplural spouts 44, 45, 46 and.47 disposed on the periphery of thefiber transportation tube 20. Compressed air is introduced through theinlet 43 into theapparatus 42 and blow through the plural spouts 44, 45, 46 and 47 against a strand of staple fibers from the periphery thereof while the staple fibers suspended in the first air flow are intertwined with each other, whereby the intertwining effect is suddenly increased due to the turbulent flow. The strand of staple fibers so intertwined passes out of the slantingportion 22 of the transportation tube, runs against a deflectingmember 23 and then, is taken up by means ofdelivery rollers 27. In this embodiment, the intertwinement occurs most effectively at the point where the second plural air flows are blown against the strand and therefore, the distance L is defined as shown in FIG. I3. Instead of the second fluid flows being directed perpendicular to the first fluid flow supporting staple fibers, the second fluid flows or at least a part may be directed at some angle other than a right angle to the first fluid flow.

In the practice of the fluid treatment using the apparatus of the type as shown for example in FIG. 13, the first fluid flow interferes with the second fluid flow occasionally causing a backward flow of the first fluid. This phenomenon depends upon the volume rate of both fluid flows. It causes unevenness of yarn, reduction of the yarn strength and reduction of the suction force for the strand resulting in lowering of the treatment efficiency. Consequently, the volume rate of both fluid flows cannot be voluntarily increased.

In order to obviate such defects, it is preferred to provide one or more vents, in the wall of the fiber transportation tube between the first fluid feed Zone and the second fluid feed zone whereby a part of the first fluid can escape from the system for the relief of pressure, as shown in FIG. 14.

In FIG. 14, orifices shown withnumerical reference 48 are those mentioned above and other members are similar to those illustrated in FIG. 13.

Another example of the type as mentioned above is shown in FIG. 15. Referring to FIG. 15, thefiber transportation tube 20 is equipped at the slanting portion thereof with a secondfluid treatment device 42 comprisingspouts 46 and 47 and withorifices 48 as mentioned above at the crook thereof.

Referring to FIG. 16, thefiber transportation tube 20 is similarly equipped at the vertical portion thereof with a secondfluid treatment device 42 comprisingspouts 45, 46 and 47. But, instead of the orifices mentioned above, anexhaust tube 49 having an inner diameter do larger than that d of the fiber transportation tube is provided on the upper. end of the vertical portion of the fiber transportation tube whereby a part of the first fluid can escape from the system.

Further, it has now been found that when a fiber cohesion treatment such as false twisting and alternate twisting is carried out together with the fluid treatment mentioned above, the intertwinement of staple fibers is far more enhanced and the surface configuration of the yarn becomes uniform. The fiber cohesion treatment may be carried out at any stage, e.g. before or after the fluid treatment or during the fluid treatment.

The fiber cohesion treatment taken just before the fluid treatment has the following advantages: (1) The grasping point of staple fibers in the fluid treatment as defined above is transferred from the front rollers to the point where the fiber cohesion treatment is carried out, c.g. false twisting point, that is the distance L is reduced and therefore, staple fibers of relatively short length can be used as a feed stock. (2) The cohesive attraction obviates undesirable scattering of staple fibers during the fluid treatment and enhances the intertwiningeffect far more. (3) Any kind of staple fiber can be smoothly supplied into the fluid treatment zone without varying the particular spinning conditions.

The fiber cohesion treatment taken after the fluid treatment has the following advantages: (1) The cohesive attraction improves uniformity ofsurface configuration of the yarn as spun and'ties'flufis of a large length around the yarn proper, resulting in a yarn of high quality. (2) Since the cohesive attraction goes upstream to the fluid treating zone, first, staple fibers of relatively short length can be used which is similar to the former case where the fiber cohesion treatment is performed just before the fluid treatment, and secondly, the cohesive attraction unifies the motion of fibers and the intertwinement thereof and prevents the scattering of fibers, in the fluid treatment zone. Likewise, the fiber cohesion treatment taken during the fluid treatment produces the combined effects of those enumerated above. (3) Desirable characteristics in the yarnsuch as bulkiness and appearance (fluffs, loops and parallelism) is readily obtainable as the end use needs.

