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Патент USA US3070960

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Jan. 1, 1963
w. B. THOMAS
3,070,950
METHOD OF‘ PRODUCING A COMPOSITE YARN
Filéd Sept. 14. 1960
I
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—
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INVENTOR.‘
WILLIAM B. THOMAS
,
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ATTORNEYS '
United States Patent ()??ce
3,070,950
Patented Jan. 1, 1963
2
1
a method of producing a composite yarn of the above
type‘in which the degree of bulk and/or stretch of the
3,070,950
METHOD OF PRODUCING A COMPOSITE YARN
William B. Thomas, Spartanburg, S.C., assignor to Massa
chusetts Mohair Plush Company, Inc., Kings Mountain,
N.C., a corporation of New York
Filed Sept. 14, 1960, Ser. No. 55,989
2 Claims. (Cl. 57-157)
This invention relates generally to an improved method
yarn may be controlled by simply varying the percentages
of staple ?bers and/or ?laments in the yarn, varying the
amount of twist applied after the staple ?bers and ?l
aments are combined, varying the texturizing, denier and/
or number of continuous ?laments, or varying the type
and size of the staple ?bers.
7 Some of the objects of the invention having been stated,
of producing a composite yarn. More particularly, this 10 other objects will appear as the description proceeds, when
taken in connection with the accompanying drawings, in
invention relates to a method of producing a composite
which—
yarn that contains a plurality of texturized continuous
FIGURE 1 is a schematic view of one type of apparatus
?laments, which have a tendency to curl or crimp when
which may be utilized to produce a bulky stretchable com
not under tension, and staple ?bers which are intermingled
therewith and locked in the continuous ?laments. The 15 posite yarn by combining texturized continuous ?laments
resulting composite yarn product has the advantage of
high bulk and stretchability with the appearance and feel
of the spun staple yarn and wearing qualities and strength
of the texturized ?laments.
In prior attempts to obtain a composite yarn having 20
and staple ?bers;
FIGURE 2 is a schematic isometric view of a portion
of the apparatus showing the manner in which the tex
turized continuous ?laments and the staple ?bers are
joined together and then twisted to interlock the staple
?bers in the ?laments;
the appearance and feel of a spun yarn and the stretchable
FIGURE 3 is an enlarged elevational view of a length
characteristics of a texturized ?lamentary yarn, a strand
of composite yarn produced in accordance with the pres
of stretchable continuous ?lament yarn has been used as
ent invention and illustrating the texturized continuous
a core and a spun staple yarn has been wrapped around
the core of stretchable yarn. While this type of compos 25 ?laments extending from opposite ends of the yarn;
FIGURE 4 is a greatly enlarged somewhat diagram
matic transverse sectional view through the yarn shown
in FIGURE 3 and illustrating the manner in which the
wrapping yarn may slide along the length of the stretch~
staple ?bers are distributed in and interlocked by the tex
able core and pile up in a knot exposing the bare stretch
able core and causing breakage of the yarn and/ or defects 30 turized continuous ?laments.
The texturized continuous ?laments which form a part
in the fabric. Many attempts have been made to success
of the composite yarn of the present invention may be
fully ply or double the two types of yarn together in vari
texturized by any of several well known conventional
ous ways to prevent the piling up of the staple yarn along
methods which impart a crimp or curl to the yarn, when
the length of the stretchable core yarn. However, even
when these attempts have been successful in preventing 35 relaxed. For example, a strand of multi?lament synthetic
yarn may be treated by twisting, heat-setting and then un
the piling up of the staple yarn, in some portions of the
twisting on conventional spinning equipment or by false
?nished fabric the core yarn is exposed and in other por
ite yarn is stretchable, it does not have high bulk and
because the two yarns are merely plied together, the
tions of the fabric, the staple yarn is exposed.
