CA1317169C - Vacuum spinning of fasciated yarn from sliver - Google Patents

Abstract

ABSTRACT

A fasciated yarn suitable for making apparel fabric and having properties approaching that of ring spun yarn is produced by vacuum spinning, including directly from sliver. The elongated hollow shaft (20) of the vacuum spinning apparatus has a vacuum reservoir (32), or interior chamber, that is generally in the shape of a right circular cone, and the interior passageway (31) of the shaft from the first end (21) thereof to the interior chamber can have the form of a right circular cone frustum. The peforations (40) operatively connected to the interior chamber have a generally wedge-shape. The perforations and the passageway sections between the first end of the shaft and the perforations are dimensioned so that they allow sufficient air flow to achieve optimum fiber wrapping action. The fasciated yarn comprises vacuum spun yarn consisting of fibers including core fibers and wrapper fibers, the wrapper fibers being predominantly individual fibers although having some groups of wrapper fibers. The groups of wrapper fibers appear as non-uniform, non-consistent groups and provide a relatively smooth appearance.
The wrapper fibers are wrapped at a helix angle of about 30° (e.g. about 30-50°), and about 20-30 percent of the fiber mass comprises the wrapper fibers. The wrappers are essentially devoid of auger or corkscrew appearance. The core fibers are essentially parallel staple fibers. Initial threading of the vacuum spinning apparatus is provided by a vacuum tube (745) mounted for rotation about an axis parallel to and spaced from the axis of rotation of the shaft, the vacuum tube being connected up to a vacuum reservoir (742) and source of vacuum (728) and rotatable from an inoperative to an operative position.

Description

~ 3 1 7 1 6~

VACUUM SPINNING OF FASCIATED YARN FROM SLIVER

In U.S. patent 4,507,913 methods and apparatus are provided for efficiently and effectively producing yarn having properties approaching those of ring spun yarn, but at much greater speeds. The basic technique disclosed in the patent is known as "vacuum spinning", and has a number of advantages compared to conventional techniques.
Until relatively recently, ring spinning equipment has made up approximately 90 percent of all spinning eguipment. However several new high speed procedures have recently been utilized including open end spinning, friction spinning, hollow core spinning, and air jet spinning. None of these new commercial systems has been successful in the production of long staple yarn, however, especially for apparel fabrics. However vacuum spinning is capable of producing long staple yarn suitable for use in apparel fabrics, the yarn approaching the properties of ring spun yarn.
Vacuum spinning has a number of advantages compared to conventional ring spinning. These include the following: Productivity can be expected to be at least 6-8 times that of commercial ring spinning. Despite this increased productivity, the properties of the yarn are more like ring spun yarn than open end or air jet type yarns. The horsepower per pound of yarn produced is considerably less than that for air jet spinning using compressed air.

1 3 1 7 1 6q Vacuum spinning lends itself to automatic end piece-up, automatic slubbing, automatic adaptation, the production of large delivery packages, and the utilization of large supply packages (e.g. 25 lb.
cans of sliver). A wide count range can be provided on long staple yarns, at least l/8 s to 1/60 s on 55 percent polyester/45 percent wool, and at least 1/8 s to l/40 s on 100 percent wool. There are lower labor costs per pound of yarn produced compared to ring spun yarn.
Further advantages of the invention are as follows: The process lends itself to high draft ratios (e.g. 10-80), can be modified to run both long and short staple yarns, and can make yarn having either "S" or "Z" twist. A number of unique novelty yarns can be produced. The apparatus is simple and easy to maintain, and the noise level can be controlled by locating the vacuum pump in a separate location, to thereby ensure compliancs with OSHA
regulations. The apparatus runs cleanly since the vacuum automatically removes lint fly, and like contaminants, and oily waste is not introduced.
Waste is reduced due to draft zone stoppage on end breaks, with a reduction in end breakage of about 400 percent compared to ring spinning since there is no tension in the yarn. Also thread-up of the broken ends can be accomplished with minimum operator intervention. The system can be run using higher weight sliver (e.g. 55 grains per yarn compared to 35-40 grains per yarn which is conventional), and carpet yarn can be produced too by lengthening the draft zone and providing a larger nozzle. Yarn steaming may not be required for most counts-blends for handling, although it may be re~uired for uniform dyeability, and steaming is easy to effect.
The yarn produced according to the present invention includes core fibers and wrapper fibers.
The wrapper fibers are predominantly individual fibers, although there are some groups of wrapper fibers. The groups of wrapper fibers appear as non-uniform, non-consistent fiber groupings, and provide a relatively smooth surface. The core fibers, on the other hand, are essentially parallel with the wrapper fibers uniformly distributed therearound. The fasciated yarn according to the invention thus loo~s most like ring spun yarn of the commonly known yarns, although it is distinct in appearance from ring spun yarn too. For instance the yarn according to the invention looks more like ring spun yarn than core spun, open-end, Murata jet spun, Toray, or DREF II prior art yarns.
The fasciated yarn according to the invention, as set forth above, essentially parallel core staple fibers. There is a uniform distribution of staple fiber wrapper fibers around the core fibers, the wrapper fibers being wrapped at a helix angle of about 30, and with about 20-30 percent of the fiber mass comprising wrapper fibers.
The fasciated yarn according to the invention 3~
can also be described as a yarn having a core of 1 31 7 1 6q essentially parallel staple fibers with the wrapped staple fibers disposed around the core forming a helix angle in ~he rang of about 30-50, and the wrapped fibers are devoid of tucked or reverse wrapped fibers and are essentially devoid of auger or corkscrew appearing wrapped fibers. Rather the wrapped fibers have a smooth appearance.
The fasciated yarn according to the invention can be produced with the predominant proportion of staple fibers of the core and covering as non-thermoplastic staple fibers. While the predominant proportion of the core and wrapped fibers can be selected from the group consisting of cotton, wool, rayon, mohair, flax, ramie, silk, and blends thereof, the yarn according to the invention also can be c~onstructed using some, or all, thermoplastic fiber, such as acrylic, polyester, and other thermoplastic fibers or blends thereof.
The yarns produced according to the present invention has surprising and desirable strength. For instance yarn produced according to the invention from a l/18 s count of 45 percent polyester and 55 percent wool will have a minimum gram break strength of about 500, while yarn according to the present invention with the same count made of 100 percent wool will have a minimum gram break strength of at least about 175. Thus even when made from 100 percent wool the ~arn according to the present invention is suitable for making apparel fabrics.