Members used for the fiber cohesion treatment include, for example, known spinners such as of the type used for false twist and alternate twist. Preferable spinners are a contact type spinner and a pneumatic vortex type spinner.

Several preferred embodiments of the apparatus involving the spinner are illustrated with reference to FIGS. 17 20. FIG. 17 diagrammatically shows an arrangement wherein afalse twist spinner 50 is provided at the point immediately upstream of afluid treatment apparatus 14. FIG. 18 shows an arrangement intended for practical use, wherein afluid treatment apparatus 14 and afalse twist spinner 50 are joined to each other through the medium of abearing 52 and thefalse twist spinner 50 is driven by a suitable drive means 51. A false twist spinner can be similarly applied to all the fluid treatment apparatus shown in FIG. and the following figures.

FIG. 19 shows an arrangement wherein a pneumatic vortex typefalse twist spinner 50 is provided at the point immediately downstream of the fluid treatment zone. In FIG. 19, a secondfluid treating nozzle 42 is integrally equipped with thefalse twist member 50. A part of the compressed air from theinlet 43 of the sec ondfluid treatment nozzle 42 is introduced throughorifices 54 into a chamber of thefalse twist member 50 and blown out therefrom through orifices 53 eccentrically directed to the path of the yarn as spun whereby the yarn is false-twisted due to the air vortex. Alternatively, a false twist spinner of contact type may also be employed.

In FIG. 19, a fiber inlet tube lll provided in a firstfluid treatment nozzle 14 is slidable along the path of staple fibers and the distance between the fiber inlet tube 11 and afiber transportation tube 20 may be varied by sliding thethumb head portion 58 thereof by hand, whereby the absorbing force in the firstfluid treatment nozzle 14 can be suitably settled. The firstfluid treatment nozzle 14 is connected with the secondfluid treatment nozzle 42 by a connectingmember 59.

In this embodiment, a strand of staple fibers passes through the fiber treatment zone under the following conditions:

As shown at the lower section of FIG. 19, the axis is drawn in parallel with the path of the strand of staple fibers, the origin being point 0 corresponding to the grasping point of thefront rollers 10, and the points atwhich the strand is under action of the fluids, i.e. the fiber-feeding flow point the turbulent flow occurring point, the false twisting point and the point of collision with the deflectingmember 23 are expressed as points P, Q, R and S, respectively. (The axis is also shown in FIG. 17.) If the apparatus is not equipped with the false twistingmember 50, staple fibers undergo the action of the fluids in a nontwisted and nearly non-cohesive state at the section between the points 0 and Q and intertwine with each other at the section between points 0' and R, as shown in the axis (a). On the contrary, in this embodiment of the present invention involving the employment of the false twistingmember 50, staple fibers are under the false twist action at the section ranging from point 0 to point R", as shown in the axis (b), and therefore, staple fibers undergo the action of turbulent flow in a false-twisted state at the section between Q" and R. That is, staple fibers are cohered together due to the'false twist action immediately after passing the grasping point of thefront rollers 10 and then, subjected to intertwinement in a considerably stable state at the section between Q" and R" to form a single yarn thereby. At the section downstream of point R", the yarns so formed are in a substantially nontwisted state or a partially twisted state on rare occasions and run against the deflectingmember 23 where the intertwinement is greatly enhanced, and then withdrawn therefrom as a substantially non-twist yarn.

FIG. 20 shows an arrangement wherein a contact type false twist spinner is provided at the point immediately downstream of the fluid treatment zone. The apparatus comprises a firstfluid treatment nozzle 14 having a fiber inlet tube 11 and afluid inlet tube 13, the nozzle having a sucking action on the strand of staple fibers, and a secondfluid treatment nozzle 42 having afiber transportation tube 20, afluid inlet tube 43 and spouts 46. 47, the nozzle having an intertwining action on the strand of staple fibers, and a slantingtube 22 withperforations 21. Further, the apparatus comprises a false twist spinner connected with the slantingtube 22. Thefalse twist spinner 50 supported with a intertwined staple fibers is preferably withdrawn out through theperforations 21 whereby the yarn is smoothly subjected to false twist without disturbance.

