WO2012100305A1

WO2012100305A1 - A multi-component yarn

Info

Publication number: WO2012100305A1
Application number: PCT/AU2012/000184
Authority: WO
Inventors: Jean-Michel LIBEAU
Original assignee: Lincspun Ltd
Priority date: 2011-01-26
Filing date: 2012-02-24
Publication date: 2012-08-02
Also published as: EP2668322A1; EP2668322A4

Abstract

A yarn spinning process for producing a multi-component yarn (B), the process comprising: providing at least a first set of fibres as a core (11) for the multi-component yarn, and sequentially wrapping about the first set of fibres a primary wrapper (8) provided from a first side of the fibres, and then with a secondary wrapper (9) provided from a second, different, side of the fibres, wherein the first set of fibres is provided with a first twist direction, the first wrapper is provided with a second twist direction and the second wrapper is provided with a third twist direction. The process is performed on a ring spinning frame, the core fibres are staple fibres such as wool and the primary and secondary wrappers can be staple fibre yarn or continuous filament yarn.

Description

A MULTI-COMPONENT YARN

FIELD OF THE INVENTION DESCRIPTION

BACKGROUND TO THE INVENTION

1. At present conventional staple fibre yarns are produced without the use of continuous filaments or pre-spun strands on spinning machines which generally draft a roving of the staple fibres and then insert twist into the attenuated strand.

2. In such existing systems, as the number of fibres in the cross-section of the staple fibre strands is reduced the evenness of the resultant yarn deteriorates. This is acknowledged in Martindale's theory ("A New Method of Yarn Measurement", Journal of Textile Institute 36, 1945, T35-47) which specifies that the coefficient of variation of the weight per unit length of such a yarn or strand deteriorates approximately in proportion to the inverse of the square root of ^' the average number of fibres in its cross-section.

3. The practical minimum is generally determined by the cost of employing labour to repair a high rate of end-breakages during spinning. A typical commercial level of yam breakages which can be sustained in advanced Western economies is in the region of 10 breaks per 100 hours of spindle operation. To achieve an end- breakage rate at this level it is typically necessary to spin with no less than an average of 45 fibres in the strand cross-section.

4. It is typically necessary to spin core-spun yarn with no less than an average of 35 fibres per cross-section (neglecting those in the core yam, i.e. the additional filament or pre-spun yarn component). Moreover, core-spun yarn cannot be used under practical conditions for the warp in weaving unless some additional step such as the addition of size or yarn plying is undertaken. Another known method of incorporating a continuous filament or pre- spun strand (known as wrapper) into a staple fibre yam is by wrap spinning (also known as hollow spindle spinning). This method however produces a staple fibre core which has no twist. In the Sirospun™ system (UK patent specification No. 1377925 and 1318413), two staple fibre roving components pass via rear roving guides, a central roving guide, front zone condenser and a drafting roller. The components are drafted and kept separate to emerge from the drafting front roller. The use of such systems results in a yarn suitable for use as warp in weaving because movement of the point at which the two strands combine causes strand twist to be trapped in the two legs so that surface hairs are held between the two strands and do not rub up so readily during the yarn abrasion which occurs to warp yams in weaving. Although modest reductions in the average number of fibres per strand have been achieved with respect to the single strands spun on earlier spinning machines, the effect is small because of the limitations on strand evenness referred to above. Each strand is still required to remain continuous and self-supporting between the front roller nip and the point where the two strands j6in. It is typically necessary to spin Sirospun™ yarn with no less than an average of 35 fibres per strand cross- section. It is also known that either one of the two strands in the Sirospun™ process can^' be replaced with a filament yam or pre-spun staple fibre yarn. The result is a staple fibre yarn twisted together with the filament or pre- spun yarn (known as wrapper). This is called Sirofil™ spinning process. The only existing spinning system known to the applicants, which is capable of producing yarns in which the staple fibre strand contains less than 30 fibres in the cross section in commercial operations, is described in NZ patent 225679. This earlier invention allows production in one operation a staple yam in which the staple fibres are twisted together with two continuous filament or pre-spun strands. The resulting yam can be used as warp yam in weaving without further treatment. This earlier system enables yarns in which the wool strand comprises a small average number of fibres in the cross-section, and in particular 14 to 30 fibres, to be produced. 10. It is therefore an object of the present invention to go at least some way towards addressing the foregoing problems and/or at least to provide the industry or public or both with a useful choice.

11. In this specification where reference has been made to patent specifications, other external documents, or other sources of information, this is generally for the purpose of providing a context for discussing the features of the invention. Unless specifically stated otherwise, reference to such external documents is not to be construed as an admission that such documents, or such sources of information, in any jurisdiction, are prior art, or form part of the common general knowledge in the art

The term "comprising" as used in this specification means "consisting at least in part of. When interpreting statements in this specification which include that term, the features, prefaced by that term in each statement, all need to be present but other features can also be present. Related terms such as "comprise" and "comprised" are to be interpreted in the same manner.

SUMMARY OF THE INVENTION

1. In a first aspect, the invention may be said to broadly consist of a yam spinning process for producing a multi-component yarn, the process comprising: providing at least a first set of fibres as a core for the multi-component yam, and sequentially wrapping about the first set of fibres a primary wrapper provided from a first side of the fibres, and then with a secondary wrapper provided from a second, different, side of the fibres.wherein the first set of fibres is provided with a first twist direction, the first wrapper is provided with a second twist direction and the second wrapper is provided with a third twist direction.

2. In a second aspect, the invention may be said to broadly consist of a yam spinning process for producing a multi-component yarn, the process comprising: mounting, in association with a ring spinning frame, two or more feeder packages of single or multi-filament yarn or pre-spun staple yam, feeding at least one primary wrapper from a first of the feeder packages to a first guide or guides for wrapping about at least a first set of fibres provided as a core for the multi- . component yam, the first guide(s) positioned to a first side of the at least first set of fibres, and feeding at least one secondary wrapper from a second of the feeder packages to a second guide or guides for wrapping about the at least first set of fibres wrapped with the primary wrapper, the second guide(s) positioned to a second side of the first fibre, the second guide spaced apart and positioned at a different side to the first guide(s). In a third aspect, the invention may be said to broadly consist of a multi-component yarn comprising: at least a first set of fibres as a core for the multi-component yarn, the fibres wrapped at least by a first primary wrapper provided from a first side of the fibres, and further wrapped by at least a secondary wrapper provided from a second, different, side of the fibres, wherein the first set of fibres is provided with a first twist direction, the first wrapper is provided with a second twist direction and the second wrapper is provided with a third twist direction. In a fourth aspect, the invention may be said to broadly consist of a multi-component yarn comprising:at least a first set of fibres provided as a core for the multi-component yam, (optionally having a first twist direction)at least one primary wrapper wrapped about the fibres in a second twist direction, and at least one secondary wrapper wrapped about the fibres and primary wrapper(s) in a third twist direction. In a fifth aspect, the invention may be said to broadly consist of a multi-component yam produced according to the process of the aspects above. Preferably, the first and second sides are different sides of the at least first set of fibres. More preferably, are substantially opposing sides of the at least first set of fibres. Preferably, the first and second sides are spaced apart from each other, separated there between by the at least first set of fibres. Preferably, the first twist direction, of the at least first set of fibres, is an S-twist or a Z-twist or has a near-net zero twist. Preferably, the second twist direction, of the primary wrapper, is an S- twist or a Z-twist or has a near-net zero twist. Preferably, the third twist direction, of the secondary wrapper, is an S- twist or a Z-twist or has a near-net zero twist. Preferably, the first twist direction is opposite to the second twist direction and the same twist direction as the third twist direction. Preferably, the first twist direction is an S-twist, the second twist direction is a Z-twist and the third twist direction is an S-twist. In an alternative, preferably the first twist direction is a Z-twist, the second twist direction is an S-twist and the third twist direction is a Z-twist.

Preferably, the primary wrapper is wrapped about the first set of fibres in a clock-wise twist direction, or alternatively in an anti-clock-wise twists direction about the first set of fibres. Preferably, the second wrapper is wrapped about the primary wrapper(s) in a clock-wise twist direction, or alternatively in an anti- clock-wise twists direction about the primary wrapper(s). Preferably, the at least first set of fibres is provided as a drafted staple fibre(s) or roving component(s). Alternatively, the first fibre is provided by drafting a staple fibre(s) or drafting a roving components). Preferably, the primary wrapper or secondary wrapper, or both, are pre-spun yams. More preferably, the primary wrapper or secondary wrapper, or both, are continuous multi-filament or continuous staple fibre yarns. Preferably, the primary wrapper or the secondary wrapper, or both, are, or are formed from, a continuous multi-filament yam. More preferably, the primary wrapper or the secondary wrapper, or both, are of a POY, Flat, FDY, DTY textured type Even more preferably, the wrappers are of a round shape type, or a trilobal shape type, or a triple-T shape type or any other shape types. Preferably, the primary wrapper or secondary wrapper, or both, are natural (e.g. plant or animal derived fibres, such as cellulose fibres) or man-made (e.g. petrochemical derived fibres, such as polyamide and polyester fibres) filament materials, or combinations of both. Alternatively, preferably the primary wrapper or secondary wrapper, or both, may be comprised of, or be formed as yarns of one or more of the following: cottons, jute, hemp, flax, sisal, silk, , woollen fibres such as wool, merino wool or cashmere.chemically modified naturally forming polymers such as those derived from cellulose, protein fibres, synthetic(s), polymeric materials including polyesters, polyurethanes, polycaprolactams, aromatic polyester, para-aramid synthetic fibres, aramids, polyamides such as the nylon polymer family including for example nylon 3, nylon 6, nylon 4-6, nylon 6, nylon 6-6, nylon 6-10, nylon 6-12, nylon 6-T, nylon 7, nylon 8, nylon 9, nylon 10, nylon 11 , nylon 12 nylon 55, nylon fibre, nylon MXD-6, viscose, polyesters, water soluble PVA yarns, elastomers, including staple fibres formed by extruding polymers (for example fibres formed from melt spinning, dry spinning or wet spinning techniques). Most preferably, the primary wrapper or secondary wrapper.or both, are (or comprise of) a nylon 6, nylon 6-6, polyester, polyester micro fibre, cationic polyester, cationic polyester micro fibre. Optionally, the primary wrapper or secondary wrapper, or both, may additionally comprise of an additional filament or fibre material, such additional filament or fibre materials being one or more of those defined above in relation to the primary or secondary wrappers. Preferably, the at least first set of fibres are natural (e.g. plant or animal derived fibres, such as wool, cotton, cellulose fibres) or man-made (e.g. petrochemical derived fibres, such as polyamide, polyester fibres) or combinations of both. Alternatively, preferably the at least first set of fibres may be comprised of, or be formed of, or from, one or more of the following: cottons, jute, hemp, flax, sisal, silk, woollen fibres such as merino or cashmere, chemically modified naturally forming polymer fibres such as those derived from cellulose, protein fibres, synthetic(s), polymeric materials including polyesters, aromatic polyester, para-aramid synthetic fibres, aramids, polyurethanes, polycaprolactams, acrylic fibres, polyamides such as the nylon polymer family including for example nylon 3, nylon 6, nylon 4-6, nylon 6, nylon 6-6, nylon 6-10, nylon 6-12, nylon 6-T, nylon 7, nylon 8, nylon 9, nylon 10, nylon 11, nylon 12 nylon 55, nylon fibre, nylon MXD-6, viscose, polyesters, water soluble PVA yarns, elastones, including staple fibres formed by extruding polymers (for example fibres formed from melt spinning, dry spinning or wet spinning techniques). Most preferably, the at least first set of fibres may only be woollen, cellulose, cotton fibres, or blended woollen, cellulose, cotton fibres with nylon 6, nylon 6-6, polyester, polyester micro fibre, cationic polyester, cationic polyester micro fibre