1 3 1 7 1 b9 The apparatus and method according to the present application also have basically all the same advantages described above with respect to vacuum spinning in general. Additionally, according to the present invention in the production of yarn from roving it is possible to construct the "nozzle" of the vacuum spinning apparatus in a simpler and more advantageous manner. By providing an interior generally conically shaped vacuum reservoir, instead of a spherical vacuum reservoir, ease of produ~tion is facilitated and a yarn having a slightly better break strength can be produced.
Also according to the present invention the production of yarn directly from sliver is 15 facilitated.
The particular "nozzle" for producing yarn having good strength properties directly from sliver, according to the present invention, preferably includes a generally conically shaped interior chamber. The perforations in communication with the interior chamber are generally wedge-shaped, and the size of the interior passageway in the shaft adjacent the first end thereof is very large compared to the diameter of the shaft passageway between the interior chamber and the second end of the shaft, and my have the shape of a right circular cone frustum. The interior chamber is dimensioned so that it is large enough to allow free fiber movement so that the fibers will be lifted up and wrap around a core of the fiber mass more securely, however the interior 1 3 1 7 1 6q chamber should not be so big that the fibers will be pulled through the perforations by the vacuum source.
The perforations and the passageway between the first end of the shaft and the perforations, are dimensioned so that optimal wrapping action can be achieved. That is, the dimensions are large enough so that they allow sufficient air flow that they do not prevent the attainment of optimal fiber wrapping action. In this way optimal wrap for any given application may be achieved.
While vacuum spinning is a generally low maintenance procedure, during the initia-l start up there are difficulties in threading the fibers through the shaft passageway to the take up mechanism. The procedure i8 not self-starting, and typically has been accomplished in the past by using a thread-up wire attaGhed to the end of the fibers and manually pushing and pulling the thread-up wire through the passageway until the fibers were completely through the passageway. Then the fibers were wrapped around a take-up cone, or like take-up mechanism.
According to the present invention a method and apparatus are provided which greatly facilitate the initial threading of a vacuum spinning system elongated hollow shaft. According to the present invention initial threading is provided in an efficient semi-automatic procedure utilizing a vacuum tube mounted for rotation with respect to a vacuum reservoir so that the second end of the tube is movable from a first, inoperative, position wherein it is spaced from the opening, to a second, operative, position wherein it is in operative communication with the opening so that a vacuum is drawn through the tube first end into the reservoir and to the source of vacuum. The axis of rotation of the tube is generally parallel to the axis of rotation of the elongated shaft of th~ vacuum spinning apparatus, so that when the tube is rotated into its second, operative, position, the first end of the tube is immediately adjacent the second end of the elongated shaft so that it sucks the connected fibers within the shaft all the way through to the end end thereof. Preferably means are provided responsive to rotation of the vacuum tube from its first to its second positions for cutting out the vacuum applied to the exterior of the elongated shaft when the vacuum tube is moved toward its second position.
The accompanying drawings illustrate preferred embodiments of the invention> and in which:

FIGURE 1 is a microphotograph at approximately 70x magnification of vacuum spun yarn according to the present invention;

FIGURE 2 is a microphotograph of the same yarn as FIGURE 1 only at a magnification of 35x;
3~

FIGURES 3 through 8 are microphotographs of other, conventional, spun yarns made respectively by core spinning, open-end, ring spun, MJS, Toray, and DR~F II techniques respectively;

FIGURE 9 is a side view of exemplary apparatus according to the present invention, shown in schematic cooperation with a vacuum source and feed roller;

FIGURE 10 is a side cross-sectional view of an exemplary "nozzle" for use with the apparatus of FI~URE 9;
FIGURES 11 through 18 are side schematic cross-sectional views of exemplary other forms of "nozzles" that may be utilized in vacuum spinning procedures;

FIGURE 19 is a side schematic view showing conventional vacuum spinning apparatus in elevation, and showing a portion of a vacuum tube of exemplary apparatus according to the invention inoperative association with the vacuum spinning apparatus;

FIGURE 20 is a side cross-sectional view of an exemplar~ vacuum spinning elongated hollow shaft showing a first end of an exemplary vacuum tube according to the present invention inoperative association with the vacuum spinning apparatus shaft;

131716'3 FIGURE 21 is a front perspective view of exemplary threading apparatus of FIGURES 19 and 20;

FIGURE 22 is a rear perspective exploded view, with portions cut away for clarity, of the apparatus o f FIGURE 21; and FIGURES 23 is a top plan schematic view of the apparatus of FIGURES 21 and 22 mounted in position with respect to the vacuum spinning apparatus of FIGURE 19.

The basic vacuum spinning apparatus 14 illustrated in FIGURE 9 is similar to that shown in U.S. patent 4,507,913. The apparatus 14 comprises an outer housing 16, of metal, ceramic, or the like, which is operatively connected up through integral nipple 17 to a vacuum source 18, such as a vacuum pump which provides 20 inches of mercury at 19 cfm (or more). The interior of the housing 16 is hollow.
The interior "nozzle" of the apparatus 14 is indicated generally by reference numeral 20, and includes a first end 21 thereof and a second end 22.
At the second end 22 a gear 24 is mounted, which is connected to appropriate other gears and drives (not shown) for effecting rotation of the "nozzle" 20. the drives can rotate the "nozzle" 20 either clockwise or counterclockwise to provide either a Z or S twist, as desired.

1 3 1 7 1 6q From a draft system (not shown) a sliver S
passes through the nip of the front feed rolls 26, and the produced yarn Y exits from the second end 22 5 of the apparatus 14.
A "nozzle" 20 according to the present invention for the production of yarn from sliver is shown in detail in FIGURE 10. The "nozzle" 20 comprises an elongated hollow shaft 30 having a first end 21 and a 10 second end 22. A through-extending passageway goes from the end 21 to the end 22. The passageway includes a first portion 31 adjacent the first end 21, an interior chamber portion 32 close to, but spaced from, the first encl 21, and a third portion 33 that extends from the portion 32 all the way to the second end 22. In the specific embodiment illustrate din FIGURE 10, the diameter of the portion 33 is 1/16th of an inch, and is substantially constant.
Mounting the shaft within the casing 16 for rotation preferably bearings 35, 36 are provided. An annular shaped flange 37 extends outwardly from, and is integral with, the shaft 30 adjacent the end 22, and the bearing 36 abuts the flange 37. The the exterior cylindrical ~urface 38 of the shaft 30 the gear 24 is press-fit so that rotation of the gear 24 effects rotation of the shaft 30.
The shaft 30 illustrated in FIGURE 10 is one that is particularly adapted for forming yarn Y from a sliver, rather than from a roving. The production of yarn directly from sliver, instead of from roving, of course has a number of advantages since it . .