As exemplified with reference to FIG. 20, when a yarn is subjected to false twist while passing through a contact-type tubular spinner, the peripheral surface of the yarn is kept in contact with the inner wall of the spinner over a stated length and therefore, excessively long fluffs are advantageously rolled up in the yarn proper, resulting in a yarn of uniform surface configuration.

FIG. 21 shows an arrangement wherein a pneumatic vortex typefalse twist spinner 50 is provided between the first fluid treating zone 14' and the second fluid treating zone 42'. The arrangement further involvesvents 48 for the relief of pressure between thefalse twist spinner 50 and the second fluid treatment zone. This apparatus has a structure such that fluid supplied through oneinlet 56 is distributed among the three treatment zones, i.e. throughorifices 58 to the first fluid treatment zonel4, throughorifices 57 to the false twisting zone and throughorifices 45, 46, 47 to the second fluid treatment zone, which is obviously advantageous from the economical and efficient viewpoints.

In a modified embodiment of the apparatus with a spinner, a device serving both as a fluid treatment apparatus and a fiber cohesion treatment apparatus may be employed. For example, referring to FIG. 13, in the case whereorifice 44, 45, 46 and 47 of the secondfluid treatment apparatus 42 are eccentrically directed to the path of the strand, i.e. air flows therethrough are blown against the first air flow to form a vortex, false twist and the intertwinement can be simultaneously achieved.

In preferred embodiments of the present invention, a deflecting member having perforations such as a perforated board and a net as shown withnumerical reference 23 in FIGS. 5, 7-10, 13 l and I7 is employed which is placed at the point immediately downstream of the outlet of the fiber transportation tube. When a fluid flow carrying the strand of staple fibers runs against the deflecting member, a part of the fluid flow is deflected backwardly therefrom to form backward flows which open the strand and intertwine the staple fibers, and simultaneously a substantial part of the fluid flow passes through the perforations which makes the staple fibers slacken and loop. Further, isolated staple fibers, which would inevitably scatter therefrom without the deflecting member, temporarily stay thereon and are caught by the strand of staple fibers to form a part of the yarn. Consequently, the deflecting member provides an increase in the yield of the yarn as well as enhancement of the intertwinement between fibers.

The deflecting member should function such that the greater part of the fluid running against it passes through it. It has been found that the ratio (t) of the diameter (D) of the staple fibers to the diameter (d) of perforations in the deflecting member has a close relation to the degree of the intertwinement and, for satisfactory results, should be within the range:

4 t (d/D) 500.

The shapes of both the perforations and the crosssection of the fibers are not critical; circular or any other shapes may be employed as long as the diameter of the inscribed or circumscribed circle satisfies the above inequality.

FIG. 22 shows the relation between the ratio in diameter (t d/D) and the degree of intertwinement (number of cycles, determined by the procedure hereinbefore described), resulting from the experiments wherein a roving of nylon staple fibers having a fineness of approximately 1.5 denier (D z 12 ,u) and various deflecting members with perforations differing from each other are employed.

The yarn obtained in accordance with the method of the present invention may be additionally finished, for example, by making the yarn contact a rotating member whereby fuzz is prevented or rolled up into the yarn proper without or with applying heat thereto in order to set the yarn, if desired.

In accordance with the present invention, various kinds of substantially non-twist yarns having handle like a spun yarn can be obtained employing various staple fibers as a feed stock.

The staple fibers used as a feed stock are not critical;

all kinds of staple fibers may be used such as syntheticv fibers, cotton, wool, regenerated fibers and the like. Further, a single kind of staple fiber, a blend of staple fibers different from each other in the material, fineness, fiber length, cross-sectional configuration, crimp characteristics, elongation or the like may also be used. A blend of staple fibers different in characteristic or heat shrinkage may also be used. In the case where a blend of staple fibers different in fluid intertwining characteristics is used, the resulting yarn has an attractive cross section wherein both staple fibers are distributed in varying proportions ranging from the central portion to the peripheral portion. Further, in the case where a blend of staple fibers different in heat shrinkage is treated in accordance with the present invention, followed by heat treatment, the resulting fiber also has an attractive cross section wherein the proportions of both staple fibers in the central portion and the peripheral portion are different from each other.

