EP4709670A1

EP4709670A1 - Yarn having pattern and splicing method of producing

Info

Publication number: EP4709670A1
Application number: EP24940776.8A
Authority: EP
Inventors: Sophie TERSIGNI; Sara ARBLASTER; Shelley CREGAN; Kat BRENNAN; Julia Scarlet Jackson
Original assignee: Spinrite Inc
Current assignee: Spinrite Inc
Priority date: 2023-05-11
Filing date: 2024-11-13
Publication date: 2026-03-18
Also published as: CN121511202A; EP4709920A1; AU2024444348A1; CN121511336A; AU2024267499A1; WO2024231900A1; WO2025233669A1

Abstract

A method for producing a yarn having a pattern characterized by a plurality segments that are assembled into a sequence of rows, i.e. clusters. The yarn is preferably knotless. The method splices segments having a different length so that the pattern can be easily arranged with visibly distinct colours.

Description

YARN HAVING PATTERN AND SPLICING METHOD OF PRODUCING

PRIORITY CLAIM

[0001] This application claims priority to PCT Application No. PCT/IB2024/054576, filed May 10, 2024, which is incorporated herein by reference.

TECHNICAL FIELD OF THE INVENTION

[0002] The present invention relates to the technical field of yams having a pattern and in particular to processes for producing yarn having a pattern using a splicing method. The yarn may be assembled based on the pattern into a sequence of rows into a workpiece.

BACKGROUND

[0003] Fibre crafters, no matter what technique, e.g., knitting, crocheting, embroidering, weaving, stitching, sewing, etc., face a common problem that involves weaving or knotting loose ends when changing colour between yarn. While the change in colour is desirable from an aesthetic perspective, each change in colour results in at least two loose ends per colour change. The effort and time to weave or knot the loose ends increases the burden on the crafter and detracts from the experience. In particular, this can be painful for those crafters with physical impairments such as arthritis and carpal tunnel. In addition, the loose ends that are weaved or knotted may become deteriorated and the integrity of the project may be compromised.

[0004] Variegated and striped yams offer crafters multicolour options, but are limited. In particular, a variegated yarn has no set length of colour repeats, and gives the appearance of a random colour effect. The colouring effect in variegated yarn can vary from short to long and create more of a colour pooling effect. Accordingly, variegated yarn is often random in colour making a distinct pattern not possible. While striped yarns have lengths of colour to create stripes. The striped colour effect has start and end points that do not have to line up with a specific point. The crafter does not have control over how the colour change falls, and thus, the stripes may be misaligned and detracts from the aesthetic appearance. Thus, similar to variegated yarn, striped yarn are limited when used to form a pattern. This is mainly due to the inability to predict the colour aesthetics that will occur in the pattern. [0005] In view of the known disadvantages and/or problems associated therewith with existing options for multicolour workpieces, the need exists for improved yarn having a pattern with segments of colour that can be reliably and predictability assembled into patterns. Other beneficial features are also discussed herein.

SUMMARY

[0006] This specification describes yams that may be assembled into a pattern such as a sequence of rows, where each row corresponds to one of the segments in the pattern. The finished workpiece may be produced in an efficient manner and reduces the tedious tasks required of the crafter. To achieve the pattern there is a method for producing a continuous yarn having a pattern having visible distinct segments that are joined by a process described herein. Preferably, the yam is a continuous yarn that is knotless. The segments of yam may be joined and gauged in a controlled manner to create segments that correspond to the pattern. In one embodiment, yarns are gauged and joined in a controlled manner to join segments together having increasing length starting from the shortest segment. The method may reduce and/or prevent knotting, which introduces undesirable variation into the continuous yarn and more particularly the individual the segment length.

[0007] In one aspect there is provided a method for producing a continuous yam for forming a pattern characterized by a plurality segments assembled into a sequence of rows and comprising the steps of feeding one or more yarns to a textile machine for gauging segment lengths and joining segment together to create a continuous yarn that can be assembled into the sequence of rows according to a pattern.