essentially eliminates a step (and the associated equipment for performing the step) in the yarn formation process. It has been found, according to the invention, that in the production of yarn from sliver, instead of from a roving, it is necessary to maximize the air flow from the first end 21 to the vacuum source 18, while still providing a restricted enough path for the movement of the fibers so that they are not pulled out of the shaft 30 by the vacuum. In the specific embodiment illustrated in FIGURE 10, this maximized air flow is provided by making the dimensions of the first passageway section 31 very large compared to the section 33, and providing perforatic-ns 40 that have a total effective area generally comparable to the effective operative area of flow in the passageway section 31, so that optimum wrap of fibers is achieved.
The passageway section 31 is substantially circular in cross-section, and for the embodiment illustrated in FIGURE 10 has a diameter of about 0.387 inches, with the outside diameter of the shaft 30 at that point begin about ~.5 inches. The intermediate portion 32 of the passageway has a generally conical configuration, in essence having ~5 the configuration of a right circular cone. The passageway portion 32 is dimensioned so that it comprises a means for allowing free fiber movement therewithin, so that the fibers can be lifted up a ~ubstantial distance to wrap around the core during the production of the yarn Y from sliver S. For the particular structure illustrated in FIGURE 10, the passageway sections 31, 32 may be formed as follows:
-Using a number 4 center drill, the end 21 is concentrically penetrated to a depth of about .51 inches.
-Using a 15/64 inch drill, the end 21 is concentrically re-penetrated to the depth of about .497 inches.
-Using a 1/4 inch end mill, the end 21 is again concentrically penetrated to a depth of about .42 inches.
-Using a 3/8 inch 60 countersink, the end 21 is again concentrically penetrated to a depth of .52 inches.
Passageway section 33 is formed merely by concentrically penetrating the end 22 with a 1/16 inch drill, and drilling all the way to the preformed passageway portion 32. Typical other dimensions of the shaft 30 are as follows: the distance 42 equals about 3/8 inch; the diame~ar o the end 22 is about 0.503 inches; the thickness of the flange 37 is about 0.125 inches; the diameter of the portion raceiving the bearing 36 is about 0.501 inches; and the length of the shat 30 from teh beginning of the first end 21 thereof until the beginning of the flange 37 is about 1.5625 inches.
Note that there is a tapered wall portion between the passageway section 32 at the perforations 40 and the passageway section 33, this tapered wall portion being illustrated by reference numeral 44 in . . .

FIGURE lO. The provision of this tapered wall, compared to the same configuration of the shaft 30 without the tapered wall, leads to significantly better results.
For the embodiment illustrated in FIGURE lO the perforations 40 are preferably four in number, and are evenly spaced around the periphery of the shaft 30. Each perforation 40 is generally wedge-shaped.
The width of each of the perforations 40 at the exterior surface of the ~haft 30, which width is indicated generally by reference numeral 46, is about .34 inches. Each of the per~orations 40 is formed by drilling an opening from the circumference to the passageway section 32 with a 3/32 inch drill at about a 34 angle, a~d then reaming to the vertical to form the surface 48 which is essentially perpendicular to an extension of the passageway third portion 33. The results achieved by providing the face 4~ generally perpendicular to the passageway section 33 are significantly improved compared to the situation where the 3/32 inch hole is drilled at a 34 angle and there is no reaming.
Other illustrative configurations of nozzles which may be utilized according to the present invention are illustrated in FI~URES ll through 15.
While all of these nozzles are useful in forming yarn, it will be seen from the comparative test results for these nozzles that some produce yarn having significantly better properties than others.
3~

13171~9 The nozzle 120 illustrated in FIGUR~ 11 has a generally constant 1/8 inch diameter through-extending passageway 133, with four rows of 1/16 inch diameter perforations 140 each at a 90 angle to the passageway 133.
The nozzle 220 in FIGURE 12 has a constant 1/8 inch diameter through-extending passageway 233 with four perforations 140 each 1/16 inch in diameter and angled in the direction of the second end 222.
The nozzle 320 illustrated in FIGURE 13 has a passageway portion 333 communicating with the second end 322 thereof that is 1/16 inch in diameter.
Adjacent the first end 321 thereof the passageway portion 331 is about 1/8 inch in diameter. Between the passageway portions 331, 333 is a 1/4 inch diameter spherical vacuum reservoir 332, with four 1/16 inch diameter angled perforations 340 extending outwardly from the reservoir 332.
The nozzle 420 of FIGURE 14 has a passageway portion 433 that is 1/16 inch in diameter, and a passageway portion 431 which is 1/~3 inch in diameter.
The passageway portion 432 may be considered a vacuum reservoir, and has a conical shape. Four 1/16 inch angled perforations 440 are provided in communication with the reservoir 432.
The FIGURE 15 nozzle 520 is essentially identical to the nozzle 20 illustrated in FIGURE 10 (note that the showing in FIGURE 15 is schematic~, except that the entire passageway section 531 has the shape of a cone frustum, and the shape of the 1 3 1 7 1 6q passageway section 532 -- and the exact points that the perforations 40 come off of it -- are slightly different.
The nozzles illustrated in FIGURES 11 through 14 are suitable for use in forming yarn from roving, but do not form particularly strong or useful yarns from a sliver. However the nozzles 520 of FIGURE 15, and 20 of FIGURE 10, are capable of forming strong yarns from sliver, having an increased tota-1 air flow from the first end thereof through the perforations to the vacuum source 18. Also the middle sections of the passageways (32, 532) allow free fiber movement so that the fibers will be lifted up and wrap around the core more securely. However the passageways 32, 532, are not so big that the fibers wil~ be pulled through the perforations 40, 540 by the vacuum from source 18. Also in these embodiments the perforations collectively have effectiva cross-sectional areas relative to the effective cross-sectional area of the passageway section between the first end of the shaft and the perforations so that the dimensions of the perforations and passageway section are not a limiting factor in attaining optimal wrapping action of the fibers~ In this way optimal wrap for any given application may be achieved.
The following table I gives the results of tests that have been done on the nozzles of FIGURES 11 through 15 utilizing the same composition of feed materials. In each case l/l9's poly/wool feed fibers were utilized. 55% 3dx3 1/2"x4 1/2" T-655 Dacron 1 3 1 7 1 6q Natural (polyester), and 45% WP644 Wool Natural. The vacuum source 18 in each case applied a vacuum of about 14-15 inches of mercury, but the volume of air 5 flow was significantly greater for the FIGURE 15 embodiment than for the other embodiments.
TABLE I