Preferably, the multi-component yarn so formed may be relaxed, for example by chemical or physical methods. More preferably, may be relaxed by an auto-claving treatment. Yet more preferably, the multi- component yam may undergo a treatment to achieve a tex twist factor of down to about 1000. Preferably, the first wrapper is wrapped by spinning or being spun about the at least first set of fibres (forming the core). More preferably, the spinning is by a ring spinning frame, the ring spinning frame imparting a twist direction to the first wrapper. Preferably, the second wrapper is wrapped by spinning or being spun about the first wrapper and the at least first set of fibres (forming the core). More preferably, the spinning is by a ring spinning frame, the ring spinning frame imparting a twist direction to the second wrapper. Preferably, the first wrapper is wrapped by spinning or being spun about the at least first set of fibres (forming the core) and subsequently combined with the second wrapper yam via a guide (optionally the guide being situated between a front drafting roller and a spindle), the resultant multi-component spun yarn product to be or being collected on a spindle or reel. Preferably, the first wrapper is provided at the first side via a first guide, and the second wrapper is provided at the second side via a second guide, the second guide spaced from the at least first set of fibres at a greater distance than the spacing of the first guide from the at least first set of fibres. More preferably, the first guide is spaced at a distance from the at least first set of fibres less than that of the second guide. Preferably, the primary wrapper is spaced via the first guide at a distance from the at least first set of fibres of less than about 30 mm, or less than about 25 mm, or less than about 20 mm, or less than about 15 mm, or less than about 10 mm, or less than about 9 mm, or less than about 8 mm, or less than about 7 mm, or less than about 6 mm, or less than about 5 mm, or less than about 4 mm, or less than about 3 mm, or less than about 2 mm, or less than about 1 mm. Alternatively, preferably the first guide is spaced at a distance from the at least first set of fibres of about 30 mm, or about 29 mm, or about 28 mm, or about 27 mm, or about 26 mm, or about 25 mm, or about 24 mm, or about 23 mm, or about 22 mm, or about 21 mm, or about 20 mm, or about 19 mm, or about 18 mm, or about 17 mm, or about 16 mm, or about 15 mm, or about 14 mm, or about 13 mm, orabout 12 mm, or about 11 mm, or about 10 mm, or about 9 mm, or about 8 mm, or about 7 mm, or about 6 mm, or about 5 mm, or about 4 mm, or about 3 mm, or about 2 mm, or about 1 mm. Preferably, the secondary wrapper is spaced via the second guide at a distance from the at least first set of fibres of more than about 8 mm, or more than about 10 mm, or more than about 15 mm, or more than about 20 mm, or more than about 25 mm, or more than about 30 mm. Alternatively, preferably the second guide is spaced at a distance from the at least first set of fibres of about 8 mm, or about 9 mm, or about 10 mm, or about 11 mm, or about 12 mm, or about 13 mm, or about 14 mm, or about 15 mm, or about 16 mm, or about 17 mm, or about 18 mm, or about 19 mm, or about 20 mm, or about 21 mm, or about 22 mm, or about 23 mm, or about 24 or about 25 mm, or about 26 mm, or about 27 mm, or about 28, or about 29, or about 30mm. Preferably, a first half twist of the primary wrapper is wound under the at least first set of fibres for capturing the fibres of the at least first set of fibres (for example when viewed from above). Preferably, the primary wrapper is a support for the at least first set of fibres. More preferably, the primary wrapper is supportive of the at least first set of fibres from the front of a roller nip until the at least first set of fibres and the primary wrapper are further wrapped by the secondary wrapper. For example, the primary wrapper operates as a wrapper and not as a core of the multi-component yarn being formed, particularly if very fine counts or very low twist multi- component yarns are being spun Preferably, the core (formed from the at least first set of fibres) comprises on average about 14 to about 100 fibres in its cross-section. Alternatively, preferably less than about 30 fibres in its cross- section, or less than about 25 fibres, or less than about 20 fibres, or less than about 15 fibres. Preferably, the multi-component yarn once so formed is wound onto a spindle or reel, optionally for example for the purposes of storage. Preferably, the multi-component yam so formed is knittable, weavable or capable of being knitted or woven. Preferably, the resultant multi-component yam has a yarn count that is approximately the sum of fibres forming the at least first set of fibres, the primary wrapper and the secondary wrapper. Preferably, the resultant multi-component yam comprises woollen fibres, cotton fibres, cellulose fibres as the at least first set of fibres and polyamide and/or polyester fibres as primary wrapper and secondary wrapper. Preferably, the at least first set of fibres has an average fibre diameter of about 10 to about 40 flm, more preferably of about 15 to about 30 flm, even more preferably of about 20 to about 25 flm. Alternatively, the at least first set of fibres has an average diameter of about 40, 39, 38, 37, 36, 35,34, 33, 32, 31, 30, 29, 28, 27, 26, 25, 24, 23, 22, 21, 20, 19, 18, 17, 16, 15, 14, 13, 12, 11, 10, 9, 8, 7, 6, 5, 4, 3, 2 or 1 flm. Preferably, the at least first set of fibres has an average fibre length of more than about 20 mm, more preferably of more than about 30 mm, even more preferably of more than about 40 mm, yet even more preferably of more than about 50 mm, most preferably of more than about 60 mm or more than about 70 mm or more than about 80 mm or more than about 90 mm or more than about 100 mm. Alternatively, the at least first set of fibres has an average fibre length of about 20, 21 , 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35, 36, 37, 38, 39, 40, 41, 42, 43, 44, 45, 46, 47, 48, 49, 50, 51, 52, 53, 54, 55,56, 57, 58, 59, 60, 61, 62, 63, 64, 65, 66, 67, 68, 69, 70, 71, 72, 73, 74, 75, 76, 77, 78, 79, 80, 81, 82,83,84, 85, 86, 87, 88, 89, 90, 91, 92, 93, 94, 95, 96, 97, 98, 99, 100, 101 , 102, 103, 104, 105, 106, 107,108, 109, 110, 111, 112, 113, 114, 115, 116, 117, 118, 119, 120, 121, 122, 123, 124, 125, 126, 127,128, 129, 130, 131, 132, 133, 134, 135, 136, 137, 138, 139, 140, 141, 142, 143, 144, 145, 146, 147,148, 149, or 150 mm.

DETAILED DESCRIPTION

Further aspects and advantages of the present invention will become apparent from the ensuing description which is given by way of example only.

1. In a first embodiment, this invention provides a yam spinning process for producing a multi-component yarn comprising providing at least a first set of fibres as a core for the multi-component yam, sequentially wrapping about the first set of fibres a primary wrapper provided from a first side of the fibres, and then with a secondary wrapper provided from a second, different, side of the fibres. Such that, the first set of fibres is provided with a first twist direction, the first wrapper is provided with a second twist direction and the second wrapper is provided, with a third twist direction.

2. In a second embodiment, this invention provides a yam spinning process for producing a multi-component yam comprising mounting, in association with a ring spinning frame, two or more feeder packages of single or multi-filament yam or pre-spun staple yarn. Then, feeding at least one primary wrapper from a first of the feeder packages to a first guide or guides for wrapping about at least a first set of fibres provided as a core for the multi-component yam, the first guide(s) positioned to a first side of the at least first set of fibres. And, feeding at least one secondary wrapper from a second of the feeder packages to a second guide or guides for wrapping about the at least first set of fibres wrapped with the primary wrapper, the second guide(s) positioned to a second side of the first fibre, the second guide spaced apart and positioned at a different side to the first guide(s).

In a third embodiment, this invention provides for a multi-component yarn comprising at least a first set of fibres as a core for the multi- component yarn. The first set of fibres are wrapped by at least by a first primary wrapper provided from a first side of the fibres, and then further wrapped by at least a secondary wrapper provided from a second, different, side of the fibres. The first set of fibres is provided with a first twist direction, the first wrapper is provided with a second twist direction and the second wrapper is provided with a third twist direction.

In a fourth embodiment, this invention provides for a multi-component yam comprising at least i) at least a first set of fibres provided as a core for the multi-component yarn, (optionally havi ng a first twist direction), ii) at least one primary wrapper wrapped about the fibres in a second twist direction, and iii) at least one secondary wrapper wrapped about the fibres and primary wrappers) in a third twist direction.

Advantageously, the first and second sides are different sides of the at least first set of fibres. For example, the first side is different and or at a substantially opposing side of the fibres to the second side. The first and second sides are spaced apart from each other, separated there between by the at least first set of fibres. In this manner, the primary wrapper can be supplied for wrapping about the first set of fibres without interaction with the secondary wrapper. The secondary wrapper is then separately supplied to the first set of fibres now wrapped with the primary wrapper.