[0008] In one aspect there is provided a method for producing a continuous yam for forming a pattern characterized by a plurality segments assembled into a sequence of rows and comprising the steps of feeding a first yarn to a textile machine to gauge a first portion, feeding a second yarn through the textile machinejoining a first end of the first portion with a first end of the second yarn to form a first joined portion, wherein the first joined portion is free of knotting, advancing the first portion, the first joined portion, and the second yam through the textile machine to gauge a second portion of the second yam, wherein the second portion has a length that is different from the first portion, feeding a third yarn through the textile machinejoining a first end of the third yam with a second end of the second portion to form a second joined portion, wherein the second joined portion is free of knotting to form the continuous yarn, advancing the second portion, the second joined portion, and the third yarn through the textile machine to gauge a third portion of the third yam, wherein the third portion has a length that is different from the first portion and the second portion, and controlling tension to prevent knotting when collecting the yarn advanced from the textile machine as the continuous yarn. In one embodiment, a pattern of segments is assembled from the continuous yarn into the sequence of rows comprising forming a ring cluster from the first portion, wherein the first portion has a second end that is not joined and forms a first loose end, partially interlocking a surrounding row with the ring cluster from the second portion, wherein the second portion has no free ends, and partially interlocking an outer row with the surrounding row from the third portion. In one embodiment, each of the joined portions, including at least the first joined portion and second joined portion may each independently have a length from 0.5 to 5 cm. In one embodiment, the third portion has a second end that is not joined and forms a second loose end. The step of joining may involve a splicing technique, including but not limited to pneumatic splicing, mechanical splicing, electrostatic splicing, adhesive bonding or heat bonding. In one embodiment, the splicing technique is preferably a wrap splicing technique.

[0009] In one embodiment, there is provided a method for producing a continuous yarn for forming a pattern characterized by at least five segments assembled into a sequence of rows and comprising the steps of feeding a first yarn to a textile machine to gauge a first portion, feeding a second yam through the textile machine joining a first end of the first portion with a first end of the second yarn to form a first joined portion, wherein the first joined portion is free of knotting, advancing the first portion, the first joined portion, and the second yarn through the textile machine to gauge a second portion of the second yarn, wherein the second portion has a length that is different from the first portion, feeding a third yarn through the textile machinejoining a first end of the third yam with a second end of the second portion to form a second joined portion, wherein the second joined portion is free of knotting to form the continuous yam, advancing the second portion, the second joined portion, and the third yarn through the textile machine to gauge a third portion of the third yarn, wherein the third portion has a length that is different from the first portion and the second portion, feeding a fourth yarn through the textile machine Joining a first end of the fourth yam with a second end of the third portion to form a third joined portion, wherein the third joined portion is free of knotting to form the continuous yam, advancing the third portion, the third joined portion, and the fourth yarn through the textile machine to gauge a fourth portion of the fourth yam, wherein the fourth portion has a length that is different from the first portion and the second portion, feeding a fifth yam through the textile machine, joining a first end of the fifth yam with a second end of the fourth portion to form a fourth joined portion, wherein the fourth joined portion is free of knotting to form the continuous yarn, and advancing the fourth portion, the fourth joined portion, and the fifth yarn through the textile machine to gauge a fifth portion of the fifth yarn, wherein the fifth portion has a length that is different from the first portion and the second portion. In one embodiment, the patterns of segments are assembled from the continuous yam into the sequence of rows comprising forming a ring cluster from the first portion, wherein the first portion has a second end that is not joined and forms a first loose end, partially interlocking a surrounding row with the ring cluster from the second portion, wherein the second portion has no free ends, and partially interlocking an outer row with the surrounding row from the third portion. In one embodiment, each of the joined portions, including at least the first, second, third, and fourth joined portions may each independently have a length from 0.5 to 5 cm. In one embodiment, the third portion has a second end that is not joined and forms a second loose end. The step of joining may involve a splicing technique, preferably a wrap splicing technique.

BRIEF DESCRIPTION OF THE DRAWINGS

[0010] Like reference numbers and designations in the various drawings indicate like elements.

[0011] FIG. l is a schematic of a textile machine in accordance with one embodiment of the invention.

[0012] FIG. 2A is a pattern of an assembly of rows in accordance with one embodiment of the invention.