TYPE OF BREAKING STRENGTH
NOZZLE STOCK (~rams/denier) ELONGATION
lO FIGURE 11 Roving 308 13.66%
FIGURE 12 Roving 349 15.65%
FIGURE 13 Roving 390 17.72%
FIGURE 14 Roving 424 14.8%
FIGURE 15 Silver 518 9.0%
Surprisingly, the breaking strength of the yarn produced by the nozzle of FIGURE 15 directly from sliver was greater than the breaking strength of the yarn produced from roving utilizing the nozzle of FIGURE 14 (which is similar in construction to that 20 Of FIGURE 15). Note that the nozzles of FIGURES 11 through 13 are suitable for use with a diffuser, while those of FIGURES 14 and 15 are not designed for use with a diffuser.
Note also that the generally conically shaped passageway section (vacuum reservoir) 432 of the FIGURE 14 nozzle achieves a yarn of higher break strength than for the spherical vacuum reservoir 332 embodiment of E'IGURE 15. Vacuum reservoirs 332, 432 also have other functions, such as providing a 3~

chamber ~volume) for radial deflection of the fibers so that the wrapping function is facilitated.
The apparatus according to the present invention thus includes an elongated hollow shaft 30 having first end 21 and a second end 22, with a through-extending passageway 31, 32, 33. At least a portion of the entire circumference is perforated, by perforations 40. Means for mounting the shaft for rotation comprise the bearings 35, 36 and the housing 16, and means for rotating the shaft about its axis comprise the gear 24 and associated po~ered components (not shown). The feed rolls 26, and other components, comprise means for passing textile fibers S through the passageway 31-33 of the shaft 30, linearly, generally along the axis of rotation thereof, the fibers being fed into the first end 21.
The source 18 applies a vacuum to the exterior of the shat 30 so that at least some of the fibers or free ends of fibers passing through the shaft will draw toward the shaft perforations 40, and will be caused to rotate with the shaft as the fibers move linearly generally along the axis of rotation, the passageway portion 32 allowing sufficient volume for the fibers to lift and wrap around the core. Withdrawing rollers, or like conventional components, are provided as means for withdrawing the formed yarn Y
from the end 22. Utilizing the embodiment illustrated in FIGURES 10 and 15, it is possible to make yarn having properties approaching that of ring spun yarn directly from sliver.

In tests run utilizing the nozzles of FIGURES 16 through 18, respectively, with different blends and worsted counts of yarn, the following results were obtained ~all results plus or minus E, and "SS" means "short staple"):

TABLE II

Yarn of Fig. 1 Another Vacuum Another Vacuum Vacuum Spun With SS

Spun Yarn Spun Yarn Urafting Arrangement ~or~t~d Count lY18.30 ~ a.48 1~18.23 ~ 0.18 lY18.11 ~ 0.16 1~17.52 ~ 0.12 Single T~ist Air Spun Air Spun Air Spun Air Spun E~enness ~ CV 15.44~ 14.73~ 15.09~ 16.59 Thin Places~1000 Yds. 36.0 4.0 6.0 34.0 Thick PlacesY1000 Yd3. 19.0 0.0 4.0 89.0 NepsY1000 Yd~. 5.0 4.0 4.0 62.0 ~ Elongation 15.40~ ~ 0.55 la.l~ ~ 0.54 12.2~ ~ 0.52 9.7% 4 0.48

2 0 ~ CV of Elongation 12.5~ 10.5~ 13.0~ 17.2 ~ Under 10~ 0.0~ 0.0~ 21.0~ 40.0~

Gram Break 504.0 ~ lZ.10 593.5 1 18.60 279.4 4 16.760 653.3 ~ 14.80 ;~ CV of Break 8.4;~ 11. n;! 9.6i~ 8.0;!

Under lZ5 Gram.s O 0 0 0 Blend - % Poly. 45.74~ 57.37~ o 59.07 Wool 54.Z6~ 4Z.63~ 1~0~ 0 ~ Cotton 0 0 0 40.93~

Shrinkage - Boil-Off 2.75~ ~ 0.31 6.22~ ~ 0.31 3.0% ~ 0.30 3.54~ ~ 0.3Z

~ry-Heat Z.31~ ~ 0.82 6.29~ ~ 0.93 1.5~ ~ 0.20 3.76~ ~ 0.30

3 O11 Content 0.56~ 0.61~ 0.58 0.12~

Itlnk Level/18" 14 . 7 lA . 7 20 . 0 19. 3 Average Staple Length 3.5" 3.5" 3.5" 1.5"
Nozzlo Uscd Fi~. 9 Fig. 11 Fig. 10 Fi~, 9 Sp~n From Sliv~r Rovin~ Roving Roving Si~:e of Input Sliver or Roving55 Grs.~Yd. 2 en~s 2.5 HR 2 ends 2.5 IIR 2 ends 1.5 HR
As can be seen from the test results, the yarn produced according to the present invention has a break strength comparable to a break strength of at least 500 gram break strength denier for a yarn produced from l/18 s count fibers of 55 percent polyester and 45 percent wool. Tests were also conducted utilizing a nozzle like that of FIGURE 17 only having the actual chamber construction like that of chamber 646 of FIGURE 18. In such tests, when yarn with a blend of 45 percent polyester and 55 percent wool was spun from sliver with a count of 1/18 s the gram break strength was 518 and the elongation 8.4 percent. When spun from 100 percent wool sliver with the same count the gram break strength was 248 and the elongation 14.1 percent.
Thus by practicing the invention, too, it is possible to produce yarn having sufficient strength ~o be used as an apparel fabric from non-thermoplastic staple fibers.
Note that the nozzle 620 of FIGURE 16 has a passageway portion 624 communicating with a second end thereof, and a passageway portion 621 communicating with a first end thereof. Between -the passageway portions 621, 624 a 1/4 inch diameter ~31716~