Methods
twisting; the synthetic yarn may be texturized by running
the same over a heated blade; by running the synthetic
of Wrapping or plying a staple yarn with a stretchable
textured core yarn are disclosed in US. Patent No. 2, 40 yarn between a heated gear arrangement; overfeeding the
synthetic yarn into a stuf?ng box; or by running the syn
854,812 issued to C. W. Harris et al. on October 7, 1958,
thetic yarn past a ?uid jet to disrupt the ?laments. The
and US. Patent No. 2,777,310 issued to Marvin H.
texturizing of the synthetic multi?lament yarns to pro
Comer on January 15, 1957.
duce a continuous multi?lament stretchable yarn forms no
In other attempts to obtain a composite yarn having
the appearance and feel "of a spun yarn, a strand of un 45 part of the present invention as the texturized strand uti
lized in the present invention may be processed in any
textured continuous ?lament yarn has been combined with
number of ways to achieve the desired degree of stretch
spun staple ?bers andthen twisted to lock the staple ?bers
ability or extensibility of the texturized strand.
in the untextured ?laments. While this type of composite
The texturized continuous ?lament strand may be
yarn has the appearance and feel of a spun yarn, it does
not have any stretchability and no greater bulk than the 50 formed of any one of several available types of thermo
plastic synthetic yarns which may be texturized to impart
total size of the continuous ?laments and the spun staple
stretchability thereto. For example, nylon or Dacron
?bers. This type of composite yarn is disclosed in US.
may be used as well as others.
Patent No. 2,825,199‘ issued to J. W. Hicks, In, on March
The staple yarns which form 'a part of the composite
4, 1958.
With the foregoing in mind, it is a primary object of 55 yarn of the present invention may be any of many dif
ferent types of staple yarns available. ‘For example,
the present invention to provide an improved method of
.the staple yarns may be of natural ?bers such as cotton
producing a composite yarn of the type having high bulk
or wool or they may be of synthetic ?bers, such as nylon,
and elasticity with the appearance and feel of spun staple
Dacron, or the like, which have been cut into the desired
yarn.
It is another object of the present invention to provide a 60 staple length. vIt is preferred that the staple ?ber material
be ‘supplied in the form of a sliver, a roving or the like
methodof producing a composite yarn of the above type
in which the ?bers have been substantially alined and
in which staple ?bers are spun into and intermingled with
partially drafted [before they are introduced to and inter
a plurality of texturized continuous ?laments and then the
mingled with the texturized continuous ?laments of the
composite strand is twisted to lock the staple ?bers into 65 stretchable strand.
the ?laments and prevent the staple ?bers from becoming
Referring to the drawings, and particularly to FIG
displaced or sliding along the length of the ?laments. '
URES l and 2, one type of apparatus is shown which
It is another object of the present invention to provide
may be utilized to combine the strand of texturized con
a method of producing a composite yarn which is easily
tinuous ?laments and the staple ?bers and then twist the
adaptable for a wide range of uses by varying the degree of 70 same to form the composite yarn of lthe present invention.
bulk and/ or stretchability of the yarn.
The parts of the apparatus shown are of the type gen
erally found on a conventional spinning frame having a
‘ It is another object of the present invention to provide
3,070,950
3
4
series of pairs of drafting rolls which include rear rolls
resulting composite yarn would have the appearance of
1%’, 11, intermediate rolls ‘12, 13, and front or delivery
rolls 14, 15. A suitable bobbin 19 supplies a roving
strand of staple ?bers 20 which is. drawn through the
pairs of rotating drafting rolls to elongate the strand 20
a slub yarn.
and draft the staple ?bers the desired amount. The con
the yarn is desired.
ventional driving arrangement of the spinning frame is
may be utilized in knit swimsuits and the like where the
It has been found that composite yarns made in ac
cordance with the present invention have many uses in
the textile ?eld where bulkiness and/ or stretchability of
For example, the composite yarn
bulk and feel of a cotton garment is desired while it is
‘arranged so that the rotational speeds of the pairs of
also desirable to have a certain amount of elasticity to
drafting rolls may be regulated to vary the amount the
roving strand 20 is drafted before it passes from the pairs 10 provide a snug ?t. The present composite yarn may also
be utilized as the terry or pile yarns in towels, rugs,
of front delivery rolls 14 and 15.
blankets or the like Where bulkiness and resiliency in the
A strand 25, comprising a plurality of texturized con
loops or tufts of the fabric is desirable so that the loops
tinuous ?laments, is withdrawn from a yarn supply pack
will recover when crushed and remain full and ?uffy ap
age 26, passes over a guide rod 27, over- a guiding roller
or element 28 and is drawn beneath the upper from; de 15 pearing. The composite yarn may also be utilized in
the knitting of hosiery where it is desired to ‘have bulki~
livery roll 14 where it joins the roving 2%). of the staple
ness combined with elasticity.