Plural strands each comprising staple fibers different from those of the other may be separately supplied into the feed treatment zone. In this case, when the feed rate of each strand is intermittently varied, yarns of attractive appearance are obtainable, e. g., in a structure where different staple fibers are alternately arranged in the longitudinal direction or a structure where the yarn diameter is periodically varied.

In addition to one or more non-twist strands of staple fibers, one or more continuous filament yarns may be simultaneously or separately supplied into the fluid treatment zone as illustrated with reference to FIGS. 7 10. The filament yarn which becomes a core in the core spun yarn of the present invention, comprises for example a conventional synthetic filament yarn, its crimped yarn, a textured yarn, an elastomeric yarn, a flat yarn, a gold or silver thread, a glass yarn and a metallic yam. Both multifilament and monofilament yams may be used. When plural filament yarns are employed, the yarns are preferably treated with fluid in a completely opened state. In particular, when an elastomeric yarn made of elastomeric material such as polyurethane or a stretch yarn is employed, it is preferable to subject it to tensioned treatment or treatment under slack conditions prior to the fluid treatment to become opened thereby. Textured yarns as herein used mean those consisting of either non-elastic, continuousfilaments or non-elastic staple fibers, both of which have been made stretchable through reformation for example by the heat-set coil, crimp or curl methods. It is further practicable that a latently crimped filament yarn or a strand of latently crimped staple fibers is subjected to the fluid treatment and then, heat-treated to develop crimps. When a core yarn is used, it is also practicable to subject the resulting yarn to tensioned treatment after the fluid treatment to straighten the core yarn component and hence, to make the yarn hold a firm appearance. Further, it is also practicable to twist the filament yarn before supplying it to the fluid treatment zone, to a certain extent e.g. less than 500 T/M whereby the intertwinement thereof with staple fibers is enhanced.

The yarn of the present invention is of high bulk and has a soft, attractive handle similar to that of conventional spun yarns. The characteristic structure such that individual staple fibers are intertwined with each other to cohere into a substantially non-twist yarn, is distinguishable from conventional yarns made due to cohesive attraction such as twist, or adhesion, melting or sticking together. In addition, the yarn of the present invention has the advantage of reduced surface lubrication since it has numerous fluffs of a relatively large length.

In the practice of the method for manufacturing the yarn of the present invention, there is no necessity to provide a high speed revolution member for twisting and therefore, the spinning speed may be increased to 200 m/min or more, for example.

The invention will now be described with reference to Examples.

EXAMPLE 1 A roving of polyacrylonitrile staple fibers (fineness of 3 d, length of 120 mm), having a yarn number of 0.7 g/m, was drawn times its original length by a drafting means and then, fed through front rollers to the fluid treatment apparatus shown in FIG. 5.

The distance L between the grasping point of the front rollers (10) and the point where the intertwinement most effectively occurs was 80 mm. Pressure and flow rate of both first and second air flows were 3 kg/cm and 150 l/min, respectively. Peripheral speed of both the front rollers (10) and the delivery rollers (27) was 200 m/min. V

The yarn having a yarn number of one thirty-fourth Nm,.so produced, exhibited an appearance as shown in FIGS. 1A and 1B and was of high bulk.

EXAMPLE 2 A roving was prepared by blending two polyacrylonitrile staple fibers of a fineness of 3 d and a length of 120 mm, one being of ordinary shrinkage and the other being of high shrinkage, in a proportion of 6:4, respectively. The roving of a yarn number of l g/m, so prepared, was drawn by a drafting means and then, supplied to a fluid treatment apparatus shown in FIG. 5. The distance L defined herein before was 80 mm. Compressed air having a pressure of 3 kg/cm was introduced through two inlets l3 and 26 into theapparatus 14, each at a flow rate of 160 l/rnin. Peripheral speed of bothfront rollers 10 anddelivery rollers 27 was 200 m/min.

The spun yarn having a yarn number of one thirtyfourth Nm, so produced, had numerous fluffs of lengths ranging approximately from 10 30 mm and exhibited superior fiber intertwinement and fiber cohesion.