spherical vacuum reservoir 622 is provided with four 1/16 inch diameter angled perforations 623 extending outwardly from the reservoir 622.
In FIGURE 17, the nozzle ~30 has a first passageway section 631 that has the shape of a cone frustum, and a second passageway section 634 that is comparable to the passageway 624 of the FIGURE 16 embodiment. It also has an intermediate passageway portion 632 that may be considered a vacuum reservoir, which has a conical shape, with four 1/16 inch angled perforations 633 in communication therewith.
The nozzle 640 of FIGURE 18 includes the first, conical, passageway portion 641, a second portion 644 comparable to the passageway portion 624 of the EIGURE 16 embodiment, and a pair of passageway portions 642, 6~6 each which are generally conical in shape and have four 1/16 inch angled perforations 643, 647, respectively extending outwardly therefrom.
Viewing the vacuum spun yarn according to the present invention illustrated in FIGURES 1 and 2, it will be seen that a fasciated yarn is provided consisting of staple fibers including core fibers and wrapper fibers. The wrapper fibers are predominantly ~ individual fibers although there are some groups of wrapper fibers. The groups of wrapper fibers appear as non-uniform, non-consistent fiber groupings and provide a relatively smooth surface. The core fibers are essentially parallel with the wrapper fibers uniformly distributed therearound. The core fibers have the same dyeability as the wrapper fibers.
Another way that the yarn of FIGURES l and 2 can be described is a fasciated yarn having essentially parallel core staple fibers and having a uniform distribution of staple wrapper fibers around the core fibers. The wrapper fibers are wrapped at a helix angle of about 30 (e.g. within the range of about 30-50), and about 20-30 percent of the fiber mass comprises wrapper fibers. The wrapped fibers are devoid of tucked or reverse wrapped fibers and are essentially devoid of auger or cor~screw appearing wrapped fibers, rather having a smooth appearance.
Comparing the vacuum spun yarn of FIGURES l and 2 to the conventional ring spun yarn of FIGURE 5, and to the other conventional spun yarns of FIGURES 3 and 5 through 8, it will be seen that the vacuum spun yarn of FIGURES l and 2 has an appearance closest to that of the ring spun yarn of FIGURE 5.
Note that the core spun yarn of FIGURE 3 has core fibers which are parallel with a filament yarn twisted (a true twist) around the mass of yarn for strength. This is not a fasciated yarn.
The open end yarn of FIGURE 4 also has true twist, with a surface dotted with wrapper fibers loose around the mass. Again this is not a fasciated yarn.
The MJS air spun yarn of FIGURE 6 is the next closest to ring spun yarn (that is ne~t closest with vacuum spun yarn being the closest) of the kno~n spun 1 3 1 7 1 6'~

yarns. The MJS yarn has fibers wrapped at approximately a 55 angle showing a small amount of twist in the core fibers. The percentage of wrapped fibers is approximately 10 percent. The wrapper fibers are more or less in the form of individual fibers.
The Toray yarn of FIGURE 7 has wrapper fibers which are disposed at approximately a 45 angle and appear to be buried deeper into the core fibers than for the other yarns, causing a corkscrew appearance.
The surface fibers tend to be tangled in the fiber mass similar to Taslan yarns. Approximately 20 percent of the fibers are wrapped surface fibers.
The auger or corkscrew look of the Toray yarn is vastly different than the smooth appearance of vacuum spun yarn.
The DREF II yarn of FIGU~E 8 is friction spun yarn with true twist and without any surface wrapped fibers. This yarn is also not a fasciated yarn.
It is noted that the fasciated yarn according to the invention can be made from 100 percent non-thermoplastic staple fibers, or the predominant portion of the staple fibers of the core and covering can be non-thermoplastic staple fibers. That is at least the predominant portion of the staple fibers forming the fasciated yarn according to the invention can be selected from the group consisting of cotton, mohair, flax, ramie, silk9 wool, rayon, and blends thereof. However the fasciated yarn according to the invention is not restricted to non-thermoplastic fibers, but also can be produced from, or from blends of (with non-thermoplastic fibers) acrylic, polyester, and other fibers.
Note that vacuum spun yarn has many differences compared to other known fasciated yarns. Some properties of vacuum spun yarns that are not true of all other fasciated yarns are as follows: vacuum spun yarn does not require thermoplastic fibers, has controlled wrapping of surface ~ibers, the wrapped fibers can be the same as the core (not fused by heat), the yarns will dye the same since the molecular structure thereof is not changed (the core and surface fibers have the same dyeability), and the wrapped fibers are laid parallel and not looped over each other in a non-uniform pattern.
According to the present invention a yarn suitable for making apparel fabric, comprising a fasciated yarn, is provided which has good strength and appearance properties, and most closely simulates ring spun yarn. Yet the yarn according to the present invention can be produced at much higher speeds than ring spun yarn and with fewer steps. For instance in ring spinning long staple yarns, first the staple fibers are blended, gilled, combed, gilled four times, used to produce a roving, spun, wound, and then put to an end use. Vacuum spun yarn according to the invention, on the other hand, made from long staple fibers is produced as follows: the fibers are blended, gilled, combed, gilled three times, vacuum spun, and put to the end use. Thus three less steps are used in vacuum spinning long staple fibers compared to ring spinning long staple fibers. In vacuum spinning short staple fibers, the same number of steps are used as for air jet spinning short staple fibers, namely blending, carding, drawing twice, spinning, and putting to an end use.
The invention also contemplates a vacuum mechanism for threading the vacuum spinning apparatus, which can be seen in FIGURES 19-23.
With reference to FIGURES 19, 20, and 23, conventional components of the vacuum spinning apparatus 714 include the housing 716 and an elongated hollow shaft 718 having a first end 719 thereof and a second end 720, with a through-extending passageway 721 (s~e FIGURE 20) from the first end 719 to the second end 720. At least a portion of the circumference of the shaft 718 is perforated, as by perforations 722 (see FIGURE 20), which typically would comprise four perforations equally spaced around the circumference of the shaft 718. The shaft 718 is mounted for rotation about an axis A-A, as by bearing means (shown schematically at 724 in FIGURE 20) extending between the shaft 718 and the housing 716. The housing 716 is connected up, through conduit 726 and valve 727 ~see FIGURE 19) to a source of vacuum 728, such as a conventional vacuum pump. The shaft is rotated about the axis A-A by a motor 729, or like power source, which is operatively connected to the shaft 71~ through gear 730 or a like standard drive structure such as a pulley or sprocket.
In a typical use of the vacuum spinning apparatus 714, drafting apparatus (not shown) nips a sliver or roving S and feeds the textile fibers of the sliver or roving S (including through a set of feed rolls 732) to the first end 719 of the shaft 718. The vacuum that is applied to the circumferential exterior of the shaft 718 causes an air flow from the first end 719, and through the perforations 722, so that at least some of the fibers or free ends of fibers passing through the shaft will draw toward the shaft perorations 722, and will be caused to rotate with the shaft as the fibers move linearly generally along the axis of rotation A-A.
Operatively associated with the second and 720 of the shaft 718 is a conventional take-up mechanism, such as the take-up cone 734 shown schematically in FIGURES 19 and 23.
The threading apparatus according to the present invention is shown generally by reference numeral 740 in FIGURES 21 through 23. A first major component of the apparatus 740 is the vacuum reservoir 742, which has walls including a front end wall 744. The reservoir 742 is operatively connected to the source of vacuum 728, as through a conventional conduit means 743.
The second major component of the apparatus 740 comprises a vacuum tube 745. The vacuum tube has an open first end 746, and an open second end 747.