The first twist direction of the at least first set of fibres can be an S-twist or a Z-twist or may even have a near-net zero twist. The second twist direction, of the primary wrapper, can then be an S- twist or a Z-twist or may even be or have a near-net zero twist. The third twist direction, of the secondary wrapper, can be an S-twist or a Z-twist or may even be or have a near-net zero twist. . However, advantageously, the first twist direction is opposite to the second twist direction and the same twist direction as the third twist direction (i.e. the second twist direction is opposite to the third direction). . For example, the first twist direction may be an S-twist; the second twist direction would therefore be a Z-twist and the third twist direction an S- twist. In an alternative configuration however, if the first twist direction is a Z-twist, the second twist direction would be an S-twist and the third twistdirection would be a Z-twist. In this manner, a multi-component yarn can be formed by the first set of wrappers and primary and secondary wrappers with a low resultant twist. Further, the primary wrapper may be wrapped about the first set of fibres in a clock-wise twist direction, or alternatively in an anti-clock-wise twists direction about the first set of fibres. Likewise, the second wrapper may be wrapped about the primary wrapper(s) in a clock-wise twist direction, or alternatively in an anti-clockwise twists direction about the primary wrappers). It will be appreciated that the at least first set of fibres is provided as a drafted staple fibre(s) or roving component(s). Alternatively, the first fibre is provided by drafting a staple fibre(s) or drafting a roving component(s). The primary wrapper or secondary wrapper, or both, can be formed from or are pre-spun yams, and may be continuous multi-filament or continuous staple fibre yams. Depending on the resultant characteristics to be achieved by the yarn to be produced, the primary wrapper or the secondary wrapper, or both, can be provided of a certain textured type (e.g. are not of a flat type). Examples of certain textures include round shape types, or a triple-T shape types, or any other textured shape types. In terms of materials, the primary wrapper or secondary wrapper, or both, can be natural materials (e.g. plant or animal derived fibres, such as cellulose fibres) or man-made materials (e.g. petrochemical derived fibres, such as polyamide fibres) filament materials, or combinations of both. These materials may be formed as yarns of one or more of the following: cottons, jute, hemp, flax, sisal, silk, woollen fibres such as merino or cashmere, chemically modified naturally formingpolymers such as those derived from cellulose, protein fibres, synthetic(s), polymeric materials including polyesters, polyurethanes, aromatic polyester, para-aramid synthetic fibres, aramids, polyurethanes polycaprolactams, polyamides such as the nylon polymer family including for example nylon 3, nylon 6, nylon 4-6, nylon 6, nylon 6-6, nylon 6-10, nylon 6-12, nylon6-T, nylon 7, nylon 8, nylon 9, nylon 10, nylon 11 , nylon 12 nylon 55, nylon fibre, nylon XD-6, viscose, polyesters, water soluble PVA yarns, elastones, including staple fibres formed by extrudingpolymers (for example fibres formed from melt spinning, dry spinning or wet spinning techniques). Optionally, the primary wrapper or secondary wrapper, or both, may comprise of an additional filament or fibre material, such additional filament or fibre materials being one or more of those defined above in relation to the primary or secondary wrappers. Such additional fibres can be introduced or included in the wrapper for additional characteristics to be imparted into the resultant yam, for example for fancy weaves or certain textures or strength or other physical or chemical properties. In terms of materials, the at least first set of fibres are preferably natural (e.g. plant or animal derived fibres, such as cellulose fibres) but may also include other man-made materials (e.g. petrochemical derived fibres, such as polyamide fibres), or combinations of both. Such materials may be, or may be comprised of, or be formed of, or from, one or more of the following: cottons, jute, hemp, flax,sisal, silk, woollen fibres such as merino or cashmere, chemically modified naturally formingpolymer fibres such as those derived from cellulose, protein fibres, synthetic(s), polymeric materials including polyesters, polyurethanes, aromatic polyester, para-aramid synthetic fibres, aramids, polyurethanes polycaprolactams, acrylic fibres, polyamides such as the nylon polymer family including for example nylon 3, nylon 6, nylon 4-6, nylon 6, nylon 6-6, nylon 6-10,nylon 6-12, nylon 6-T, nylon 7, nylon 8, nylon 9, nylon 10, nylon 11 , nylon 12 nylon 55, nylon fibre, nylon MXD-6, viscose, polyesters, water soluble PVA yams, elastones, including staple fibres formed by extruding polymers (for example fibres formed from melt spinning, dry spinning or wet spinning techniques). In respect of the first set of fibres, these are provided having an average fibre diameter of about 10 to about 40 flm, more preferably of about 15 to about 30 flm, even more preferably of about 20 to about 25 flm. Alternatively, the at least first set of fibres has an average diameter of about 40, 39, 38, 37, 36, 35, 34, 33, 32, 31, 30, 29, 28, 27, 26, 25, 24, 23, 22, 21, 20, 19, 18, 17, 16, 15. 14, 13, 12, 11, 10, 9, 8, 7, 6, 5, 4, 3, 2 or 1 flm. The first set of fibres are also provided having an average fibre length of more than about 20 of more than about 30 mm, more preferably of more than about 40 mm, even more preferably of more than about 50 mm, yet even more preferably of more than about 60 mm, most preferably of more than about 70 mm or more than about 80 mm. of more than about 90 of more than about 100 5. Alternatively, the at least first set of fibres has an average fibre length of about 20, 21 , 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35, 36, 37, 38, 39, 40, 41, 42, 43, 44, 45, 46, 47, 48, 49, 50, 51, 52, 53, 54, 55, 56, 57, 58, 59, 60, 61, 62, 63, 64, 65, 66, 67, 68, 69, 70, 71, 72, 73, 74, 75, 76, 77, 78, 79, 80, 81, 82,83,84, 85, 86, 87, 88, 89, 90, 91, 92, 93, 94, 95, 96, 97, 98, 99. 100, 101, 102, 103, 104, 105, 106, 107,108, 109, 110, 111, 112, 113, 114, 115, 116, 117, 118, 119, 120, 121, 122, 123, 124, 125, 126, 127,128, 129, 130, 131, 132, 133, 134, 135, 136, 137, 138, 139, 140, 141, 142, 143, 144, 145, 146, 147,148, 149, or 150 mm. 6. Such first set of fibres can be pre-treated for enhancing or improving their chemical or physical characteristics or properties. For example, the first set of fibres can be pre-treated to minimise shrinkage or distortion once formed into a multi-component yam for weaving. A Hercosett™ type treatment is one such treatment enabling the improvement of fibre characteristics. Treatments suchas those that provide for shrink-resistance or treatments to allow subsequently woven material or garments from the multi-component yarn to retain their appearance after repeated machine washing and tumble drying by reducing shrinkage are preferred. To further enhance the low twist factor of a resultant multi-component yam so formed, the yam may be relaxed, for example by chemical or physical methods. For example, such methods can include auto-clave treatments or techniques.

Claims

1. A yarn spinning process for producing a multi-component yarn, the process comprising: providing at least a first set of fibres as a core for the multi- component yam, and sequentially wrapping about the first set of fibres a primary wrapper provided from a first side of the fibres, and then with a secondary wrapper provided from a second, different, side of the fibres, wherein the first set of fibres is provided with a first twist direction, the first wrapper is provided with a second twist direction and the second wrapper is provided with a third twist direction.

2. A yarn spinning process for producing a multi-component yam, the process comprising:mounting, in association with a ring spinning frame, two or more feeder packages of single or multi-filament yarn or pre-spun staple yarn, feeding at least one primary wrapper from a first of the feeder packages to a first guide or guides for wrapping about at least a first set of fibres provided as a core for the multi-component yam, the first guide(s) positioned to a first side of the at least first set of fibres, and feeding at least one secondary wrapper from a second of the feeder packages to a second guide or guides for wrapping about the at least first set of fibres wrapped with the primary wrapper, the second guide(s) positioned to a second side of the first fibre, the second guide spaced apart and positioned at a different side to the first guide(s).

A multi-component yarn comprising: at least a first set of fibres as a core for the multi-component yam, the fibres wrapped at least by a first primary wrapper provided from a first side of the fibres, and further wrapped by at least a secondary wrapper provided from a second, different, side of the fibres, wherein the first set of fibres is provided with a first twist direction, the first wrapper is provided with a second twist direction and the second wrapper is provided with a third twist direction.

A multi-component yarn comprising: at least a first set of fibres provided as a core for the multi-component yarn, (optionally having a first twist directionat least one primary wrapper wrapped about the fibres in a second twist direction.and at least one secondary wrapper wrapped about the fibres and primary wrappers) in a third twist direction.

5. A multi-component yarn produced as defined by claim 1 or claim 2.

6. The process or yarn as claimed in any one of claims 1 to 5, wherein the first and second sides are different sides of the at least first set of fibres.

7. The process or yam as claimed in claim 6, wherein the first and second sides aresubstantially opposing sides of the at least first set of fibres.

8. The process or yarn as claimed in any one of claims 1 to 7, wherein the first and second sides are spaced apart from each other, separated there between by the at least first set of fibres.

9. The process or yarn as claimed in any one of claims 1 to 7, wherein the first twist direction, of the at least first set of fibres, is an S-twist or a Z-twist or has a near-net zero twist.

10. The process or yarn as claimed in any one of claims 1 to 7, wherein the second twist direction, of the primary wrapper, is an S-twist or a Z-twist or has a near-net zero twist.

11. The^' process or yarn as claimed in any one of claims 1 to 7, wherein the third twistdirection, of the secondary wrapper, is an S-twist or a Z-twist or has a near-net zero twist.

12. The process or yarn as claimed in any one of claims 1 to 11 , wherein the first twist direction is opposite to the second twist direction and the same twist direction as the third twist direction.

13. The process or yam as claimed in any one of claims 1 to 12, wherein either i) the first twist direction is an S-twist, the second twist direction is a Z-twist and the third twist direction is an S-twist, or ii) the first twist direction is a Z-twist, the second twist direction is an S-twist and the third twist direction is a Z-twist.

14. The process or yarn as claimed in any one of claims 1 to 13, wherein the primary wrapper is wrapped about the first set of fibres in either i) a clockwise twist direction, or it) in an anti-clock-wise twists direction about the first set of fibres.

15. The process or yam as claimed in any one of claims 1 to 14, wherein the second wrapper is wrapped about the primary wrapper(s) in i) an anti-clockwise twist direction, or ii) a clock- wise twist direction about the primary wrappers).

16. The process or yam as claimed in any one of claims 1 to 15, wherein the at least first set of fibres is provided as a drafted staple fibre(s) or roving component(s), or the at least first set of fibres is provided by drafting a staple fibre(s) or drafting a roving component(s).

17. The process or yam as claimed in any one of claims 1 to 16, wherein the primary wrapper or secondary wrapper, or both, are pre-spun yarns.

18. The process or yarn as claimed in any one of claims 1 to 17, wherein the primary wrapper or secondary wrapper, or both, are, or are formed from, a continuous multi-filament yam, such as staple fibre yams.

19. The process or yam as claimed in any one of claims 1 to 18, wherein the primary wrapper or the secondary wrapper, or both, are of a POY, Flat, FDY, DTY textured type, the wrappers are of a round shape type, or a trilobal shape type, or a triple-T shape type or any other shape types.

20. The process or yarn as claimed in any one of claims 1 to 19, wherein the primary wrapper or secondary wrapper, or both, are natural (e.g. plant or animal derived fibres, such as cellulose fibres) or man-made (e.g.

petrochemical derived fibres, such as polyamide fibres) filament materials, or combinations of both.

21. The process or yarn as claimed in any one of claims 1 to 19, wherein the primary wrapper or secondary wrapper, or both, are comprised of, or are formed as yams of one or more of the following: cottons, jute, hemp, flax, sisal, silk, woollen fibres such as merino or cashmere, chemically modified naturally forming polymers such as those derived from cellulose, protein fibres, synthetic(s), polymeric materials including polyesters.polyurethanes, polycaprolactams, aromatic polyester, para-aramid synthetic fibres, aramids, polyamides such as the nylon polymer family including for example nylon 3, nylon 6, nylon 4-6, nylon 6, nylon 6-6, nylon 6-10, nylon 6- 12, nylon 6-T, nylon 7, nylon 8, nylon 9, nylon 10, nylon 11 , nylon 12 nylon 55, nylon fibre, nylon MXD-6, viscose, polyesters, water soluble PVA yams, elastones, including staple fibres formed by extruding polymers (for example fibres formed from melt spinning, dry spinning or wet spinning techniques).