The spun yarn was wound into hanks, and then subjected to steaming at a temperature of C for 10 minutes under relaxed conditions to be made bulky thereby, and then rewound by a hank reeling machine. When it was rewound at the rate of 2 kg per reel, the yarn was smoothly unravelled and no yarn breakages could be observed.

EXAMPLE 3 A blended roving used in Example 2 and a polyamide multifilament yarn having a total fineness of 50 d and comprising 24 filaments were simultaneously supplied into the fluid treatment apparatus shown in FIG. 5. A core spun yarn of high bulk and softness was obtained.

EXAMPLE 4 A roving of polyacrylonitrile staple fibers having a fineness of 3 d and various lengths (average length of 150 mm and maximum length of 200 mm) was supplied to the fluid treatment apparatus shown in FIG. 5. The treatment conditions were as follows:

149 m/min Peripheral speed (V,) of thefront rollers 10 Peripheral speed (V,) of thedelivery rollers 27 I27 m/min Take-up speed m/min Pressure of the air introduced through the inlet 3.0 kg/em 13 Pressure of the air introduced through theinlet 32 kg/cm Deflecting member Distance (L) a wire gauge 70 mm 0.03 ,(V V /V 0.5

EXAMPLE 5 Using a fluid treatment apparatus shown in FIG. 8, a roving of polyester staple fibers having a fineness of 2.5 d and various lengths (average length of 128 mm) and two polyester filament yarns each having a total fineness of 50 d and comprising 48 filaments were treated under the following conditions:

7 Peripheral speed (V,) of the feed rollers [04 m/min Peripheral speed (V,) of the feed rollers 10' I06 m/min Peripheral speed (V of thedelivery rollers 27 87 rn/min 2.5 kg/cm Pressure of the air introduced through theinlet 13 Pressure of the air introduced through the 3.5 kg/cm inlet 13' lntersecting angle between the twoair inlet 45tubes 13 and 13Distance L 55 mm Deflecting member a wire gauge The yarn having a yam number of 1/15.5 Nm, so produced, was a fancy one of very high bulk involving a suitable number of fiuffs and loops.

Likewise, various yarns of unusual and attractive appearances were obtainable under varying conditions of feed speeds of both the roving and the filament yarn, delivery speed and air pressure.

EXAMPLE 6 Using a fluid treatment apparatus shown in FIG. 9, a roving of polyacrylonitrile staple fibers having a fineness of 3 d and various lengths (average length of 128 mm) and two polyamide multifilament yarns each having a total fineness of 50 d and comprising 34 filaments were treated under the following conditions:

Over-feed rate in the air treatment Zone 127! Distance I 40 mm Distance L 98 mm Air pressure 4.0 kg/cm Speed ofuir flow (V )at the vicinity ofthe outlet 1200 m/min in thetube 22 Peripheral speed of thedelivery rollers 27 100 m/min 0.03 Q (V, V2)/V 0.50

The yarn, so produced, exhibited the following properties:

Yarn number l/l6.5 Nm

Tensile strength 1.5 g/d Elongation l4'7r Degree ofintertwinement 35 cycles The yarn was of very high bulk. In the case where the yarns were doubled and then false-twisted, the resulting yarn exhibited extremely reduced yarn unevenness and could be used for various articles of clothing.

EXAMPLE 7 Using a fluid treatment apparatus shown in FIG. 13, a roving of polyacrylonitrile staple fibers having a fineness of 3 d and various lengths average length of 128 mamas treated under the following conditions:

- Continued Peripheral speed (V,) of thefront rollers 10 I20 m/min Peripheral speed (V of thedelivery rollers 27 107 m/min Pressure of the air introduced through the inlet 4.0 kg/cm 13 Pressure of the air introduced through the inlet 4.5 kg/cm Distance L mm a wire gauge of 300meshes Deflecting member 23 The spun yarn having a yarn number of 1/12.0 N m,

so produced, was of high bulk. The yarn exhibited strong intertwinement between the staple fibers although the yam was not substantially twisted, and a considerably reduced unevenness, and was quite suitable for knitting.