?bers, in a manner to be presently described. It is pre
Another important advantage of the composite yarn
ferred that the strandv oftexturized ?laments have only
of the present invention is that novel coloring effects
a small amount of twist imparted thereto so that. ‘as they
may be achieved in the yarn. When the ?laments and
pass beneath the roll 14, the-?laments will form a?at
staple ?bers have different dyeing characteristics, either
ribbon as they join the ?attened ribbon of staple ?bers
cross-dyeing or union-dyeing may be utilized. Also, the,
20. Then ‘as they pass from between the rolls 14, 15,
?laments and staple ?bers may be precolored to secure
the ribbons of continuous‘ ?laments _25;and staple ?bers
blended or contrasting colors in the ?nal yarn.
20 combine ‘and the staple ?bers of the strand 2i} inter
Although the present composite yarn has many appli
mingle among, around ‘and between the continuous ?la 25
cations, it is believed to be helpfulrto a better under
ments 25 ‘so that the staple ?bers are completely inte
standing _of the invention to describe a practical embodi
grated with the continuous ?laments to form the compos
ment of the yarn which is given solely by way of example.
ite yarn indicated at Y.
As the composite yarnY leaves the bight of the. de
Example
livery rolls 14 ‘and ‘15, it is directed downwardly through 30
One
type
of
standard
cotton yarn presently used to
a pig-tail yarn guide 30, throughia rotating traveler'31.
and onto a rotating take-up package 32. The take-up‘
form the loopsor tufts of a Woven carpet is a 1.375/1
cottoncount yarn which yields 1155 yards per pound and
package 32 ‘includes a rotating bobbin which isrotated
in ‘order to provide proper coverage, a carpet mill will=
in the conventional manner toimpart thedesired amount
of twist in the yarn Y before the same is wound onto. 35 form 14 tufts orpile loops per inch in the paper with this,
the bobbin. The speed of the delivery rolls 14, 15 in
relation to the speed, of thetake-up package may be
varied in the conventionalmanner to impart the desired
size of alljcotton'yarn. In order to form a comparable
size composite yarn in accordancewith the present in
vention, any suitable sliver of roving staple cotton ?bers is‘
fed between the drafting, rolls and drafted down ‘to a cot
amount of twist to the yarn Y. H the strand 25 has a
small amount of twist in it when it is delivered to the. 40 ton vcount 1.67/1. A strand of‘ texturized ?laments of
roll 14, then the twist applied to the composite yarn ‘Y
should be mthe opposite direction to causethe ?laments
nylon having 34 ?laments and a total denierv 70 is joined
with the drafted cotton staple ?bers as, the two pass be
tween the front delivery rolls 14, and 15 where the cotton‘
staple ?bers are intermingled with the texturized ?laments,
they passibetween the rolls 14, 15 to 1611,1116 staple ?bers 45 and the composite yarn is given a ‘twist of approximately‘
in-termingle therewith.
3% turns per inch before itv is collected on the take-up;
to return to zerotwist before being ?nally twisted. This .
allows the ?laments to open up, and ‘separate as soon ‘as.
Referring to FIGURE 3, it willbe noted that the com
posite yarn Y is made up of the. individual texturized
continuous ?laments 25which- are shown projecting out
package 32.,
.
The resulting composite yarn, before bulking, is the
same size as the standard 1.3,75/1 cotton yarn usually
wardly from opposite ends thereof and the intermingled 50 used .and yields the same number of yards per ‘pound.
The composite yarn formed. contains 84% cotton staple,
staple ?bers 20 which cover and substantially obscurev
the texturized ?laments 25. The sectional viewof the
?bers and 16% texturized continuous?larnents. It has
been found that only eight tufts (ii pile loops per inch are
yarn Y, shown in FIGURE 4, illustrates the separation
of the ?laments 25 and the intermingling of the staple
requiredof the composite/yarn, and whenthe carpet is
?bers 20 therewith. Thus, the resulting ‘composite yarn 55 ?nished, the composite yarn will bulk approximately 20%,
toiprovide the same. coverageas the cotton yarn which
Y has the feel and appearance of the staple ?bers 20‘ and
required fourteen tufts per inch. It is apparent that with
also has greatstrength which is providedby the texturized
a lesser number of tufts .or. pile loops required per inch,
?laments 25. When the yarn Y is relaxed, the ?lamentsv
25itend~to return to their crimped or curled condition to
thereby expand the yarn and give the same high bulk
and stretchability. In order to speed up the crimping
a lesser amount of the composite yarn will be utilized in
making the carpet thereby reducing the cost of manufac
ture.