22. The process or yarn as claimed in any one of claims 1 to 21 , wherein the primary wrapperor secondary wrapper, or both, are (or comprise of) a nylon 6-6.

23. The process or yarn as claimed in any one of claims 1 to 22, wherein the primary wrapper or secondary wrapper, or both, additionally comprise of an additional filament or fibre material, such additional filament or fibre materials being one or more of those as definedin claim 21 or claim 22.

24. The process or yam as claimed in any one of claims 1 to 23, wherein the at least first set of fibres are natural (e.g. plant or animal derived fibres, such as cellulose fibres) or man-made(e.g. petrochemical derived fibres, such as polyamide fibres) or combinations of both.

25. The process or yarn as claimed in any one of claims 1 to 24, wherein the at least first set of fibres may be comprised of, or be formed of, or from, one or more of the following: cottons, jute, hemp, flax, sisal, silk, woollen fibres such as merino or cashmere, chemically modified naturally forming polymer fibres such as those derived from cellulose, protein fibres, synthetic(s), polymeric materials including polyesters, polyurethanes.polycaprolactams, aromatic polyester, para-aramid synthetic fibres, aramids, acrylic fibres, polyamides such as the nylon polymer family including for example nylon 3, nylon 6, nylon 4-6, nylon 6, nylon 6-6, nylon 6-10, nylon 6-12, nylon 6-T, nylon 7, nylon 8, nylon 9, nylon 10, nylon 11 , nylon 12 nylon 55, nylon fibre, nylon MXD-6, viscose, polyesters, water soluble PVA yarns, elastones, including staple fibres formed by extruding polymers (for example fibres formed from melt spinning, dry spinning or wet spinning techniques).

26. The process or yam as claimed in any one of claims 1 to 25, wherein the at least first set of fibres are woollen, cotton, cellulose fibres, for example merino wool fibres.

27. The process or yarn as claimed in any one of claims 1 to 26, wherein the multi-component yarn undergoes a treatment to achieve a tex twist factor of down to about 1000.

28. The process or yam as claimed in any one of claims 1 to 27, wherein the multi-componentyarn so formed is relaxed by chemical or physical methods, for example by an auto-claving treatment.

29. The process or yam as claimed in any one of claims 1 to 28, wherein the first wrapper is wrapped by spinning or being spun about the at least first set of fibres (forming the core), for example the spinning is by a ring spinning frame, the ring spinning frame imparting a twist direction to the first wrapper.

30. The process or yam as claimed in any one of claims 1 to 29, wherein the second wrapper is wrapped by spinning or being spun about the first wrapper and the at least first set of fibres (forming the core), for example the spinning is by a ring spinning frame, the ring spinning frame imparting a twist direction to the second wrapper.

31. The process or yarn as claimed in any one of claims 1 to 30, wherein the first wrapper is wrapped by spinning or being spun about the at least first set of fibres (forming the core) and subsequently combined with the second wrapper yam via a guide (optionally the guide being situated between a front drafting roller and a spindle), the resultant multi-component spun yarn product to be or being collected on a spindle or reel.

32. The process or yarn as claimed in any one of claims 1 to 31 , wherein the first wrapper is provided at the first side via a first guide, and the second wrapper is provided at the second side via a second guide, the second guide spaced from the at least first set of fibres at a greater distance than the spacing of the first guide from the at least first set of fibres.

33. The process or yarn as claimed in claim Z2, wherein the first guide is spaced at a distancefrom the at least first set of fibres less than that of the second guide.

34. The process or yam as claimed in claim 32 or claim 33, wherein the

secondary wrapper is spaced via the second guide at a distance from the at least first set of fibres of more than about 8 mm, or more than about 15 mm, or more than about 20 mm, or more than about

25 mm, or more than about 30 mm.

35. The process or yam as claimed in any one of claims 32 to 34, wherein the second guide isspaced at a distance from the at least first set of fibres of about 8 mm, or about 9 mm or about 10 mm or about 11 mm, or about 12 mm, or about 13 mm, or about 14 mm, or about 15 mm, or about 16 mm, or about 17 mm, or about 18 mm, or about 19 mm, or about 20 mm, or about 21 mm, or about 22 mm, or about 23 mm, or about 24 or about 25 mm, or about 26 mm, or about 27mm, or about 28, or about 29, or about 30mm.

36. The process or yarn as claimed in any one of claims 32 to 35, wherein the primary wrapper is spaced via the first guide at a distance from the at least first set of fibres of less than about 30 mm, or less than about 25 mm, or less than about 20 mm, or less than about 15 mm, or less than about 10 mm, or less than about 9 mm, or less than about 8 mm, or less than about 7 mm, or less than about 6 mm, or less than about 5 mm, or less than about 4 mm, or less than about 3 mm, or less than about 2 mm, or less than about 1 mm.

37. The process or yam as claimed in any one of claims 32 to 36, wherein the first guide is spaced at a distance from the at least first set of fibres of about 30 mm, or about 29 mm, or about 28 mm, or about 27 mm, or about 26 mm, or about 25 mm, or about 24 mm, or about 23 mm, or about 22 mm, or about 21 mm, or about 20 mm, or about 19 mm, or about 18 mm, or about 17 mm, or about 16 mm, or about 15 mm, or about 14 mm, or about 13 mm, or about 12 mm, or about 11 mm, or about 10 mm, or about 9 mm, or about 8 mm, or about 7 mm, or about 6 mm, or about 5 mm, or about 4 mm, or about 3 mm, or about 2 mm, or about 1 mm.

38. The process or yarn as claimed in any one of claims 1 to 37, wherein a first half twist of the primary wrapper is wound under the at least first set of fibres for capturing the fibres of the at least first set of fibres (for example when viewed from above).

39. The process or yarn as claimed in any one of claims 1 to 38, wherein the primary wrapper is a support for the at least first set of fibres.

40. The process or yarn as claimed in any one of claims 1 to 39, wherein the primary wrapper is supportive of the at least first set of fibres from the front of a roller nip until the at least first set of fibres and the primary wrapper are further wrapped by the secondary wrapper.

41. The process or yam as claimed in any one of claims 1 to 40, wherein the core (formed from the at least first set of fibres) comprises on average about 14 to about 100 fibres in its cross-section.

42. The process or yam as claimed in any one of claims 1 to 41 , wherein the core (formed from the at least first set of fibres) comprises on average less than about 100 fibres in its cross-section, or less than about 25 fibres, or less than about 20 fibres, or less than about 15 fibres.

43. The process or yarn as claimed in any one of claims 1 to 42, wherein the multi-component yam once so formed is wound onto a spindle or reel, for example for the purposes of storage.

44. The process or yarn as claimed in any one of claims 1 to 43, wherein the multi-component yam so formed is knittable, weavable or capable of being knitted or woven.

45; The process or yam as claimed in any one of claims 1 to 44, wherein the resultant multi-component yarn comprises woollen fibres, cotton fibres, cellulose fibres as the at least first set of fibres and polyamide and/or polyester fibres as primary wrapper and secondary wrapper.

46. The process or yarn as claimed in claim 45, wherein the woollen fibres are merino wool fibres cotton fibres, cellulose fibres and the polyamide are nylon 6-6 fibres and/or polyester fibres.

47. The process or yarn as claimed in any one of claims 1 to 46, wherein the at least first set of fibres has an average fibre diameter of about 10 to about 40 flm, or about 15 to about 30 flm, or about 20 to about 25 flm.

48. The process or yarn as claimed in any one of claims 1 to 47, wherein the at least first set of fibres has an average diameter of about 40, 39, 38, 37, 36, 35, 34, 33, 32, 31, 30, 29, 28, 27, 26, 25, 24, 23, 22, 21, 20, 19, 18, 17, 16, 15, 14, 13, 12, 11, 10, 9, 8, 7, 6, 5, 4, 3, 2 or 1 flm.

49. The process or yarn as claimed in any one of claims 1 to 48, wherein the at least first set of fibres has an average fibre length of more than about 20 mm, or more than about 30 mm or more than about 40 mm, or more than about 50 mm, or more than about 60 mm, or more than about 70 mm or more than about 80 mm, or more than about 90 mm, or more than about 100 mm.

50. The process or yarn as claimed in any one of claims 1 to 49, wherein the at least first set of fibres has an average fibre length of about 20, 21 , 22, 23, 24, 25, 26, 27, 28, 28, 29, 30, 31, 32, 33, 34, 35, 36, 37, 38, 39, 40, 41, 42,43, 44, 45, 46, 47, 48, 49, 50, 51, 52, 53, 54, 55, 56, 57, 58, 59, 60, 61, 62, 63, 64, 65, 66, 67,68, 69, 70, 71, 72, 73, 74, 75, 76, 77, 78, 79, 80, 81, 82,83, 84, 85, 86, 87, 88, 89, 90, 91, 92,93, 94, 95, 96, 97, 98, 99, -100, 101, 102, 103, 104, 105, 106, 107, 108, 109, 110, 111, 112, 113, 114, 115, 116, 117, 118, 119, 120, 121, 122, 123, 124, 125, 126, 127, 128, 129, 130, 131, 132, 133, 134, 135, 136, 137, 138, 139, 140, 141, 142, 143, 144, 145, 146, 147, 148, 149, or 150 mm.

51. The process or yam as claimed in any one of claims 1 to 50, wherein the at least first set of fibres is pre-treated, for example the first set of fibres has undergone a chemical or physical (or both) pre-treatment.

52. The process or yarn as claimed in any one of claims 1 to 51 , wherein the first set of fibres has been pre-treated to minimise shrinkage or distortion once formed into a multi- component yarn for weaving, for example a shrink-resistant treatment or a fibre shrinkage reducing treatment.

53. The process or yam as claimed in any one of claims 1 to 52, wherein the first set of fibres has been pre-treated by a treatment to allow subsequently woven material or garments from the multi-component yarn to retain their appearance after repeated machine washing

and tumble drying by reducing shrinkage.

54. The process or yarn as claimed in any one of claims 1 to 53, wherein the first set of fibres is merino wool having an average fibre diameter about 19.3 flm and an average fibre length of greater than about 68 mm, the primary wrapper is a nylon 6, 6 having a filament dtex of about 22/7/1, and the secondary wrapper is a nylon 6, 6 having a filament dtex of about

22/7/1.

55. The process or yarn as claimed in claim 54, wherein the wool is about 74% by mass of themulti-component yarn, the primary and secondary wrappers each being about 13% by mass of the multi-component yarn.

56. The process or yarn as claimed in any one of claims 1 to 53, wherein the first set of fibres is a merino wool having an average fibre diameter about

20.5 flm and an average fibre length of greater than about 68 mm, and the primary wrapper is a nylon 6, 6 having a filament dtex of about 22/7/1, and the secondary wrapper is a nylon 6, 6 having a filament dtex of about 22/7/1.

57. The process or yarn as claimed in claim 56, wherein the wool is about 80% by mass of the multi-component yarn, the primary and secondary wrappers each being about 7.5% by mass of the multi-component yarn.