[0013] FIG. 2B is a pattern of an assembly of three rows in accordance with one embodiment of the invention.

[0014] FIG. 2C is a pattern of an assembly of rows in flower shape in accordance with one embodiment of the invention.

[0015] FIG. 2D is a pattern of an assemble of rows in accordance with one embodiment of the invention.

[0016] FIG. 3 is an assembled rows from the yarn produced in accordance with one embodiment of the invention. [0017] FIG. 4 is an assembled rows from different balls of yarn produced by a conventional process.

DETAILED DESCRIPTION

[0018] The method of the present invention gauges and joins segments having increasing length to produce a yarn having a pattern. In one embodiment, segments of yarn are gauged and joined using a continuous or semi-continuous process. In general, the each yarn is fed to the textile machine along a series of rollers and gauged and joined in a splicer. Once the continuous yarn is formed, the craft workpiece may be assembled into the sequence of rows according to a pattern.

[0019] In one embodiment, one or more of the segments may be joined using a splicing technique. The splicing technique may be used to add a segment having a visually distinguishable colour after dyeing or may be used to replace one segment in pattern. In one embodiment, the splicing technique may be used to assemble each segment having a visually distinguishable colour for the pattern. Adjacent segments are partially overlapped up to 5 cm, e.g., up to 4 cm, up to 3 cm, up to 2.5 cm or up to 2.2 cm. In one embodiment, a thread wrap may be applied to the partially overlapped segments with a machine splicer. In terms of ranges the adjacent segments may be overlapped by 0.5 cm to 5 cm, e.g., 0.5 cm to 4.5 cm, 0.5 to 4 cm or 1 to 4 cm. The thread wrap may be a fine yarn, which may be tightly wrapped in a helical course. The machine splicer may apply tension to the thread wrap. The segments are joined together to form a bond that is not easily separated. In one embodiment, the segments are joined together to form a high strength bond that resist separation when assembled into a pattern. In some embodiments, the partially overlapping segments may be wrapped or twisted together prior to being thread wrap. For purposes of this disclosure when the segments are spliced together the segments may be considered to be knotless due in part to the relatively thin spliced yarn segments, which is much thinner than a rigid knot.

[0020] Accordingly, in one embodiment, there is provided a method for producing a yam having a pattern characterized by a plurality segments that are assembled into a sequence of rows using a splicing technique as described herein. The splicing technique involves providing one or more segments having different lengths, each segment having a visually distinguishable colour. As a reference, a first segment having the shortest length is spliced at one end with a second segment, preferably a segment that is longer. One end of the first segment is not spliced and this is the free or loose end. The ends of the first segment and second segments are partially overlapped and spliced using a thread wrap. Next, the opposing end of the second segment is spliced with a third segment. The process repeats until the desired number of segments are assembled into one continuous yarn that is knotless. The last segment may have a second free end. The patterns of segments may be assembled into the sequence of rows comprising forming a ring cluster from the first segment, having a first loose end, partially interlocking a surrounding row with the ring cluster from the second segment intermediately adjacent to the first segment, wherein the surrounding row has no free ends, and partially interlocking an outer row with the surrounding row from a third segment that is longer than the second segment, wherein the third segment is spliced at one end with the second segment and the outer row has a second loose end. Although one second segment is described, it should be understood that multiple segments may be used to form a corresponding number of surrounding rows.