1 3 1 7 1 6~

The apparatus 740 also comprises means for defining an opening 7~9 in the reservoir wall 744, and means for mounting the tube 745 for rotation. In the exemplary embodiment illustrated in the drawings, the means for mounting the tube 745 for rotation comprises the cylinder 750 having a shaft 751 extending outwardly therefrom generally parallel to the second end 747 of the vacuum tube 745, and concentric with the cylinder 750. The shaft 751 passes through bearing opening 753 in the reservoir wall 744, and the free end of the shaft 751 is held within the reservoir 742 by the E-clip 754, or a like attachment mechanism. The vacuum tube 745 has a substantially straight central portion 756, a first end portion 757 which contains the first end opening 746 and which is generally perpendicular to the portion 756, and a second end portion 758 containing the second end opening 747 which is also generally perpendicular to the central portion 756 and generally parallel to the first end portion 757. The second end portion 758 is mounted within the cylinder 750 so that it is off-center; i.e. so that the second end opening 747 is radially spaced from the shaft 751, as seen in FIGURE 22.
~ The cylinder 750, shaft 751, bearing opening 753, and like components comprising means or mounting the tube 745 for rotation, mount the tube 745 for rotation with respect to the vacuum reservoir 742, about the axis B-B, so that the tube 745 is moved from a first, inoperative, position (see FIGURES 21 through 23) wherein it is not in operative communication with the reservoir 742, to a second, opera~ive position (dotted line position in FIGURE
22, and the position shown in FIGURES 19 and 20) wherein it is in operative communication with the reservoir 742 ~ue to the fact that the second end opening 747 of the vacuum tube is aligned with the opening 749 in the vacuum reservoir wall 744. In this operative position, the vacuum pulled by vacuum source 728 causes air to flow through the first open end 746 o the vacuum tube 74S, all the way through the vacuum tube 745 and through the opening 749 into the reservoir 742, and then ultimately through conduit 743 to the vacuum source 728.
Suitable stop mechanisms (not shown) may be provided on the cylinder 750 and the vacuum reservoir 742 to stop the rotation of the vacuum tube 745 in the operative position wherein the o~enings 747, 749 are aligned. Additionally, spring means not shown), such as a torsion spring connected between the shaft 751 and the reservoir wall 744 within the reservoir 742, may be provided to bias the tube 745 to its inoperative position.
It is also highly desirable to prevent a vacuum from being applied to the circumferential exterior of the shaft 718 when the vacuum tube 745 is in its operative position. In its operative position the first open end 746 thereof is immediately adjacent the second end 720 of the shaft 718 and in alignment with the passageway 721, as illustrated in FIGURES 19 28 1 31 71 6'~

and 20. The cut-out of the application of the vacuum source 728 to the housing 716 may be effected by operatively connecting the tube 745 to an electrical switch -- shown schematically by reference numeral 761 in FIGURE 19 -- that is responsive to the pivotal movement of the vacuum tube 745 from its inoperative position to its operative position. The switch 761 may be a mercury switch mounted on the tube 45, a reed switch mounted within cylinder 750 and cooperating with a magnet associated with reservoir wall 744, or any of a wide variety of other commercially available structures. The electrical switch 761 is operatively connected to a source of electrical power 762, and to a conventional solenoid operator 763 for the valve 727.
In the exemplary embodiment schematically illustrated in FIGURE 19, when the tube 745 is moved to its operative position the switch 761 is closed, causing actuation of the solenoid operator 763 to move valve 727 to its closed position so that no vacuum is applied to the interior of the housing 716.
When the tube 745 is moved back to its first, inoperative position, the switch 761 opens, deactivating the solenoid actuator 763, so that the ?', valve 727 moves to its normal open position.
As illustrated in FIGURE 23. the axis of rotation B-B of the vacuum tube 745 is preferably mounted so that it is parallel to, but horizontally spaced from, the axis of rotation A-A of the hollow shaft 718. Also the vacuum tube 745 is mounted so 131716~

that it does not interfere with the take-up cona 734, or like take-up mechanism.
In a typical operation of the threading apparatus, connected fibers F (see FIGURE 20) are fed into the first end 719 of the hollow shaft 718.
Typically the connected fibers F would be the roving or sliver itself, which may or may not have been subjected to a drafting operation. Once the fibers F
are initially fed into the opening 719, the vacuum tube 745 is manually engaged by the operator and moved from its inoperative position 5FIGURES 21 and 23 and the solid line position in FIGURE 22) to an operative positoin (FIGURES 19 and 20 and dotted line in EIGURE 22), tube 745 rotating about the shaft 51 and axis B-B so that the first open end 746 thereof is adjacent the second end 720 of the shaft 718, and in alignment with the passageway 721. In this position the tube 745 is operatively connected through openings 747 and 749, and vacuum reservoir 742, to the vacuum source 728, and the tube 745 sucks the connected fibers F so that a segment thereof is pulled all the way through the passageway 721 (see FIGURE 20). During the manual pivotal movement of the tube 745 to its operative position the switch 761 is closed and the valve 727 closed in response to the switch closure.
Once a segment of the connected fibers F has been sucked completely through the passageway 721, the vacuum tube 745 is moved back to its inoperative position. Then the se~nent of connected fibers, a 30 13l7l69 portion of which extends outwardly from the second end 720 of the shaft 718, is operatively connected to the take-up cone 734, or a like take-up mechanism.
Then the motor 729 is started and the vacuum spinning operation utilizing the apparatus 714 begins.
In the event of the necessity for a rethreading for an "ends down" situation, motor 729 may continue to drive the shaft 718 as rethreading is effected.