58. The process or yam as claimed in any one of claims 1 to 53, wherein the first set of fibres is a merino wool having an average fibre diameter about 20.5 flm and an average fibre length of greater than about 68 mm, and the primary wrapper is a nylon 6, 6 having a filament dtex of about 22/7/1, and the secondary wrapper is a nylon 6, 6 having a filament

dtex of about 22/7/1.

59. The process or yarn as claimed in claim 58, wherein the first set of fibres comprises about15% by mass of an additional fibre, the additional fibre being cashmere wool having an average fibre diameter of about 16 flm and an average fibre length of about 26 to about 36 mm.

60. The- process or yarn as claimed in claim 58 or claim 59, wherein the wool is about 70% by mass of the multi-component yam, the primary and secondary wrappers each being about 7.5% by mass of the multi-component yarn.

61. The process or yam as claimed in any one of claims 1 to 53, wherein the first set of fibres is a merino wool having an average fibre diameter about 20.6 flm and an average fibre length of greater than about 68 mm, and the primary wrapper is a nylon 6, 6 having a filament dtex of about 17/5/1, and the secondary wrapper is a nylon 6, 6 having a filament

dtex of about 17/5/1.

62. The process or yarn as claimed in claim 61 , wherein the wool is about 70% by mass of themulti-cdmponent yam, the primary and secondary wrappers each being about 15% by mass of the multi-component yarn.

63. The process or yarn as claimed in any one of claims 1 to 53, wherein the first set of fibres is a merino wool having an average fibre diameter about 19.3 flm and an average fibre length of greater than about 68 mm, and the primary wrapper is a nylon 6, 6 having a filament dtex of about 22/7/1 , and the secondary wrapper is a nylon 6, 6 having a filament

dtex of about 22/7/1,

64. The process or yarn as claimed in claim 63, wherein the wool is about 74% by mass of the multi-component yam, the primary and secondary wrappers each being about 13% by mass of the multi-component yarn.

65. The process or yam as claimed in any one of claims 1 to 53, wherein the first set of fibres is a merino wool having an average fibre diameter about 19.5 flm and an average fibre length of greater than about 68 mm, and the primary wrapper is a nylon 6, 6 having a filament dtex of about 17/5/1 , and the secondary wrapper is a nylon 6, 6 having a filament dtex of about 78/68/1.

66. The process or yarn as claimed in claim 65, wherein the wool is about 62% by mass of the multi-component yarn, the primary wrapper being about 6.8% by mass and the secondary wrapper being about 31.2% by mass of the multi-component yarn.

67. The process or yarn as claimed in any one of claims 1 to 53, wherein the first set of fibres is a merino wool having an average fibre diameter about 22.5 flm and an average fibre length of greater than about 68 mm, and the primary wrapper is a nylon 6, 6 having a filament dtex of about 22/7/1, and the secondary wrapper is a nylon 6, 6 having a filament dtex of about 22/7/1.

68. The process or yam as claimed in claim 67, wherein the wool is about 87% by mass of the multi-component yam, the primary and secondary wrappers each being about 6.5% by mass of the multi-component yam.

69. The process or yarn as claimed in any one of claims 1 to 53, wherein the first set of fibres is a merino wool having an average fibre diameter about 23.5 flm and an average fibre length of greater than about 68 mm, and the primary wrapper is a nylon 6, 6 having a filament dtex of about 22/7/1 , and the secondary wrapper is a nylon 6, 6 having a filament dtex of about 22/7/1.

70. The process or yarn as claimed in claim 69, wherein the wool is about 87% by mass of themulti-component yam, the primary and secondary wrappers each being about 6.5% by mass of the multi-component yarn.

71. The process or yarn as claimed in any one of claims 1 to 53, wherein the first set of fibres is a merino wool having an average fibre diameter about 26-28 flm and an average fibre length of greater than about 68 mm, and the primary wrapper is a nylon 6, 6 having a filament dtex of about 22/7/1, and the secondary wrapper is a nylon 6, 6 having a filament dtex of about 22/7/1.

72. The process or yarn as claimed in claim 71 i wherein the first set of fibres comprises about 43.5% by mass of an additional fibre, the additional fibre being an acrylic, the acrylic fibres having an average fibre diameter of about 3.4 dtex and an average fibre length of about 75 mm.

73. The process or yam as claimed in claim 71 or claim 72, wherein the wool is about 43.5%by mass of the multi-component yarn, the primary and secondary wrappers each being about 6.5% by mass of the multi-component yarn.

74. The process or yarn as claimed in any one of claims 1 to 53, wherein the first set of fibres is a merino wool having an average fibre diameter about 23.5 flm and an average fibre length of about 68 mm, and the primary wrapper is a nylon 6, 6 having a filament dtex of about 22/7/1 , and the secondary wrapper is a nylon 6, 6 having a filament dtex of about

22/7/1.

75. The process or yam as claimed in claim 74, wherein the wool is about 87% by mass of the multi-component yarn, the primary and secondary wrappers each being about 6.5% by mass of the multi-component yarn.

76. The process or yam as claimed in any one of claims 1 to 53, wherein the first set of fibres is a merino wool having an average fibre diameter about 18.9 flm and an average fibre length of greater than about 68 mm, and the primary wrapper is a nylon 6, 6 having a filament dtex of about 17/5/1, and the secondary wrapper is a nylon 6, 6 having a filament dtex of about 17/5/1.

77. The process or yam as claimed in claim 76, wherein the wool is about 83% by mass of themulti-component yarn, the primary and secondary wrappers each being about 8.5% by mass of the multi-component yarn.

78. The process or yarn as claimed in any one of claims 1 to 53, wherein the first set of fibres is a merino wool having an average fibre diameter about 23.5 flm and an average fibre length of greater than about 68 mm, and the primary wrapper is a nylon 6, 6 having a filament dtex of about 22/7/1 , and the secondary wrapper is a nylon 6, 6 having a filament dtex of about 22/7/1.

79. The process or yarn as claimed in claim 78, wherein the wool is about 87% by mass of the multi-component yam, the primary and secondary wrappers each having about 6.5% by mass of the multi-component yarn.

80. The process or yarn as claimed in any one of claims 1 to 53, wherein the first set of fibres is a merino wool having an average fibre diameter about 23.5 flm and an average fibre length of greater than about 68 mm, and the primary wrapper is a nylon 6, 6 having a filament dtex of about 22/7/1 , and the secondary wrapper is a nylon 6, 6 having a filament dtex of about 22/7/1.

81. The process or yam as claimed in claim 80, wherein the wool is about 87% by mass of the multi-component yam, the primary and secondary wrappers each having about 6.5% by mass of the multi-component yarn.

82. The process or yarn as claimed in any one of claims 1 to 53, wherein the first set of fibres is a merino wool having an average fibre diameter about 26 flm and an average fibre length of about 70 mm, and the primary wrapper is a nylon 6, 6 having a filament dtex of about 17/5/1 , and the secondary wrapper is a nylon 6, 6 having a filament dtex of about 17/5/1.

83. The process or yarn as claimed in claim 82, wherein the wool is about 91.5% by mass of the multi-component yam, the primary and secondary wrappers each being about 4.25% by mass of the multi-component yarn.

84. The process or yarn as claimed in any one of claims 1 to 53, wherein the first set of fibres is a merino wool having an average fibre diameter about 26 flm and an average fibre length of greater than about 70 mm, and the primary wrapper is a nylon 6, 6 having a filament dtex of about 17/5/1 , and the secondary wrapper is a nylon 6, 6 having a filament dtex of about 17/5/1.

85. The process or yam as claimed claim 84, wherein the wool is about 91.5% by mass of the multi-component yarn, the primary and secondary wrappers each being about 4.25% by mass of the multi-component yarn.

86. The process or yarn as claimed in any one of claims 1 to 53, wherein the first set of

fibres is a merino wool having an average fibre diameter about 26 flm and an average fibre length of about 65 mm, and the primary wrapper is a nylon 6, 6 having a filament dtex of about 17/5/1 , and the secondary wrapper is a nylon 6, 6 having a filament dtex of about 17/5/1.

87. The process or yarn as claimed in claim 86, wherein the wool is about 91 % by mass of the multi-component yam, the primary and secondary wrappers each being about 4.5% by mass of the multi-component yam.

88. The process or yam as claimed in any one of claims 1 to 53, wherein the first set of fibres is a merino wool having an average fibre diameter about 26 flm and an average fibre length of greater than about 58 mm, and the primary wrapper is a nylon 6, 6 having a filament dtex of about 17/5/1 , and the secondary wrapper is a nylon 6, 6 having a filament dtex of about 17/5/1.

89. The process or yam as claimed in claim 88, wherein the first set of fibres comprises about45.5% of an additional fibre, the additional fibre being a viscose, the viscose fibres having an average fibre length of between about 75 to about 100 mm and an average fibrediameter of about 3.3 dtex.

90. The process or yam as claimed in claim 88 or claim 89, wherein the wool is about 45.5% by mass of the multi-component yam, the primary and secondary wrappers each being about 4.5% by mass of the multi-component yarn.

91. The process or yarn as claimed in any one of claims 1 to 53, wherein the first set of fibre is a merino wool having an average fibre diameter about 19.3 flm and an average fibre length of greater than about 68 mm, and the primary wrapper is a nylon 6, 6 having a filament dtex of about 50/46/1 , and the secondary wrapper is a nylon 6, 6 having a filament dtex of about 17/5/1.

92. The process or yarn as claimed in claim 91 , wherein the wool is about 60% by mass of themulti-component yam, the primary wrapper being about 30% by mass of the multi- component yam and the secondary wrapper being about 10% by mass of the multi-component yarn.

93. The process or yarn as claimed in any one of claims 1 to 53, wherein the first set of fibresis a merino wool having an average fibre diameter about 26 flm and an average fibre length of greater than about 58 mm, and the primary wrapper is a nylon 6, 6 having afilamentdtex of about 17/5/1, and the secondary wrapper is a nylon 6, 6 having a filament dtex of about 17/5/1.

94. The process or yam as claimed in claim 93, wherein the first set of fibres comprises about 45.75% by mass of an additional fibre, the additional fibre being a viscose, the viscose fibres having an average fibre length of about 75 . mm to about 100 mm and an average fibre diameter of about 3.3 dtex mm.

95. The process or yarn as claimed in claim 93 or claim 94, wherein the wool is about 45.75% by mass of the multi-component yam, the primary and secondary wrappers each being about 4.25% by mass of the multi- .

component yarn.

96. The process or yarn as claimed in any one of claims 1 to 53, wherein the first set of fibres is a merino wool having an average fibre diameter about 26 flm and an average fibre length of greater than about 58 mm, and the primary wrapper is a nylon 6, 6 having a filament dtex of about 17/5/1, and the secondary wrapper is a nylon 6, 6 having a filament dtex of about 17/5/1.

97. The process or yarn as claimed in claim 96, wherein the first set of fibres comprises about 45.75% by mass of an additional fibre, the additional fibre being a viscose, the viscose fibres having an average fibre length of about 75 mm to about 100 mm. and having an average fibre diameter of 3.3 dtex.