[0021] In accordance with one embodiment of the disclosed process, FIG. 1 shows a system 100 for producing a continuous yarn 102. System 100 comprises a textile machine 104, feed spools 106, splicer 108, and collection spool 110. In one embodiment, the system 100 comprises a plurality of feed spools 106 to supply one or more of the segments in the continuous yarn 102. In some embodiments, one feed spool 106 may be used to each segment. The splicer 108 may be incorporated into the textile machine 104 or may be a separate component. In some embodiments, the splicer may be an pneumatic splicer, a mechanical splicer (i.e. wrap splicer), or other entanglement procedure. In some embodiments, the filaments of the yarn may be randomly intermingled to form the joined portion. For purposes of illustration in FIG. 1, a wrap splicer is demonstrated with a wrap yarn spool 112. The wrap yam spool 112 supplies a fine yam that is used for joining the overlapping ends of the yarn. The wrap yam may be tightly wrapped to produce a joined portion with a high strength. In one embodiment, the thickness of the joined portion having the wrap yam is less than a knot and thus the joined portion may be considered knotless. Using a wrap yarn may be advantageous to prevent the crafter from accidentally pulling the segments apart when crafting the pattern. [0022] To form the continuous yarn 102, separate yarns 114 are fed from the feed spool 106 into the textile machine 104 and joined together to form joined portions using the splicer 108. Once joined, the yam is advanced through the textile machine 104 and collected on the collection spool 110. Preferably, the joining produces a joined portion that is free of knotting. The continuous yarn 102 may comprise a number of joined portions to join multiple segments to allow the segments to be assembled into a sequence of rows as described herein.

[0023] In one embodiment, the yarn on each of the feed spool 106 may be dyed to a different colour. In some embodiments, the textile machine may dye the yarn after removing the yarn from feed spool.

[0024] In FIG. 1, yam 114 from feed spool 106 enters textile machine 104 and passes through drafting rollers 116 to the inlet roller 118. The yarn 114 passes through a gauge unit 120 to gauge the segment length. Exemplified lengths are shown in the tables below. The gauge unit 120 cuts yarn 114 once gauged. Gauge unit 120 may be any suitable unit for measuring the length of the yarn as shown in the tables provided herein. In one embodiment, gauge unit may be an electronic yarn meter, laser measurer, mechanical counter or other suitable cutting machines. The cut yam travels through delivery rollers 122 before passing along guide roller 124 and into the splicer 108. Once the second end of the cut yarn travels through the splicer 108, the yam 114 is held by pressure rolls 126. In some embodiments, the splicer may comprise a track for holding the overlapping ends of the yarn 114 and yam 114’. Next, yarn 114’ from feed spool 106’ enter textile machine 104 using a similar path. Yarn 114’ passes through drafting rollers 116’ to the inlet roller 118’. In one embodiment, the first end of yarn 114’ may be joined with the second end of 114. Accordingly 114’ yarn may pass through the gauge unit 120’ without cutting until after yarn is joined. In some embodiments, the gauge unit 120’ may cut the yarn 114’ prior to being joined. Although each yam is shown with a separate gauge unit, in some embodiments, one gauge unit may be used for gauging each of the yams. The joined portion may be created by overlapping the ends to form a joined portion that is from 0.5 cm to 5 cm in length. The ends once joined are preferably not free or loose and are preferably bounded with the wrap yarn. Once joined using the splicer, preferably using a wrap yarn (not shown) from the wrap spool 112, the first yarn, joined portion and second yarn is advanced over the back roller 128, along a lag roller 130 and through tensioners 132 to prevent knotting of the continuous yarn 102 once joined. A tension sensor (not shown) may be used in addition to the tensioners 132 to detect tensile properties of the continuous yam 102. By detecting potential defects further winding of the continuous yarn 102 on the collection spool 110 may be avoided. After detecting no detects, the continuous yarn 102 may be eventually collected on the collection spool 110. After the yarn is joined, the gauge unit 120’ may cut the yarn 114’ to a length as shown on the tables enclosed herein. In one embodiment, the length of yam 114’ may be different from yarn 114 and preferably is longer. In addition, each yarn may have a different colour so as to be visible distinct to the user. The process continues with gauging and joining yarn to form the segments necessary to form the pattern. Once one pattern is completed, the textile machine 104 may add additional segments to the continuous yarn using a similar process.

[0025] Each roller of the textile machine may be independently driven by a motor to control the speed of the yam traveling therethrough. In one embodiment, any type of adjustable timing device may control the inputs to the motors and corresponding rollers, such as a microcomputer. The process described herein operates in a controlled manner to avoid random segments being joined which would not align with the pattern.