Also, using the composite yarn of the present invention
or curling of the ?laments 25 to bulk the yarn, the yarn,
as the pile yarn in a carpet, the_overall weight of the
or the fabric made therefrom, may be subjected to heat.
carpet will be reduced by approximately 20%, the pile
This heat may be dry or wet and may be applied before 65
loops or tufts of the composite yarn have greater strength
or during the ?nishing and/ or dyeing process.
and wear longer than loops or tufts formed of cotton
The speed of the drafting rolls may be maintained in
the same relationship so that the same amount of staple
?bers are fed to and intermingled throughout the length
of the texturized ?lament strand 25. However, if de
vgsired, the speed. of. the drafting rolls can be varied at
times to feed a greater amount of staple ?bers to the tex
turized ?lament strand~25 and then feed a lesser amount
yarns. Also, the pile loops or tufts formed of the present
composite yarn have more resiliency than-loops or tufts
of cotton. yarn and will return to their normal position
after remaining crushed for a considerable length of time.
It has been found thatv composite yarns can be made
in accordance With the present invention Which have a
wide range of sizes. Also, by varying the amount and
type of texturized ?laments and/orstaple ?bers utilized,;
of staple ,?bers to the texturized ?lament strand. 25. By
varying the speed of the drafting rolls in this manner the 75 the characteristics of the composite yarns formed there
3,070,950
5
from can be formed to suit a wide range of uses.
6
Gen
erally, it has been found that the higher the percentage of
texturized ?laments used the greater the bulk and stretch
ability of the composite yarn and the lower the percent
age of texturized ?laments used the lower the bulk and
stretchability of the composite yarn. From an econom
ical point of view, it would not be practical to utilize more
locked in a plurality of ‘texturized ?laments and the com
posite yarn and/ or fabric 'knit or woven therefrom has
the hand, feel and appearance of a spun staple yarn and
the strength and elasticity of a stretchable ?lamentary
yarn.
In the drawings and speci?cation there has been set
forth a preferred embodiment of the invention and, al
though speci?c terms are employed, they are used in a
than 50% of texturized ?laments because the texturized
generic and descriptive sense only and not for purposes
?laments are so much more expensive than cotton staple.
Also, when more than 50% of texturized ?laments are 10 of limitation, the scope of the invention ‘being de?ned in
ing less than 5% of texturized ?laments, however, the
the claims.
I claim:
1. A method of producing a composite yarn contain
ing a plurality of texturized continuous ?laments and
staple ?bers which comprises drafting a single roving of
amount of bulking would be too small to be of any real
staple ?bers to a predetermined degree to form a ribbon
utilized, the composite yarn begins to take on more of
the characteristics of the ‘texturized ?laments and no
longer has the predominate appearance of a spun staple
yarn. Some bulking is present in a composite yarn utiliz
value. For the above reasons, it is contemplated that the
percentage of texturized ?laments utilized will be within
of the staple ?bers, feeding a single twisted strand of tex
turized continuous ?laments while guiding the strand of
the range of from 5 to 50% and in most instances the
?laments into contact with the ribbon of staple ?bers dur
percentage of texturized ?laments will be Within the range 20 ing the last stages of the drafting of the staple ?bers to
of from 10 to 40%.
cause the staple ?bers to intermingle with the texturized
The amount of twist applied to the composite yarn also
continuous ?laments, and then applying twist to the com~
affect the degree of bulk and elasticity of the composite
bined ?laments and staple ?bers in a direction opposite
yarn. Generally, the more twist applied to the yarn the
the direction of twist in the strand of texturized continu
less bulk and elasticity because if the yarn is highly 25 ous ?laments to initially remove the twist from the strand
twisted, the texturized ?laments do not have the freedom
of ?laments and then apply thereto to lock the staple
to return to crimped or curled position when relaxed. In ,
?bers between and among the ?laments.