98. The process or yarn as claimed in claim 96 or claim 97, wherein the wool is about 45.75% by mass of the multi-component yarn, the primary and secondary wrappers each being about 4.25% by mass of the multi- component yarn.

A significant advantage associated with this invention is the ability to provide for a multi-component yarn formed from a core (formed from the at least first set of fibres) that comprises on average about 14 to about 100 fibres in its cross-section. Although the core may have about 30 fibres in its cross-section, or less than about 25 fibres, or less than about 20 fibres, or less than about 15 fibres. Reduced core fibres are enabled by the configuration of primary and secondary wrappers.

Examples of this invention will now be described with reference to the production of a range of multi-component yarns including two standard twists for weaving yarns and an ultra-low twist particularly for knitting yarns, pre-spun cotton yarns wrapped and spun with coarse wool fibres to have a wool fibre content of about

19 fibres in cross section. Figures 5 and 6 graphically illustrate the diiferences between conventional yarns and yarns made according to this invention.

1. This invention desirable aims to provide for:

- reducing the average number of fibres in the cross-section of the at least first set of fibres or staple fibre used to less than 30,

- wrapping the first set of fibres or staple fibre with a first (primary) wrapper in the Z or S twist direction, and

- wrapping the wrapped first set of fibres or staple fibre with a second (secondary) wrapper in an opposite twist direction to the first (primary) wrapper (i.e. in the S or Z twist direction respectively), and a

wrapping/spinning twist in an opposite twist direction to the first (primary) wrapper.

2. Such a yarn is produced that provides the following advantages:

i) is less twist lively and therefore can be more efficiently set when autoclaving/relaxing the yam (tex twist down to about 1000 achievable), ii) individual filaments of the yam are embedded better in the drafted staple fibre material,

iii) improved yarn evenness (irregularity) (coefficient of variation of yarn linear density alongyarn length),

iv) reduced imperfections (thick and thin places and neps),

v) improved pilling resistance,

vi) improved abrasion resistance,

vii) improved initial fabric appearance and its appearance retention in use and after washing.

3. The resulting improved yam characteristics further allow for improved spinning manufacturing performance, better performance in winding, weaving and knitting. In addition, there is enabled a spun yam with a low twist to be formed which is particularly useful in some knitting applications.

4. Such a yam provides for increased levels of yam abrasion resistance, abrasion resistance of vyhich is also useful with the low tex twist factor, for knitting purposes.

5. The relative twist directions of core (first set of fibres) and primary and secondary wrappers is provided such that in the resultant yam the primary wrapper is not overly tight or loose and the secondary wrapper is not slack. The combination of alternative suggested twist directions capture the wool fibres in the yarn body in an improved manner than other yarns.

6. It will be appreciated the previous twist levels that may be used in prior yarns have been mostly for weaving yams and were relatively high twist levels. The need for an improved selection of particular combinations of twist directions of primary and secondary wrappers and spinning twist did not arise for high twist weaving yams and therefore has not previously been considered as viable in the past. Because of the increasing demand for lightweight jersey and other knitted fabrics for next-to-skin and mid- . layer apparel applications, such as for casual and sportswear applications, significant opportunities exist for low to medium twist knitting yams that are fine, even, and provide better pilling and abrasion resistance.

7. The invention may also provide for improvements for low to medium twist yams which are mostly used for knitting purposes. Such purpose is enabled as the new yarn is capable of producing soft handle, quick drying, high breathability, and reduced stitch distortion (due to twist stability) characteristics. Again, such applications include next-to-skin knits (conventional types), stretch- compression knits, and active sportswear.

8. In addition, yams with certain primary and secondary wrappers can be used for introducing specific functionality. For example, fancy textures, high tenacity, high stretch, antistatic, antimicrobial and conductive properties.

9. Yarns of this invention are suitable for all long and short staple fibres, whether natural or synthetic, and all filament or staple yarn primary and/or secondary wrappers.

10. Examples of these further include, where one of, or both, of the wrappers is/are a soluble type (e.g. PVA - polyvinyl alcohol), the resulting yarn in the fabric becomes lighter after fabric wet processing and fabric becomes softer and fuller. Such yarns and fabric are considered relatively easy to process before finishing. Where for example ultra-fine or ultra-denier filament yam for primary and/or secondary wrapper is used, again, these are considered relatively easy to process.

Example 1

The cotton yams can be 8 tex singles yams and the wool can be advantageously 19 fibres each of 1.26 tex (35 micron average fibre diameter), making a total of 24 tex. The resulting yarn is approximately 40 tex (25 Nm), 60/40% wool/cotton by weight and has a coefficient of variation of mass per unit length by Uster Testing of 15.5%.

Typically the end breakage rate is found to be 5 or less ends down per hundred spindle hours. No existing system known to the applicants is capable of producing such a yarn in one spinning process..

The present invention is suitable for use with a ring spinning frame part of which is shown in Figure 1 and as described above.

1. The spinning frame is modified and includes mountings either thereon or in association there with, for example, creels (fig 10) on which packages of filament yam or cotton are mounted.

2. The yarn 8 (Figure 2 and 3) from a first of the packages is fed to an adjustable width V- Roller feed system (Fig 8) then behind the drafting roller 6 to a guide 12.

3. The strands 8, 9 and 11 are twisted while passing through a guide 13 toward a spindle 14 on which the spun yarn is collected. This invention can be used in association with a ring spinning frame adapted to operate a

Sirospun™ system. In this case the breakout device is either removed or not used.

1. In use, the strands 8, 9 and 11 can have associated therewith at points marked A stop motion sensors adapted to indicate yam or filament breakages which are adapted to activate a cutter at B. The spinning frame can include an air suction means to collect the broken fibre strands in the event of yam breakages during processing.

2. In use, the staple strand 11 is entrained with strand 8 while passing

through the guide 12. The twist in the spun yam at B travels between guide 13 and drafting roller 6 to promote twisting of the strand 11 and strand 8. The combined material 8 and 11 is spun with strand 9 at or before the guide 13 and is collected on the spindle 14 to form a package of yarn for further use.

Example 2

A wool roving of average fibre diameter 29 microns was drafted to approximately 25.5 tex and then had an average of approximately 26 fibres per cross-section. In the same drafting and spinning process this strand of wool fibres was twisted together with firstly one continuous filament nylon textured yam of 22 decitex and 7 filaments and secondly one continuous filament nylon yarn of 22 decitex and 7 filaments, to form a composite yarn of resultant count 30 tex (33.3 Nm) with 670 turns per metre (tpm) twist. Yarn breakage rates ranging from 3 to 6 per 100 spindle hours were recorded.

The yarn breaking load was 3.33 Newtons and the yam extension at break was 21 %.The irregularity of the yarn was measured on an Uster instrument and was 24.5%. Example 3

A wool roving of average fibre diameter 35 micron was drafted to approximately 18.5 tex and then had an average of approximately 15 fibres per yarn cross-section. In the same drafting and spinning process or machine this strand of wool fibres was twisted firstly with one 7.6 tex pre- spun cotton yarn and secondly with one 4 tex continuous filament silk yam to give a resultant count of 30 tex (33.3 Nm) with 880 turns per metre (tpm) twist. The recorded end breakage rate was 6.5 breaks per 100 spindle hours.

The average yam breaking load was 3.6 Newtons and the average extension at break was 10.5%. The Uster coefficient of variation of yarn linear density was 20.8%.

Example 4

Wool mean fibre diameter 18.5 micron

Yam count 16.7 tex (60 Nm) Yarn twist 486 tpm S

Number of wool fibres in the yam cross-section = 45

Yarn A: Primary (core) wrapper = continuous multi-filament nylon 17 dtex Z-twist.

Secondary wrapper = as above but S-twist.

Yam B: Primary wrapper = 17 dtex Z-twist. Secondary wrapper = 17 dtex Z-twist.

Test results on Yarn A and Yarn B:

Yam A Yam B

User evenness (Uster 3) CV% 16.00 16.50

Thin (-50%)/ 1 km 30 68

Thick (+50%)/1 km 15 15

Neps (+200%)/ 1 km 8 5

Hairiness, H 5.86 6.28

Tenacity, cN/tex 16.23 15.60

Breaking elongation % 24.5 22.5

Breaking energy, cN.cm 2317 2044 The results demonstrate a yam having greater evenness, lower occurrences of thin places, lower hairiness, higher tenacity and greater extensibility.

Accordingly, this invention provides for an improved yam manufacturing process capable of producing fine yams comprising twisted staple fibres and filaments or pre-spun yams. The staple fibre component can even comprise on average 19 or less fibres in the cross-section under commercially viable conditions.

Examples 5-28

The following examples 5-28 listed in Tables 1 and 2 are specific yarn

constructions formed according to the invention. With reference to tables:

Final yarn count: The resultant yarn count in metric count. In x/y, x = yarn metric

count and y = number of plies. Metric count, Nm is the number of kilometres of yarn per one kilogram of yam. Nm = 1000/tex, where tex is the number of grams of yam per 1 kilometre of yam.

Twist: Twist is expressed in number of turns per metre of yarn

(known

as TPM). S and Z are twist directions. Yarn is spun with either S or Z twist direction.

Viscose: The viscose used is a flame-resistant viscose produced by

Lenzing™ under the name of 'Lenzing FR 3.3' having a titer dtex of 3.3, staple length of 51,60, 75, 90 mm, tenacity condition of 23 cN/dtex, elongation condition of 17%, wet state tenacity of 11 cN/tex and Limiting Oxygen Index (LOI) of 28%.

Nylon: The nylon used is nylon 6.6. Wool micron: The average diameter of wool fibre being used, measured in micrometres.

Wool length: The average length of wool fibre being used, measured in

millimetres.

Treatment 'NT: Means no treatment was applied (no shrink-resist

t reatment).

Treatment TEC: Means a Total Easy Care™ treatment was applied. Such a treatment allows garments to retain their appearance after repeated machine washing and tumble drying by reducing shrinkage.

Treatment Ή': Means a Hercosett™ treatment (such as chlorine-

Hercosett) was applied. Alternatively, any other treatment for reducing shrinkage that generally involves a chlorine pre-treatment followed by application of a polyamide - epichloridine resin.

Wool %: Means the percentage of wool used in the yarn by mass (weight).

Additional fibre fineness: Means the average fibre diameter of any additional optional

(in micrometres), fibres used.

Additional fibre length: Means the average length of additional optional fibres used with the roving, e.g. lengths of additional viscose, acrylics, nylons

Additional fibre %: Means the percentage of additional fibre used with the roving, e.g. a length of viscose, acrylic, nylon, in the whole yarn by mass (weight).

Filament dtex: This measurement is given as a ratio in respect of

decitex/number of filaments in the yarn/number of ends of the yarn used. Filament %: This is the percentage of filament yam by weight of resulting yarn.

Filament 1 refers to a primary wrapper. Filament 2 refers to a secondary wrapper.