[0026] To maintain the joining and gauging of the yam, each yam may be monitored to control the feed rate and/or tension on the yam. The monitoring may be done at predefined locations throughout the process. The data may be communicated to a processor that can control the method by adjusting the speed of the rollers or deflection of the yarn. The feed rate of the yarns and continuous yarn may be controlled to prevent knotting. Knotting occurs when the yarn breaks and requires the broken ends to be knotted together. Such knotting may reduce the length of the segment and introduce additional variations in the segment length. In addition, knotting interrupts the process. In some embodiments, a monitor may be used for detecting defects, i.e., breakage or weakness, in the continuous yarn that may lead to breakage.

[0027] In one embodiment, to achieve consistent patterning throughout the continuous yarn, the process joins the segments of yam from shortest to longest, with the shortest segment comprising the pull-end of the yam. This pull-end is accessed by the crafter when assembling the yarn into the plurality rows, which may also be referred to as clusters. In one embodiment, the shortest segment of the yarn which comprises the pull-end of the yarn may form the ring cluster, i.e. initial row.

[0028] As described herein, the number of segments may vary and in one embodiment the pattern may comprise the first three segments, i.e. the first, second and third segments, as shown in Table 1. In another embodiment, the pattern may comprise at least three segments as shown in Table 1, provided that shortest segment is included. Each segment may independently increase in length by at least 50 cm, e.g., preferably at least 75 cm or more preferably at least 100 cm. The increase in the segment length may be predetermined by the desired assembly of rows.

Table 1

Broad (cm) Preferred (cm) More Preferred

(cm)

First Segment 250 to 420 280 to 380 310 to 360

(Shortest)

Second Segment 375 to 675 450 to 610 500 to 580

Third Segment 570 to 950 650 to 875 720 to 840

Four Segment 750 to 1300 875 to 1200 950 to 1125

Fifth Segment 1000 to 1800 1150 to 1600 1300 to 1525

[0029] For the purpose of this disclosure the terms “yarn” and “fibre” refer to any fibre, natural (such as cotton, hemp, linen, silk, and/or wool), artificial (such as polyesters and/or acrylic), or blended, used in the fibre arts, including crochet, macrame, needlepoint, knitting, embroidery, tapestry, and/or another process of working fibre.

[0030] As indicated herein the pattern has a plurality of segments. Each pattern of segments forms one workpiece comprising an assembly of rows as described herein, for example, using the Granny square pattern or shape pattern. In one pattern of segments, each of the segments may have increasing length (or decreasing length), meaning that the segments are arranged from shortest to longest (or longest to shortest). While the method may be operated to start the dyeing with the shortest segment, the method may also be operated by starting with the longest segment and working in descending order. The number of segments in a pattern may range from three to ten segments, e.g., from three to eight segments, from four to eight segments, or from four to six segments. Typically each segment corresponds to one row, but in some embodiments one segment may be used for two or more rows. Each skein of yarn has more than one assembly of segments, and preferably the yarn comprises from 2 to 35 assemblies of segments, from 4 to 33 assemblies of segments, or more preferably from 6 to 16 assemblies of segments. Having a sufficient amount of assemblies of segments is desirable by the crafter to prepare and assemble the yam into a workpiece. Each assembly of segments may be separated by the user or worked together to form a larger workpiece. Thus, several workpieces each comprising a pattern of rows may be obtained from one skein of yarn.

[0031] The method may allow joining and gauging in a continuous or semi-continuous process so that the segments are arranged in colour sequence in a continuous yarn. This eliminates intermptions between the rows that are distinguished by varying colours. Although it is preferred that each segment has a different colour, in some embodiments, the colour may be repeated.

[0032] The length of each segment may vary depending on the pattern and yarn. In one embodiment, the shortest segment may have a length from 150 cm to 250 cm as shown in Table 2, e.g., from 175 cm to 240 cm, or more preferably from 200 cm to 225 cm.

[0033] Table 2 provides exemplary ranges for a five segment pattern.