Claims (44)

WHAT IS CLAIMED IS

1. Apparatus for forming yarn comprising: an elongated hollow shaft having a first end and a second end, a through-extending passageway from the first end to the second end, at least a portion of the entire circumference of the shaft being perforated by perforations: means for mounting said shaft for rotation about an axis:
means for rotating said shaft about its axis means for Passing textile fibers through the through-extending passageway of said shaft linearly, generally along the axis of rotation thereof, the fibers being fed into the first end thereof; means for applying a vacuum to the exterior of said shaft so that at least some of the fibers or free ends of fibers passing through said shaft will draw toward the shaft perforations and will be caused to rotate with said shaft as said fibers move linearly generally along the axis of rotation means for withdrawing formed yarn from the second end of said shaft, opposite said first end thereof and means provided between the first end and second end of said shaft for allowing free fiber movement so that at least some of the fibers or free ends of fibers adjacent said perforations will rise up and wrap around a core of fibers as the fibers pass through the passageway.

2. Apparatus as recited in claim 1 wherein said means for allowing free fiber movement comprises means defining a generally conically shaped portion of said passageway having larger cross-sectional area portions thereof closer to said first end, and smaller cross-sectional area portions thereof closer to said second end.

3. Apparatus as recited in claim 2 wherein said conical portion comprises a right circular cone having the center thereof in alignment with said e first and second ends.

4. Apparatus as recited in claim 3 wherein said perforations comprise perforations that extend from said conical portion to the exterior of said shaft.

5. Apparatus as recited in claim 4 wherein each of said perforations is generally wedge-shaped.

6. Apparatus as recited in claim 5 wherein a wall defining each of said perforations closest to said first end extends generally perpendicularly to the axis of rotation of said shaft.

7. Apparatus as recited in claim 6 wherein said shaft includes a tapered wall portion extending between the portion of each perforation closest to said second end and intersecting said passageway, and said passageway.

B. Apparatus as recited in claim 7 wherein said passageway includes, adjacent said first end thereof, a portion having the shape of a cone frustum, and wherein said passageway from said conical portion to said second end has a substantially constant diameter circular configuration, and is of significantly less cross-sectional dimension than said conical portion and said cone frustum portion adjacent said first end.

9. Apparatus for forming yarn comprising: an elongated hollow shaft having a first end and a second end, a through-extending passageway from the first end to the second end, at least a portion of the entire circumference of the shaft being perforated by perforations; means for mounting said shaft for rotation about an axis;
means for rotating said shaft about its axis; means for passing textile fibers through the through-extending passageway of said shaft linearly, generally along the axis of rotation thereof, the fibers being fed into the first end thereof; means for applying a vacuum to the exterior or said shaft so that at least some of the fibers or free ends of fibers passing through said shaft will draw toward the shaft perforations and will be caused to rotate with said shaft as said fibers move linearly generally along the axis of rotation; means for withdrawing formed yarn from the second end of said shaft, opposite said first end thereof; and wherein said passageway includes a first portion adjacent said first end of said shaft, said first portion having the shape of a cone frustum, and having a significantly greater cross-sectional ?? than a portion of said passageway adjacent said second end of said shaft.

10. Apparatus as recited in claim 9 wherein the total effective cross-sectional areas of all of said perforations is generally equal to the effective operative cross-sectional area of said first portion of said passageway, so that optimum fiber wrapping action can be attained

11. Apparatus as recited in claim 10 wherein each of said perforations has a generally wedge-shape.

12. Apparatus as recited in claim 11 wherein a wall defining each of said perforations closest to said first end extends generally perpendicularly to the axis of rotation of said shaft.

13 Apparatus for forming yarn comprising: an elongated hollow shaft having a first end and a second end, a through-extending passageway from the first end to the second end, at least a portion of the entire circumference of the shaft being perforated by perforations; means for mounting said shaft for rotation about an axis;
means for rotating said shaft about its axis; means for passing textile fibers through the through-extending passageway of said shaft linearly, generally along the axis of rotation thereof, the fibers being fed into the first end thereof; means for applying a vacuum to the exterior of said shaft so that at least some of the fibers or free ends of fibers passing through said shaft will draw toward the shaft perforations and will be caused to rotate with said shaft as said fibers move linearly generally along the axis of rotation; means for withdrawing formed yarn from the second end of said shaft, opposite said first end thereof and wherein said perforations have effective cross-sectional areas relative to the effective cross-sectional area of said passageway between said first end and said perforations so that optimum fiber wrapping action is achieved.

14. Apparatus as recited in claim 13 wherein each of said perforations has a generally wedge-shape.

15. Apparatus as recited in claim 14 wherein a wall defining each of said perforations closest to said first end extends generally perpendicularly to the axis of rotation of said shaft.

16. Apparatus for forming yarn comprising: an elongated hollow shaft having a first end and a second end, a through-extending passageway from the first end to the second end, at least a portion of the entire circumference of the shaft being perforated by perforations means for mounting said shaft for rotation about an axis;
means for rotating said shaft about its axis means for passing textile fibers through the through-extending passageway of said shaft linearly, generally along the axis of rotation thereof, the fibers being fed into the first end thereof; means for applying a vacuum to the exterior of said shaft so that at least some of the fibers or free ends of fibers passing through said shaft will draw toward the shaft perforations and will be caused to rotate with said shaft as said fibers move linearly generally along the axis of rotation; means for withdrawing formed yarn from the second end of said sheet, opposite said first end thereof: and means defining a combined vacuum reservoir and chamber for radial deflection of fibers in said shaft adjacent said first end thereof and from which said perforations extend, said combined vacuum reservoir and chamber having a generally conical shape.

17. A method of spinning yarn comprising the steps of:
drafting a sliver of fibers so as to produce a drafted sliver;
feeding the drafted sliver in a linear direction A, in a fiber mass;
passing the fiber mass into the interior of a hollow shaft rotatable about an axis generally coincident with the direction A, the shaft having perforations along the circumference of a portion thereof, and having an enlarged interior chamber at the perforations;
applying a vacuum to the circumferential exterior of the perforated portion of the shaft sufficient to attract some of the fiber mass inside the shaft toward the shaft interior surface; and rotating the shaft at high speed so that the ends of certain of the fibers interior of the shaft rotate with the shaft as they are moving in the direction A, and so that those ends extend into the enlarged interior chamber so as to ultimately wrap around other portions of the fiber mass, to produce a final yarn.

