Yarn structure and method for producing same

Abstract

A continuous yarn structure comprising at least one yarn element formed from a plurality of continuous filaments or a plurality of staple fiber lengths, the yarn structure comprising periodically repeating lengths of high bulk, substantially unentangled continuous filaments or staple fiber lengths alternating with lengths of compacted continuous filaments of staple fiber lengths in which substantially all filaments or fiber lengths are mutually entangled throughout the volume of the compacted lengths. Also disclosed is a method for producing such yarn. The method comprises the steps of feeding at least one multiple filament yarn element or multiple staple fiber element under tension to a first treatment zone having a predetermined cross-sectional area; continuously directing a fluid at the yarn element in a direction substantially perpendicular to the travel of the element, the fluid being applied at a pressure of at least about 100 p.s.i.; and then feeding the yarn element directly to an outlet zone of cross-sectional area lesser than the treatment zone cross-sectional area.

We claim: 
     
       1. A continuous yarn structure comprising at least one .Iadd.air jet entangled .Iaddend.yarn element formed from a plurality of fibers, said yarn structure comprising lengths of high bulk, substantially un-entangled yarn element fibers alternating with lengths of compacted yarn element fibers in which substantially all fibers are mutually entangled throughout the volume of the compacted .Iadd.yarn .Iaddend.lengths, .Iadd.at least some of the yarn element fibers each having a cross-sectional area in certain portions of the yarn differing in size from that in other portions of said yarn so that .Iaddend.at least some of the individual fibers have a lesser cross-sectional area in the final yarn structure than .[.in their unprocessed lengths.]. .Iadd.prior to being air entangled.Iaddend.. 
     
     
       2. The yarn structure as claimed in claim 1 wherein fibers engage with and disengage from adjacent fibers in a random generally straight line path in the high bulk lengths in the yarn structure. 
     
     
       3. The yarn structure as claimed in claim 1 wherein each compacted length is shorter than the adjacent high bulk lengths. 
     
     
       4. The yarn structure as claimed in claim 3 wherein each said compacted length is approximately one-eighth inch and each said high bulk length is approximately one-half inch. 
     
     
       5. The yarn structure as claimed in claim 1 wherein the fibers are continuous filaments. 
     
     
       6. The yarn structure as claimed in claim 1 wherein said yarn element includes electrically conductive material. 
     
     
       7. The yarn structure as claimed .Iadd.wherein said certain portions of the yarn are said high bulk lengths and said other portions are said compacted lengths and .Iaddend.in claim 1 wherein some of the yarn element fibers .Iadd.each .Iaddend.have a lesser cross-sectional area in the high bulk lengths than in the compacted lengths. 
     
     
       8. The yarn structure as claimed in claim 7 wherein the fibers are continuous filaments. .Iadd. 9. A continuous yarn structure of the type suitable for use in forming carpet pile comprising a plurality of air jet entangled yarn elements each formed from a plurality of fibers, said yarn elements being interengagingly combined to provide lengths of high bulk, substantially unentangled yarn element fibers alternating with yarn lengths of compacted yarn element fibers in which substantially all fibers are mutually entangled throughout the volume of the compacted lengths, at least some of the yarn element fibers each having a cross-sectional area in certain portions of the yarn differing in size from that in other portions of said yarn so that at least some of the individual fibers have a lesser cross-sectional area in the final yarn structure than prior to being air entangled. .Iaddend.