Table 2

Broad (cm) Preferred (cm) More Preferred

(cm)

First Segment 150 to 250 175 to 240 200 to 225

(Shortest)

Second Segment 300 to 475 325 to 440 350 to 400

Third Segment 500 to 625 520 to 600 525 to 575

Four Segment 650 to 800 675 to 840 690 to 715

Fifth Segment 800 to 1000 825 to 950 840 to 900

[0034] In one embodiment, the segment length may vary and generally follows a pattern where the lengths in each segment increase. In one embodiment, the shortest segment has a length from 550 cm to 750 cm, e.g., from 575 cm to 700 cm, or more preferably from 590 cm to 650 cm. The increase in the segment length may be predetermined by the desired assembly of rows. Table 3 illustrates exemplary ranges for a six segment pattern, where the third and sixth segment follow increasing length pattern from the first segment and the second, fourth and fifth segment follow a different increasing length pattern from the first segment.

Table 3

Broad (cm) Preferred (cm) More Preferred

(cm)

First Segment 550 to 750 575 to 700 590 to 650

(Shortest)

Second Segment 1100 to l400 1150 to l350 1200 to l275

Third Segment 700 to 1000 750 to 950 800 to 875

Four Segment 1800 to 2400 1900 to 2300 2100 to 2250

Fifth Segment 2500 to 3200 2700 to 3000 2800 to 2900

Sixth Segment 1500 to 2000 1600 to 1900 1700 to 1800

[0035] In one embodiment, the workpiece may form a shape such as a flower, circle, fruit, hearts, spirals, triangles, starbursts, etc. The number of segments may vary depending on the style. In one embodiment, there is provided a continuous yarn with three segments. Accordingly, in this embodiment, the shortest segment may have a length from 125 cm to 225 cm, e.g., from 130 cm to 200 cm, or more preferably from 150 cm to 175 cm as shown in Table 4. The remaining segments have an increasing length as shown in Table 4.

Table 4

Broad (cm) Preferred (cm) More Preferred

(cm)

First Segment 125 to 225 130 to 200 150 to 175

(Shortest)

Second Segment 750 to 1250 800 to 1100 850 to 925

Third Segment 1500 to 2500 1800 to 2350 2000 to 2250

[0036] To achieve the consistent and repeatable patterning that the crafter desires, the variation in the length of segments between patterns should have minimal variation in the continuous yarn. The method described herein achieves minimal variation, which improves the experience of crafting and the ease of using the yam. The variation is determined based on a similar coloured segments in different patterns. In one embodiment, the length of segments of similar colour in different patterns varies by less than 4%, e.g., less than 3%, less than 2%, less than 1%, less than 0.5%, and by less than 0.1%. Having a variation of less than 4% may preserve the visible distinct colour. Being over 4% introduces too much variation and makes the yarn undesirable to obtain the pattern. Accordingly, when the shortest length is dyed blue and has a length of 200 cm, every remaining pattern has a short blue segment that is similar in length, namely in particular 200 cm ± 4%, e.g., 200 cm ± 0.5%.

[0037] In one embodiment, each segment is knotless, referring to no knots are introduced during formation of the continuous yarn. For purposes of the present disclosure, the splicing and resulting joined portion is considered to be knotless. Thus, the continuous yarn that is processed according to the embodiments of the present invention may be knotless. In some embodiments, the raw yarn prior to dyeing may contain knots. Preferably, the raw yarn is also knotless. For purposes of the present disclosure, knotting relates to when the yarn breaks during dyeing. One issue with knotting is that the segment length may be effected in an uncontrolled manner. This introduces too much variation into the yam resulting in a pattern that is not aligned to match the assembly. Thus, it is difficult to reliably control the length of the segment within ± 4%, or more preferably ± 0.5%, when knotting occurs. By controlling the feed rate of and/or the tension on the yarn to prevent knotting and achieving a knotless configuration, the method produces yarn having patterns with consistent lengths. If breakage occurs, the monitoring section may signal to discard the yarn.