18. A method as recited in claim 17 wherein the method steps are practiced so that the final yarn produced has a break strength comparable to a break strength of at least 500 grams per denier for a yarn produced from 1/19's count fibers of 55 percent polyester and 45 percent wool.

19. A method of making yarn having properties near those of ring-spun-yarn, comprising the steps of: passing air and a bundle of fibers through a rotating hollow shaft having generally radially extending perforations open to a vacuum:
and allowing air to pass through the perforations to thereby radially deflect certain of the fiber ends of the bundle of fibers for wrapping about the remainder of the bundle of fibers.

20. A method as recited in claim 19 wherein said yarn is made at a speed at least six times as fast as commercially feasible by a ring spinning frame.

21. Apparatus for forming yarn as recited in claim 1 wherein said means for rotating said shaft about its axis comprises means for effecting either clockwise or counterclockwise rotation so that the apparatus can make yarn having either a Z
or S twist, as desired.

22. A yarn for use in making apparel fabric comprising:
a central core of staple fibers substantially parallel to one another; and a covering of staple fibers which have one end imbedded in the core and the remainder wrapped around the core such that the wrapping portions of the covering fibers form a helix angle within the range of about 30-50°; and wherein the predominant proportion of staple fibers of the core and covering are non-thermoplastic staple fibers.

23. A fasciated yarn consisting of staple fibers including core fibers and wrapper fibers, the wrapper fibers being predominantly individual fibers although having some groups of wrapper fibers, the groups of wrapper fibers appearing as non-uniform, non-consistent fiber groupings, and providing a relatively smooth surface; and wherein the core fibers are essentially parallel with the wrapper fibers uniformly distributed therearound, the wrapped fibers having the same dyeability.

24. A fasciated yarn having essentially parallel core staple fibers, and uniform distribution of staple wrapper fibers around the core fibers, the wrapper fibers being wrapped at a helix angle of about 30°, and with about 20-30 percent of the fiber mass comprising wrapper fibers, the fasciated yarn having an appearance closely approximating that of ring spun yarn.

25. A yarn-having properties generally comparable to those of ring spun yarn, produced by practicing the steps of:
(a) feeding a plurality of free fibers in a linear direction A, in a fiber mass, certain of the fibers having free trailing ends;
(b) passing the fiber mass into the interior of the hollow rotatable shaft through the entrance thereof;
(c) establishing an air flow with respect to the shaft to effect separation of the free trailing ends of the fibers, (d) rotating the shaft at high speed about the axis so that the trailing ends of the fibers wrap around other portions of the fiber mass to produce a yarn; and (e) withdrawing the yarn through the exit of the shaft.

26. A fasciated yarn having a core of essentially parallel staple fibers, and wrapped staple fibers disposed around the core, the wrapped staple fibers forming a helix angle in the range of about 30-50°; the wrapped fibers being devoid of tucked or reverse wrapped fibers, and being essentially devoid of auger or corkscrew appearing wrapped fibers, rather having a smooth appearance of wrapped fibers.

27. A yarn as recited in claim 26 wherein the predominant proportion of staple fibers of the core and wrapping fibers are non-thermoplastic staple fibers.

28. A yarn as recited in claim 27 wherein the predominant proportion of core and wrapped fibers of the yarn are selected from the group consisting of cotton, wool, rayon, mohair, flax, ramie, silk, and blends thereof.

29. A yarn as recited in claim 25 wherein the predominant proportion of core and wrapped fibers of the yarn are selected from the group consisting of cotton, wool, rayon, mohair, flax, ramie, silk, and blends thereof.

30, A yarn as recited in claim 23 wherein the predominant proportion of core and wrapped fibers of the yarn are selected from the group consisting of cotton, wool, rayon, mohair, flax, ramie, silk, and blends thereof.

31. A yarn as recited in claim 22 wherein the predominant proportion of core and wrapped fibers of the yarn are selected from the group consisting of cotton, wool, rayon, mohair, flax, ramie, silk, and blends thereof.

32. A fasciated yarn as recited in claim 23 including thermoplastic fibers.

33. A fasciated yarn as recited in claim 24 including thermoplastic fibers.

34. A fasciated yarn as recited in claim 26 including thermoplastic fibers

35. A fasciated yarn as recited in claim 26 having a break strength comparable to a break strength of at least about 500 gram break strength for a yarn produced from approximately 1/18's count fibers of 55 percent polyester and 45 percent wool.

36. A fasciated yarn as recited in claim 26 produced from 100 percent non-thermoplastic fiber, and having a break strength comparable to a break strength of at least about 175 gram break for a yarn produced from approximately 1/18's count fibers of 100 percent wool.

37. A fasciated yarn as recited in claim 27 having a break strength comparable to a break strength of at least about 500 gram break strength for a yarn produced from approximately 1/18's count fibers of 55 percent polyester and 45 percent wool.

38. A fasciated yarn as recited in claim 27 produced from 100 percent non-thermoplastic fiber, and having a break strength comparable to a break strength of at least about 175 gram break strength for a yarn produced from approximately 1/18's count fibers of 100 percent wool.

39. A fasciated yarn as recited in claim 26 having a break strength comparable to a break strength of at least about 500 gram break for a yarn produced from approximately 1/18's count fibers of 55 percent polyester and 45 percent wool.

40. A fasciated yarn as recited in claim 26 produced from 100 percent non-thermoplastic fiber, and having a break strength comparable to a break strength of at least about 175 gram break for a yarn produced from approximately 1/18's count fibers of 100 percent wool.

41. A yarn as recited in claim 22 having a break strength comparable to a break strength of at least about 500 gram break for a yarn produced from approximately 1/18's count fibers of 55 percent polyester and 45 percent wool.

42. A fasciated yarn as recited in claim 22 produced from 100 percent non-thermoplastic fiber, and having a break strength comparable to a break strength of at least about 175 gram break for a yarn produced from approximately 1/18's count fibers of 100 percent wool.

43. Vacuum spun yarn composed of a plurality of predetermined fibers and fiber count, said yarn having-a break strength close to the break strength of ring spun yarn made from the same predetermined fibers and fiber count, and having a break strength significantly greater than the break strength of open end spun yarn, having the same predetermined fibers and fiber count.

44. A yarn as recited in claim 25 produced by practicing step (c) by establishing an air flow path that is initially substantially unidirectionally in direction A, and then is deflected to move at an angle with respect to the direction A away from the shaft.