most cases, it is preferred that the amount of twist be low,
2. A method of producing a high bulk of texturized con
less than 5 turns per inch, although this will be deter~
composite yarn including a plurality of texturized con
mined by the size of the composite yarn, the amount and 30 tinuous synthetic ?laments and cotton staple ?bers inter
character of the texturized ?laments and/ or staple ?bers.
mingled therewith and having the appearance and feel
Other factors can also change the degree of bulk and
of the staple ?bers and the wearing qualities and strength
elasticity of the composite yarn. For example, the ?ner
of the texturized ?laments, said method comprising the
the denier of the individual ?laments of the texturized
steps of drafting a single strand of the cotton staple ?bers
strand utilized, the resulting ‘composite yarn will be more 35 to a predetermined degree by passing the strand through
bulky, have more elasticity and have a softer hand. If
a plurality of drafting rolls de?ning a drafting zone, feed
the type and/ or size of staple ?bers is changed, the char
ing a single twisted strand of the texturized continuous
acteristics of the resulting composite yarn will also be
synthetic ?laments into contact with the strand of staple
changed. For example, it is generally true that the longer
?bers immediately prior to the staple ?bers leaving the
the staple ?bers the less bulk and elasticity of the com 40 drafting zone to cause the staple ?bers to be intermingled
posite yarn.
with the texturized continuous ?laments, and then deliver
From the foregoing, it will be apparent that composite
ing the combined texturized continuous ?laments and
yarns having varying degrees of bulk and elasticity can
staple ?bers from the drafting zone while applying twist to
be made in accordance with the present invention and
the combined ?laments and staple ?bers in a direction op
these composite yarns can be used in making a wide 45 posite the direction of original twist in the strand of tex
variety of fabrics. The degree of bulkiness and elasticity
turized continuous ?laments to initially remove the twist
of the composite yarn ‘can be controlled by varying the
from the strand of ?laments and then apply twist thereto
percentages of texturized ?laments and/or staple ?bers,
to cause the staple cotton ?bers to be interlocked between
the amount of twist applied after the staple ?bers and
and among the continuous ?laments.
?laments are combined, varying the texturizing, denier 50
and/or number of continuous ?lament, and/or varying
References Cited in the ?le of this patent
the type and size of the staple ?bers. While it is pre
UNITED STATES PATENTS
ferred that the percentage of texturized ?laments be
2,506,667v
Hall _________________ __ May 9, 1950
generally less than the percentage of staple ?bers, it is
Hicks _______________ .._ Mar. 4, 1958
within the scope of the present invention to change these 55 2,825,199
2,880,566
Schlums _____________ _._ Apr. 7, 1959
percentages if desired. The percentages of texturized ?la
2,902,820
Bronson et al. _______ __ Sept. 8, 1959
ment and staple ?bers in the composite yarn are deter~
2,971,322
Bouvet ______________ __ Feb. 14, 1961
mined by the desired characteristics of the composite yarn
FOREIGN PATENTS
and/or resulting fabric and may be changed to provide
60
the desired characteristics.
1,158,282
France ______________ __ Jan. 20, 1958
It is thus seen that an improved bulky and stretchable
71,568
France _____________ _... July 15, 1959
composite yarn and method of making the same has been
(1st Addition to N0. 1,158,282)
provided in which staple ?bers are intermingled and
(Corresponding British 850,059, Sept. 28, 1960)
,s. /
1
UNITED STATES PATENT OFFICE
‘CERTIFICATE OF CORRECTION
Patent No. 3,070,950
January 1, 1963
William B, Thomas
It is hereby certified that error appears in the above numbered pat
ent requiring correction and that the said Letters Patent should read as
corrected below.
Column 4, line 35, for "capet" read —— carpet ——,
column 5, line 23, for "affect" read —— effects ——-‘,’ lines 51,
56 and 57, for "filament", each occurrence, read '—- filaments
——; column 6,
line 26, after "apply" insert -==— twist ——.
Signed and sealed this 11th day of June 1963,,
(SEAL)
Attest:
‘ERNEST w. SWIDER
I Attesting Officer
DAVID L. LADD
,
,
Commissioner of Patents
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