[0038] Once the yam is produced, a crafter may use the yarn to assemble the pattern into a sequence of rows. In general, the sequence of rows may be used for patterns that are assembled with different rows having different colours. Many different designs may be assembled in this manner, including but not limited to flowers, stars, fruits, objects, starbursts, spirals, etc. In one embodiment, the sequence of rows may be referred to a Granny Square as shown by the pattern 200 in FIG. 2A with five rows (clusters) or the pattern 200’ in FIG. 2B with three rows (clusters). The diagrams used in FIGS. 2A-2D use slip stitches, represented by dots, chain stitches, represented by ovals, and double crotch stitches, represented by T with a diagonal line. Each row is labelled by a number, 1 to 5, 1 to 3, 1 to 6, or 1 to 10. Although these diagrams are illustrative of patterns, the embodiments of the present invention are not limited to these patterns. As shown in FIG. 2A, the shortest segment forming the ring cluster (first cluster or row) 201 at a middle position surrounded by the other rows. In one embodiment, the pattern may begin with the slip stitch in the ring cluster. Although not shown it should be understand that the ring cluster 201 may have a loose end. This loose end of the ring cluster may not joined when forming the continuous yarn. The next row in the pattern is shown by surrounding row 202 and partially interlocks with the ring cluster 201 and is formed a segment intermediately adjacent to the shortest segment. In the Granny Square, the stitching may be joined as shown in FIGS. 2A and FIG. 2B to partially interlock the additional rows. In FIG. 2A, there are two additional surrounding rows, 203 and

204 that may partially interlock in a similar fashion. In the pattern with five segments, the outer row 205 that partially interlocks with the surrounding row 204. In one embodiment, the outer row 205 may be obtained from the segment having the longest length in the pattern. Similar to the ring cluster 201, the outer row 205 would also have a loose end that is not shown in FIG. 2A. In one embodiment, there are no loose ends between the inner sequence of rows.

[0039] FIG. 2C represents a sequence of rows that form a flower shape pattern 200”. As shown in FIG. 2C there are five rows that comprise the flower shape pattern 200”. The first row 201 (or ring cluster) is represented as an inner circle. The second row 202 and third row 203 forms the petals of the flower design. Thus, the second row 202 may partially interlock within the first row 201 to form the necessary petal design. The fourth row 204 and fifth row

205 is the background that may provide a visually pleasing contrast to the flower design. Depending on the style, the rows as represented by the row cluster 203 in FIG. 2C may be significantly longer than the previous segments and may interlock within the second row 202. [0040] In FIG. 2D, the pattern 200” has ten rows. Although each row may have a visually distinguishable colour, in one embodiment, adjacent pairs of row may have a similar colour. In some embodiments, three adjacent rows may have the similar colour. In the pattern 200” shown in FIG. 2D, the innermost row 210 and the adjacent row 212 have a similar colour. Rows 210 and 212 may together form a ring cluster. Accordingly, one segment of the yarn may be used form both the innermost row 210 and the adjacent row 212. The next two adjacent rows (214 and 216) have a similar colour. Row 218 has a colour that is distinguishable from row 216, but does not have a similar adjacent pair with the same colour. Row 218 corresponds to one segment of the yarn. Continuing the pattern, rows 220 and 222 have a similar colour, while rows 224 and 226 have a similar colour. The outermost row 228 has a colour that is distinguishable from row 226, but does not have a similar adjacent pair with the same colour. In total the pattern 200” shown in FIG. 2D has six segments to form ten rows.

[0041] By having all the colours arranged as a plurality of segments allows ease of use for the crafter. The crafter can use one skein of yarn to make an article from the pattern without having to use multiple balls of different colour yarns. By having one skein improves the ease of transport and allows for crafting in a variety of settings, including while traveling or commuting. This also reduces the number of skeins necessary to produce a pattern.

[0042] In one embodiment, the pattern having a plurality of segments reduces the number of loose ends. The loose ends need to be secured by weaving or knotting to prevent the pattern from unravelling. As shown in FIG. 3, there is a pattern 300 wherein the ring cluster 301 has a first loose end 310 and the outer row 305 has a second loose end 312. The length of the first loose end 310 and the second loose end 312 may vary to allow the user to tie each loose end. In comparison to the prior method shown in FIG. 4, the pattern 400 has 10 loose ends (410-419), while the yarn produced according to the present invention reduces the number of loose ends to no more than two. In addition to the weaving being tedious and timeconsuming, the weave can cause discomfort to the crafter. By weaving all 10 loose ends in the prior method in FIG. 4, the tension on the yam may become compromised resulting in a reduction in tension. The previous method of weaving the loose ends results may lead to a pattern that is subject to wear and can lead to excess expansion and quality deterioration.

