Non-twisted, heather yarn and method for producing same

Abstract

A non-twisted, heather yarn is formed of a plurality of major yarn bundles at least one of which is of a substantially different color from the remaining bundles. Each major yarn bundle is formed of a multiplicity of continuous filaments and has from about 10 to about 90 percent of its filaments cohering to form secondary bundles with the remaining filaments of each major bundle varying in number along the length of the yarn, being interlaced with other major bundles of the yarn, and being randomly located about the yarn axis. Each of the secondary bundles in each unit length of the yarn of about 6 inches has a portion thereof formed of greater than about 30 percent of the filaments of its major bundle and each of the secondary bundles in each unit length of yarn of about 8 inches is non-uniformly, differently oriented relative to the yarn axis.

What is claimed is: 
     
       1. A yarn having an axis and being formed of a multiplicity of continuous filaments, said filaments forming a plurality of major bundles at least one of which is of substantially different color relative to the remaining bundles, each of said bundles having from about 10 to about 90 percent of its filaments cohering to form a secondary bundle with the remaining filaments of the major bundle varying in number along the length of the yarn, being interlaced with other major bundles of the yarn, and being randomly oriented about the yarn axis, each of said secondary bundles in each unit length of yarn of about 6 inches having a portion thereof formed of greater than about 30 percent of the filaments of its major bundle and each of said secondary bundles in each unit length of yarn of about 8 inches being non-uniformly located relative to the yarn axis. 
     
     
       2. A yarn, as set forth in claim 1, wherein at least a portion of the filaments are crimped. 
     
     
       3. A yarn, as set forth in claim 1, wherein the major bundles are each of a substantially different color than the remaining bundles. 
     
     
       4. A yarn, as set forth in claim 1, wherein the remaining filaments of each major bundle are interlaced with the remaining filaments of another major bundle. 
     
     
       5. A yarn, as set forth in claim 1, wherein a portion of the remaining filaments of a major bundle are interlaced with the secondary bundle of another major bundle. 
     
     
       6. A yarn, as set forth in claim 1, wherein at least a portion of the filaments are of a tri-lobal configuration. 
     
     
       7. A yarn, as set forth in claim 1, wherein the filaments are formed of a composition selected from the group consisting of polypropylene, nylon, polyester, and copolymers thereof. 
     
     
       8. A yarn, as set forth in claim 1, wherein the filaments are pigmented filaments. 
     
     
       9. A method for forming a composite yarn having a plurality of non-twisted major yarn bundles at least a portion of which are of substantially different colors one to the others with said major yarn bundles each being formed of a multiplicity of continuous, synthetic filaments, comprising: drawing each of a plurality of major yarn bundles with a drawing roll being driven at a peripheral speed in the range of about 500-2,000 meters per minute;   bringing the major yarn bundles into contact one with the other for forming a composite yarn;   impacting the yarn with gas streams discharging from a plurality of jets spaced a substantially equal arcuate distance one from the others about the axis of the yarn and directed generally toward said axis while said yarn is being moved past the discharging gas streams, said yarn being moved past the discharging gas streams at a rate of about 62 percent to about 85 percent of the speed of the yarn on the drawing roll, being under a tension during impacting in the range of 0.008-0.03 grams per denier and being impacted by streams having feed pressures in the range of about 40-150 psi for randomly entangling portions of the filaments and positioning portions of the yarn differently relative to the yarn axis for forming a yarn having a unique heather appearance.   
     
     
       10. In the method, as set forth in claim 9, including texturing the composite yarn prior to the entangling step. 
     
     
       11. A method, as set forth in claim 10, wherein the textured yarn is quenched prior to the entangling step. 
     
     
       12. A method, as set forth in claim 11, wherein the quenched yarn is placed under a tension in the range of about 0.03-0.20 grams per denier at a location upstream of the entangling zone. 
     
     
       13. A method, as set forth in claim 9, wherein the filaments of at least one of the major bundles are of a tri-lobal configuration. 
     
     
       14. A method, as set forth in claim 9, wherein the filaments of each of the major bundles are of a tri-lobal configuration. 
     
     
       15. A method, as set forth in claim 9, wherein the major bundles are each of a substantially different color.