It has been confirmed from further experiments wherein the ratio of V, to V was varied that a satisfactory yarn is not obtainable unless V, is larger than V EXAMPLE 8 Using a fluid treatment apparatus shown in FIG. 18, a blended strand of two kinds of polyacrylonitrile staple fibers of equal weight, one having a fineness of 3 d and various lengths (average length of 128 mm) and the other having a fineness of 5 d and various lengths (average length of 102 mm) was treated under the following conditions:

Peripheral speed (V,) offront rollers 10 I50 m/min.

Peripheral speed (V,) of delivery rollers 132 m/min Take-up speed 145 m/min Number of revolutions of false-twist spinner 50 l8.000 rpm Pressure of the compressed air 4.0 kg/cm a wire gauge of 300 meshes Deflecting member The yarn having a yarn number of 1 I 3.5 Nm, so produced, was of very high bulk and quite suitable for various knitted and woven goods. Its workability was excellent i.e. yarn breakage was only 15.5 times/1,000 sp. hr. and yield was 97 percent.

EXAMPLE 9 Using a fluid treatment apparatus shown in FIG. 21, a roving of polyester staple fibers having a fineness of 1.5 d and various lengths (average length of 125 mm) was treated under the following conditions:

Peripheral speed (V,) of front rollers (not I03 m/min shown) Peripheral speed (V of delivery rollers (not m/min shown) Peripheral speed of take-up roller (not shown) I04 m/min Pressure of the air introduced throughinlet 56 4.5 kg/cm d and 0 6, and 6 0.3 m/m, 30, 20 and 15, respectively.

Claims (10)

1. A method of manufacturing a yarn having handle like spun yarn characterized in grasping a substantially non-twist strand of staple fibers at a fiber grasping point, supplying said fibers from said point to a fluid treatment zone, intertwining said staple fibers with each other in said zone with a turbulent flow to cohere into a single yarn, at least some of said staple fibers supplied to said fluid treatment zone having a length larger than the distance between said fiber grasping point in the fiber feed zone and the point where the intertwinement due to said turbulent flow most effectively occurs in said fluid treatment zone whereby a substantially non-twist yarn is produced, part of said staple fibers forming loops and fluffs projecting out of the periphery of said yarn, and then running the non-twist yarn accompanying a fluid flow against a deflecting member with perforations through which a substantial part of the fluid flow passes, whereby the intertwinement between the staple fibers and the formation of the loops and the fluffs are enhanced.

2. A method as claimed in claim 1 further characterized in that at least two fluid flows are blown against said substantially non-twist strand of said staple fibers in said fluid treatment zone whereby said staple fibers are intertwined with each other.

3. A method as claimed in claim 2 further characterized in that a first fluid flow is blown against said strand of said staple fibers and then, a second fluid flow is blown against said strand of said staple fibers while said staple fibers are suspended in and transported by the first fluid flow in a partially intertwined state.

4. A method as claimed in claim 3 further characterized in that said second fluid flow is blown against said strand of said staple fibers from a direction inclined to the course of said first fluid flow suspending and transporting said strand of said staple fibers at which intersection point said staple fibers alter their course and are suspended in and transported by the second fluid flow.

5. A method as claimed in claim 3 further characterized in that said second fluid flow to be blown against said strand of said staple fibers suspended in and transported by said first fluid flow in a partially intertwined state is a vortex flow.

6. A method as claimed in claim 3 further characterized by venting said first fluid flow accompanied by said strand of the staple fibers for the relief of pressure, between two points at which said first fluid flow and said second fluid flow are blown against said strand of the staple fibers, respectively.

7. A method as claimed in claim 1 further characterized in that said strand of said staple fibers, after said staple fibers are at least partially intertwined with each other in the fluid treatment zone and withdrawn therefrom while being suspended in the fluid flow, is turned back and made to pass countercurrentwise through said fluid flow.

8. A method as claimed in claim 1 further characterized in that said strand of said staple fibers is subjected to alternate twisting before the fluid treatment.

9. A method as claimed in claim 1 further characterized in that said substantially non-twist strand of said staple fibers is supplied together with a continuous filament yarn to the fluid treatment zone.

10. A method as claimed in claim 1 further characterized in that said strand of said staple fibers is subjected to alternate twisting during the fluid treatment.

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