[0043] In one embodiment, the finished workpiece may be a sweater, scarf, blanket, towel, placemat, table cloth, linens, rug, jacket, robe, dress or any other suitable type of garment.

[0044] While the disclosure has been described in detail, modifications within the spirit and scope of the disclosure will be readily apparent to those of skill in the art. In view of the foregoing discussion, relevant knowledge in the art and references discussed above in connection with the Background and Detailed Description, the disclosures of which are all incorporated herein by reference. In addition, it should be understood that aspects of the disclosure and portions of various embodiments and various features recited below and/or in the appended claims may be combined or interchanged either in whole or in part. In the foregoing descriptions of the various embodiments, those embodiments which refer to another embodiment may be appropriately combined with other embodiments as will be appreciated by one of skill in the art. Furthermore, those of ordinary skill in the art will appreciate that the foregoing description is by way of example only, and is not intended to limit the disclosure.

Claims

What is Claimed is:

1. A method for producing a continuous yarn for forming a pattern characterized by a plurality segments assembled into a sequence of rows and comprising the steps of: feeding a first yarn to a textile machine to gauge a first portion; feeding a second yarn through the textile machine; joining a first end of the first portion with a first end of the second yarn to form a first joined portion, wherein the first joined portion is free of knotting; advancing the first portion, the first joined portion, and the second yarn through the textile machine to gauge a second portion of the second yam, wherein the second portion has a length that is different from the first portion; feeding a third yarn through the textile machine; joining a first end of the third yarn with a second end of the second portion to form a second joined portion, wherein the second joined portion is free of knotting to form the continuous yarn; advancing the second portion, the second joined portion, and the third yarn through the textile machine to gauge a third portion of the third yam, wherein the third portion has a length that is different from the first portion and the second portion; controlling tension to prevent knotting when collecting the yarn advanced from the textile machine as the continuous yam, whereby a pattern of segments is assembled from the continuous yam into the sequence of rows comprising: forming a ring cluster from the first portion, wherein the first portion has a second end that is not joined and forms a first loose end; partially interlocking a surrounding row with the ring cluster from the second portion, wherein the second portion has no free ends; and partially interlocking an outer row with the surrounding row from the third portion.

2. The method of claim 1, wherein the first joined portion is from 0.5 to 5 cm in length.

3. The method of claim 1, wherein the second joined portion is from 0.5 to 5 cm in length.

4. The method of claim 1, further comprising: feeding a fourth yam through the textile machine; joining a first end of the fourth yarn with a second end of the third portion to form a third joined portion, wherein the third joined portion is free of knotting to form the continuous yarn; advancing the third portion, the third joined portion, and the fourth yam through the textile machine to gauge a fourth portion of the fourth yarn, wherein the fourth portion has a length that is different from the first portion and the second portion.

5. The method of claim 4, further comprising: feeding a fifth yarn through the textile machine; joining a first end of the fifth yam with a second end of the fourth portion to form a fourth joined portion, wherein the fourth joined portion is free of knotting to form the continuous yarn; advancing the fourth portion, the fourth joined portion, and the fifth yarn through the textile machine to gauge a fifth portion of the fifth yarn, wherein the fifth portion has a length that is different from the first portion and the second portion.

6. The method of claim 5, wherein the fifth portion has a second end that is not joined and forms a second loose end.

7. The method of claim 1, wherein the third portion has a second end that is not joined and forms a second loose end.

8. The method of claim 1, wherein the step of joining involves a splicing technique, preferably a wrap splicing technique.

9. The method of claim 1, wherein the first portion has a length from 250 cm to 420 cm, preferably from 280 cm to 380 cm.

10. The method of claim 1, wherein the second portion has a length from 375 cm to 675 cm, preferably from 450 cm to 610 cm.

11. The method of claim 1, wherein the length between the first portion and second portion is at least 50 cm, preferably at least 75 cm or more preferably at least 100 cm.

12. The method of claim 1, wherein the first portion has a first colour that varies by less than 4%, preferably by less than 0.5%.

13. The method of claim 12, wherein the second portion has a second colour, and wherein the first colour is visible distinct from the second colour.