In a typical method of constructing an improved yarn according to any of the examples 5-28 in Table 1 below, the following steps are undertaken. a. Select wool to be used as the roving staple fibre, e.g. the Merino wool with roperties

as set out in examples 5-28. The wool having been subjected to a desired pre-treatment(e.g. TEC, H, NT).

b. Select an optional additional fibre material, e.g. the Cashmere wool, or viscose or acryfc materials with properties as set out in certain of the examples 5-28.

c. Select a first filament wrapper number 1 , e.g. nylon 6.6 with properties as set out in examples 5-28.

d. Select a second filament wrapper 2, e.g. nylon 6. 6 with properties as set out in Examples 5-28.

Table 1A: Examples 5-15 of components forming multi-component yams

Example no. 11 12 13 14 15 16

Final Yam Count

(Nm) 60/1 60/1 28/1 28/1 28/1 28/1

Twist 420 S 420 Z 395 S 395 S 420 S 395 S

Wool Type Merino Merino Merino Merino Merino Merino

Wool Average

Diameter (micron) 19.5 19.5 22.5 23.5 26-28 23.5

Wool Length

(mm) >68 >68 >68 >68 >68 >68

Treatment HT HT HT HT HT HT

Wool Percentage

43 43 87 43.5 87 %

Additional Fibre

type - - - - Acrylic -

Additional

Fineness

(micron/dtex) 3.4 dtex

Additional Fibre

Length (mm) - - - - 75 -

Additional Fibre

% - - - - 43.5 -

Filament Wrapper

no. 1 Nylon 6,6 Nylon 6,6 Nylon 6,6 Nylon 6,6 Nylon 6,6 Nylon 6,6

Filament wrapper 17/5/1 17/5/1 22/7/1 22/7/1 22/7/1 22/7/1 no. 1 (dtex)

Filament 1 % 10.2 10.2 6.5 6.5 6.5 6.5

Filament 1 (T wist) Z S Z Z Z Z

Filament 1 (Shape) Round Round Round Round Round Round

Filament Wrapper

no. 2 Nylon 6,6 Nylon 6,6 Nylon 6,6 Nylon 6,6 Nylon 6,6 Nylon 6,6

Filament 2 (dtex) 78/68/1 78/68/1 22/7/1 22/7/1 22/7/1 22/7/1

Filament 2 % 46/8 46.8 6.5 6.5 6.5 6.5

Filament 2 Twist S Z S S S s

Filament 2 Shape Triple-T Triple-T Round Round Round Round Example no. 17 18 19 20 21 22

Final Yam Count

(Nm) 50/1 50/1 23/1 23/1 23/1 23/1

Twist 460 S 460 Z 520 Z 520 Z 520 S 520 Z

Wool Type Merino Merino Merino Merino Merino Merino

Wool Average

Diameter (micron) 18.9 18.9 26 26 26 26

Wool Length

(mm) >68 >68 >70 >70 >65 >65

N OR

Treatment HT HT N OR HT N OR HT HT N OR HT

Wool Percentage 83 83 91.5 ^• 91.5 91 91 %

Additional Fibre

type - - - - - -

Additional

Fineness

(micron dtex)

Additional Fibre

•

Length (mm) - - - - -

Additional Fibre

% - - - - -

Filament Wrapper

no. 1 Nylon 6,6 Nylon 6,6 Nylon 6,6 Nylon 6,6 Nylon 6,6 Nylon 6,6

Filament wrapper 17/5/1 17/5/1 17/51 17/5/1 17/5/1 17/5/1 no. 1 (dtex)

Filament 1 % 8.5 8.5 4.25 4.25 4.5 4.5

Filament 1 (Twist) Z S Z S Z S

Filament 1 (Shape) Round Round Round Round Round Round

Filament Wrapper

no. 2 Nylon 6,6 Nylon 6,6 Nylon 6,6 Nylon 6,6 Nylon 6,6 Nylon 6,6

Filament 2 (dtex) 17/5/1 17/5/1 17/5/1 17/5/1 17/5/1 17/5/1

Filament 2 % 8.5 8.5 4.25 4.25 4.5 4.5

Filament 2 Twist S Z S Z S Z

Filament 2 Shape Round Round Round Round Round Round Example no. 23 24 25 26 27 28

Final Yarn Count

(Nm) 23/1 23/1 60/1 60/1 25/1 25/1

Twist 520 S 520 Z 380 S 380 Z 520 S 520 Z

Wool Type Merino Merino Merino Merino Merino Merino

Wool Average

Diameter (micron) 26 26 19.3 19.3 26 26

Wool Length

(mm) >58 >58 >68 >6& >58 >58

Treatment N OR HT N OR HT HT HT N OR HT N OR HT

Wool Percentage 45.5 45.5 60 60 45.75 45.75 %

Additional Fibre

type - - - - - -

Additional

Fineness Viscose 3.3 Viscose 3.3 Viscose 3.3 Viscose 3.3 (micron/dtex) dtex dtex dtex dtex

Additional Fibre

Length (mm) 75-100 75-100 - - 75-100 75-100

Additional Fibre

% 45.5 45.5 - 45.75 45.75

Filament Wrapper

no. 1 Nylon 6,6 Nylon 6,6 Nylon 6,6 Nylon 6,6 Nylon 6,6 Nylon 6,6

Filament wrapper 17/5/1 17/5/1 50/46/1 50/46/1 17/5/1 17/5/1 no. 1 (dtex)

Filament 1 % 4.5 4.5 30 30 4.25 4.25

Filament 1 (Twist) Z S - - Z S

Filament 1 (Shape) Round Round Air Air Round Round textured textured

Filament Wrapper

no. 2 Nylon 6,6 Nylon 6,6 Nylon 6,6 Nylon 6,6 Nylon 6,6 Nylon 6,6

Filament 2 (dtex) 17/5/1 17/5/1 17/5/1 - 17/5/1 17/5/1 17/5/1

Filament 2 % 4.5 4.5 10 10 4.25 4.25

Filament 2 Twist S Z - - S Z

Filament 2 Shape Round Round Round Round Round Round CLAIMS YARNS

1. Preferably, the at least first set of fibres is pre-treated. More preferably, the first set of fibres has undergone a chemical or physical (or both) pre-treatment. Most preferably, the first set of fibres has been pre-treated to minimise shrinkage or distortion once formed into a multi-component yarn for weaving.

2. Preferably, the at least first set of fibres is pre-treated by a shrink-resistant treatment.

More preferably, by a fibre shrinkage reducing treatment. Most preferably, by a treatment to allow subsequently woven material or garments from the multi- component yarn to retain their appearance after repeated machine washing and tumble drying by reducing shrinkage.

3. Preferably, the first set of fibres is merino wool having an average fibre diameter about 19.3 flm and an average fibre length of greater than about 68 mm, the primary wrapper is a nylon 6, 6 having a filament dtex of about 22/7/1 , and the secondary wrapper is a nylon 6, 6 having a filament dtex of about 22/7/1. More preferably, the wool is about 74% by mass of the multi-component yarn, the primary and secondary wrappers each being about 13% by mass of the multi-component yarn.

4. Preferably, the first set of fibres is a merino wool having an average fibre diameter about 20.5 flm and an average fibre length of greater than about 68 mm, and the primary wrapper is a nylon 6, 6 having a filament dtex of about 22/7/1 , and the secondary wrapper is a nylon 6, 6 having a filament dtex of about 22/7/1. More preferably, the wool is about 80% by mass of the multi-component yarn, the primary and secondary wrappers each being about 7.5% by mass of the multi-component yarn.

5. Preferably, the first set of fibres is a merino wool having an average fibre diameter about 20.5 flm and an average fibre length of greater than about 68 mm, and the primary wrapper is a nylon 6, 6 having a filament dtex of about 22/7/1, and the secondary wrapper is a nylon 6, 6 having a filament dtex of about 22/7/1. More preferably, the first set of fibres comprises about 15% by mass of an additional fibre, the additional fibre being cashmere wool having an average fibre diameter of about 6 flm and an average fibre length of about 26 to about 36 mm. Even more preferably, the wool is about 70% by mass of the multi-component yarn, the primary and secondary wrappers each being about 7.5% by mass of the multi-component yarn.

6. Preferably, the first set of fibres is a merino wool having an average fibre diameter about 20.6 flm and an average fibre length of greater than about 68 mm, and the primary wrapper is a nylon 6, 6 having a filament dtex of about 17/5/1, and the secondary wrapper is a nylon 6, 6 having a filament dtex of about 17/5/1. More preferably, the wool is about 70% by mass of the multi-component yarn, the primary and secondary wrappers each being about 15% by mass of the multi-component yarn.

7. Preferably, the first set of fibres is a merino wool having an average fibre diameter about 19.3 flm and an average fibre length of greater than about 68 mm, and the primary wrapper is a nylon 6, 6 having a filament dtex of about 22/7/1 , and the secondary wrapper is a nylon 6, 6 having a filament dtex of about 22/7/1. More preferably, the wool is about 74% by mass of the multi-component yarn, the primary and secondary wrappers each being about 13% by mass of the multi-component yarn.

8. Preferably, the first set of fibres is a merino wool having an average fibre diameter about 19.5 flm and an average fibre length of greater than about 68 mm, and the primary wrapper is a nylon 6, 6 having a filament dtex of about 17/5/1, and the secondary wrapper is a nylon 6, 6 having a filament dtex of about 78/68/1. More preferably, the wool is about 62% by mass of the multi-component yarn, the primary wrapper being about 6.8% by mass and the secondary wrapper being about 31.2% by mass of the multi-component yarn.

9. Preferably, the first set of fibres is a merino wool having an average fibre diameter about 22.5 flm and an average fibre length of greater than about 68 mm, and the primary wrapper is a nylon 6, 6 having a filament dtex of about 22/7/1, and the secondary wrapper is a nylon 6, 6 having a filament dtex of about 22/7/1. More preferably, the wool is about 87% by mass of the multi-component yarn, the primary and secondary wrappers each being about 6.5% by mass of the multi-component yarn.

10. Preferably, the first set of fibres is a merino wool having an average fibre diameter abbut 23.5 flm and an average fibre length of greater than about 68 mm, and the primary wrapper is a nylon 6, 6 having a filament dtex of about 22/7/1, and the secondary wrapper is a nylon 6, 6 having a filament dtex of about 22/7/1. More preferably, the wool is about 87% by mass of the multi-component yarn, the primary and secondary wrappers each being about 6.5% by mass of the multi-component yarn.

11. Preferably, the first set of fibres is a merino wool having an average fibre diameter about 26-28 flm and an average fibre length of greater than about 68 mm, and the primary wrapper is a nylon 6, 6 having a filament dtex of about 22/7/1 , and the secondary wrapper is a nylon 6, 6 having a filament dtex of about 22/7/1. More preferably, the first set of fibres comprises about 43.5% by mass of an additional fibre, the additional fibre being an acrylic, the acrylic fibres having an average fibre diameter of about 3.4 dtex and an average fibre length of about 75 mm. Even more preferably, the wool is about 43.5% by mass of the multi-component yarn, the primary and secondary wrappers each being about 6.5% by mass of the multi-component yarn. 2. Preferably, the first set of fibres is a merino wool having an average fibre diameter about 23.5 flm and an average fibre length of about 68 mm, and

the primary wrapper is a nylon 6, 6 having a filament dtex of about 22/7/1 , and the secondary wrapper is a nylon 6, 6 having a filament dtex of about 22/7/1. More preferably, the wool is about 87% by mass of the multi-component yarn, the primary and secondary wrappers each being about 6.5% by mass of the multi-component yarn.

13. Preferably, the first set of fibres is a merino wool having an average fibre diameter about 18.9 flm and an average fibre length of greater than about 68 mm, and the primary wrapper is a nylon 6, 6 having a filament dtex of about 17/5/1, and the secondary wrapper is a nylon 6, 6 having a filament dtex of about 17/5/1. More preferably, the wool is about 83% by mass of the multi-component yarn, the primary and secondary wrappers each being about 8.5% by mass of the multi-component yarn.

14. Preferably, the first set of fibres is a merino wool having an average fibre diameter about 23.5 flm and an average fibre length of greater than about 68 mm, and the primary wrapper is a nylon 6, 6 having a filament dtex of about 22/7/1, and the secondary wrapper is a nylon 6, 6 having a filament dtex of about 22/7/1. More preferably, the wool is about 87% by mass of the multi-component yam, the primary and secondary wrappers each having about 6.5% by mass of the multi-component yarn.

15. Preferably, the first set of fibres is a merino wool having an average fibre diameter about 23.5 flm and an average fibre length of greater than about 68 mm, and the primary wrapper is a nylon 6, 6 having a filament dtex of about 22/7/1, and the secondary wrapper is a nylon 6, 6 having a filament dtex of about 22/7/1. More preferably, the wool is about 87% by mass of the multi-component yarn, the primary and secondary wrappers each having about 6.5% by mass of the multi-component yarn.

16. Preferably, the first set of fibres is a merino wool having an average fibre diameter about 26 flm and an average fibre length of about 70 mm, and

the primary wrapper is a nylon 6, 6 having a filament dtex of about 17/5/1 , and the secondary wrapper is a nylon 6, 6 having a filament dtex of about 17/5/1. More preferably, the wool is about 91.5% by mass of the multi-component yarn, the primary and secondary wrappers each being about 4.25% by mass of the multi-component yarn.

17. Preferably, the first set of fibres is a merino wool having an average fibre diameter about 26 flm and an average fibre length of greater than about 70 mm, and the primary wrapper is a nylon 6, 6 having a filament dtex of about 17/5/1, and the secondary wrapper is a nylon 6, 6 having a filament dtex of about 17/5/1. More preferably, the wool is about 91.5% by mass of the multi-component yarn, the primary and secondary wrappers each being about 4.25% by mass of the multi-component yarn.

18. Preferably, the first set of fibres is a merino wool having an average fibre diameter about 26 flm and an average fibre length of about 65 mm, and

the primary wrapper is a nylon 6, 6 having a filament dtex of about 17/5/1 , and the secondary wrapper is a nylon 6, 6 having a filament dtex of about 17/5/1. More preferably, the wool is about 91% by mass of the multi-component yarn, the primary and secondary wrappers each being about 4.5% by mass of the multi-component yarn.

19. Preferably, the first set of fibres is a merino wool having an average fibre diameter about 26 flm and an average fibre length of greater than about 58 mm, and the primary wrapper is a nylon 6, 6 having a filament dtex of about 17/5/1, and the secondary wrapper is a nylon 6, 6 having a filament dtex of about 17/5/1. More preferably, the first set of fibres comprises about 45.5% of an additional fibre, the additional fibre being a viscose, the viscose fibres having an average fibre length of between about 75 to about 100 mm and an average fibre diameter of about 3.3 dtex. Even more preferably, the wool is about 45.5% by mass of the multi-component yam, the primary and secondary wrappers each being about 4.5% by mass of the multi- component yarn.

20. Preferably, the first set of fibres is a merino wool having an average fibre diameter about 19.3 flm and an average fibre length of greater than about 68 mm, and the primary wrapper is a nylon 6, 6 having a filament dtex of about 50/46/1, and the secondary wrapper is a nylon 6, 6 having a filament dtex of about 17/5/1.

21. Preferably, the wool is about 60% by mass of the multi-component yarn, the primary wrapper being about 30% by mass of the multi-component yam and the secondary wrapper being about 10% by mass of the multi-component yarn.

22. Preferably, the first set of fibres is a merino wool having an average fibre diameter about 26 flm and an average fibre length of greater than about 58 mm, and the primary wrapper is a nylon 6, 6 having a filament dtex of about 17/5/1, and the secondary wrapper is a nylon 6, 6 having a filament dtex of about 17/5/1. More preferably, the first set of fibres comprises about 45.75% by mass of an additional fibre, the additional fibre being a viscose, the viscose fibres having an average fibre length of about 75 mm to about 100 mm and an average fibre diameter of about 3.3 dtex mm. Even more preferably, the wool is about 45.75% by mass of the multi-component yarn, the primary and secondary wrappers each being about 4.25% by mass of the multi-component yarn.

23. Preferably, the first set of fibres is a merino wool having an average fibre diameter about 26 flm and an average fibre length of greater than about 58 mm, and the primary wrapper is a nylon 6, 6 having a filament dtex of about 17/5/1, and the secondary wrapper is a nylon 6, 6 having a filament dtex of about 17/5/1. More preferably, first set of fibres comprises about 45.75% by mass of an additional fibre, the additional fibre being a viscose, the viscose fibres having an average fibre length of about 75 mm to about 100 mm and having an average fibre diameter of 3.3 dtex. Even more preferably, the wool is about 45.75% by mass of the multi-component yarn, the primary and secondary wrappers each being about 4.25% by mass of the multi-component yam.

24. Preferably, the viscose has the properties of a staple fibre of about 3.3 dtex, a staple length of about 65 mm, a tenacity condition of about 23 cN/dtex, an elongation condition of about 17%, a wet state tenacity of about 11 cN/tex, a wet modulus of about 2.5 cN/tex, and a Limiting Oxygen Index (LOI) of about 28%.

Advantageously, the multi-component yarn manufactured according to this invention may enable the engineering of technical yarns to be realised more readily as the pre* spun yarns can be placed or included in the multi-component yarn product more strategically/ For example placing or including certain yarns or materials as or with the primary or secondary wrapper (or both) yarn or materials (i.e. at centre or core or surface of the produced multi-component yarn or the wrappers used therefore).

1. Preferably, for example, primary or secondary wrapper or both, materials may be selected according to those that provide for controlled characteristics of one or more of: anti-static yam, conductive yarn, stretch yarn, high-tenacity yam, flame-resist yarn, fancy yarns.

Advantageously, one or more of the following benefits may be achievable by this invention: the resulting multi-component yarn is less twist-lively and is able to be set, say by autoclaving, more efficiently; individual filaments of the multi-filament yarn embed better in the drafted staple fibre material; fibres in the drafted strand or roving become or are trapped in or locked into the resulting multi-component yam structure; improved yarn evenness (or irregularity) (coefficient of variation of yam linear density along its length) and imperfection (thick and thin places and neps); improved pilling resistance, improved abrasion resistance, improved initial fabric appearance and its appearance retention in use and washing.

1. Preferably, the resultant multi-component yarn may be constructed by being spun with a tex twist factor of down to about 1000 (or Alpha metric ( J(m = tex twist factor/31 .62). Such a yam produced may be used to form a knitted fabric. Such formed knitted fabrics may have reduced incidence of spirality and/or stitch distortion because of zero or near zero residual torque in produced yam being knitted.

According to the present invention, enabled is the production of an ultra-low-twist multi-component yarn that: (i) can be spun with a tex twist factor (= turns/metre. Tex) of down to about 1000 (Alpha metric, (J(m .= 31 .62 ((J(m is tpm/^Nm, where tpm yarn twist in turns per metre and Nm is yarn metric count) which is more than 50% lower than that of unknown conventional knitting twist level) (Note: tex is the count of yarn in direct system and Nm is the 5 count of yarn in metric, indirect system.); (ii) has the potential to produce torque-free singles yam after an autoclave setting step. (This step may give zero or near zero spirality in single jersey knitted fabric,); and (iii) when used as weft in a woven construction may produce a softer handle.

The yarn of this invention enables the knitting yam to be spun even at 50% of normal level of singles knitting twist factor of 2400-2500 t m.❖tex (Alpha metric (J(m 75- 80).

1. Preferably, the resultant yarn is a composite yarn of woollen, cotton, cellulose fibres as a drafted staple fibre or roving and two, or optionally more, filaments or staple yams as the primary and secondary wrappers, together forming the resultant yarn.

2. Preferably, the resultant yarn is weavable as singles warp or weft without sizing.

3. Preferably, the primary wrapper is a support for the staple fibre or roving. More

preferably, the primary wrapper is supportive of the staple fibre or roving from the front roller nip until the staple fibre or roving and primary wrapper are further wrapped by the secondary wrapper. (It is considered

important that it operates as a wrapper and not as a core, particularly if very fine counts or very low twists are to be spun.)

4. Preferably, a resulting multi-component yarn count is approximately the sum of the staple fibre or roving strand count and the total fibre count of the primary and secondary wrappers.

5. Preferably, the primary or the secondary wrapper(s), or both, are, or are formed from, a continuous multi-filament yarn. More preferably, the primary or secondary or both wrappers are of a textured type (e.g. are not of a flat type). Textured filament is preferred because it may have enhanced grip of woollen, cotton, cellulose core fibres.

6. Preferably, the first wrapper yarn is about wrapped by spinning or being spun about the drafted staple fibre or roving and subsequently combined with the second wrapper yam via a guide situated between the front drafting roller and a spindle on to which the resultant multi-component spun yarn product is collected or to be collected.

7. Preferably, the multi-component yam may be relaxed by auto-clave, for example to achieve a tex twist of down to about 1000.

In addition, the inventors have found that the yarn produced in the manner above results in a softer, fuller handle in both woven and knitted fabric constructions.

The twist directions indicated about which primary and secondary wrappers are provided about the core or drafted staple fibre or roving are those as typically used in the weaving industry. The core or drafted staple fibre or roving may also have been twisted in the Z or S-twist directions.

As used herein, "S-twist" means a left-handed twist or twist that would be un-laid by turning the yarn in a counter clockwise direction.

As used herein, "Z-twist" means a right handed twist or twist that would be un-laid by turning the yarn in a clockwise direction.

This invention may also be said broadly to consist in the parts, elements and features referred to or indicated in the specification of the application, individually or collectively, and any or all combinations of any two or more of said parts, elements or features, and where specific integers are mentioned herein which have known equivalents in the art to which this invention relates, such known equivalents are deemed to be incorporated herein as if individually set forth.

As used herein the term "and/or" means "and" or "or", or both. As used herein "(s)" following a noun means the plural and/or singular forms of the noun.