Multi-colored yarn and textile formed therefrom

Abstract

A space-dyed yarn and textile construction formed therefrom is provided. The space-dyed yarn includes a multiplicity of discrete color segments arranged along the length of the yarn. The color segments are of finite lengths which may be in the range of less than about 2 inches. The yarns may have linear densities under about 500 denier. A process and apparatus for production of the space-dyed yarns are also provided.

That which is claimed is:  
     
         1 . A yarn comprising: a plurality of discrete color segments arranged in a predefined spaced relation along said yarn, wherein at least a portion of said color segments are of finite length less than about 2 inches and wherein said yarn has a linear density of not greater than about 500 denier.  
     
     
         2 . The yarn as recited in  claim 1 , wherein said yarn is a single ply yarn.  
     
     
         3 . The yarn as recited in  claim 2 , wherein said yarn has a linear density in the range of about 70 to about 250 denier.  
     
     
         4 . The yarn as recited in  claim 1 , wherein said yarn is a single ply continuous filament yarn.  
     
     
         5 . The yarn as recited in  claim 4 , wherein said yarn has a linear density in the range of about 70 to about 250 denier.  
     
     
         6 . The yarn as recited in  claim 1 , wherein said yarn is a multi-filament yarn.  
     
     
         7 . The yarn as recited in  claim 6 , wherein said yarn has a linear density of about 70 to about 150 denier.  
     
     
         8 . The yarn as recited in  claim 1 , wherein said yarn is an untextured yarn.  
     
     
         9 . The yarn as recited in  claim 1 , wherein said yarn is a partially oriented yarn.  
     
     
         10 . The yarn as recited in  claim 1 , wherein at least a portion of said color segments comprise a first topically applied dye segment and at least a second topically applied dye segment disposed over said first topically applied dye segment.  
     
     
         11 . A yarn comprising: a plurality of discrete color segments arranged in a predefined spaced relation along said yarn, wherein at least a portion of said color segments are of finite length less than about 0.5 inches and wherein said yarn has a linear density of not greater than about 500 denier.  
     
     
         12 . A textile material comprising: a plurality of multi-colored yarns wherein said multi-colored yarns have a linear density of not greater than about 500 denier and include a plurality of discrete color segments of finite length arranged in predefined spaced relation along said mult-colored yarns and wherein at least a portion of said discrete color segments have a length less than about 2 inches.  
     
     
         13 . The textile material as recited in  claim 12 , wherein the textile material is a woven fabric.  
     
     
         14 . The textile material as recited in  claim 13 , wherein the woven fabric has a mass per unit area in the range of about 9 to about 20 ounces per square yard.  
     
     
         15 . The textile material as recited in  claim 13 , wherein the woven fabric is selected from the group consisting of: dobbie woven fabric and jacquard woven fabric.  
     
     
         16 . The textile material as recited in  claim 15 , wherein at least a portion of said multi-colored yarns are single ply yarns.  
     
     
         17 . The textile material as recited in  claim 16 , wherein said multicolored yarns have a linear density in the range of about 70 to about 250 denier.  
     
     
         18 . The textile material as recited in  claim 12 , wherein the textile material is a woven fabric comprising a plurality of multi-filament warp yarns having a linear density of about 70 to about 150 denier disposed within the woven fabric at a weave density of about 35 to about 130 warp yarns per inch, and wherein the multi-filament warp yarns are interwoven with a plurality of multi-filament weft yarns having a linear density of about 70 to about 150 denier disposed within the woven fabric at a weave density of about 25 to about 60 weft yarns per inch.  
     
     
         19 . The textile material as recited in  claim 18 , wherein the multi-filament warp yarns are disposed within the woven fabric at a weave density of about 40 to about 125 warp yarns per inch.  
     
     
         20 . The textile material as recited in  claim 18 , wherein the multi-filament weft yarns are disposed within the woven fabric at a weave density of about 30 to about 54 weft yarns per inch  
     
     
         21 . The textile material as recited in  claim 12 , wherein the textile material is a knit fabric.  
     
     
         22 . The textile material as recited in  claim 21 , wherein the knit fabric has a mass per unit area in the range of about 9 to about 16 ounces per square yard.  
     
     
         23 . The textile material as recited in  claim 21 , wherein said multicolored yarns are single ply continuous filament yarns.  
     
     
         24 . The textile material as recited in  claim 23 , wherein said multicolored yarns have a linear density in the range of about 70 to about 250 denier.  
     
     
         25 . The textile material as recited in  claim 12 , wherein the textile material is a nap knit fabric comprising a plurality of multi-filament yarns having a linear density of about 70 to about 150 denier.  
     
     
         26 . The textile material as recited in  claim 25 , wherein the nap knit fabric has about 33 courses per inch and about 25 wales per inch.  
     
     
         27 . The textile material as recited in  claim 12 , wherein the textile material is a double needle bar knit fabric and wherein said multi-colored yarns are multi-filament yarns having a linear density of about 70 to about 150 denier.  
     
     
         28 . The textile material as recited in  claim 27 , wherein said double needle bar knit fabric is about a 32 gauge construction having a fabric weight of about 9 to about 12 ounces per square yard.  
     
     
         29 . The textile material as recited in  claim 27 , wherein said double needle bar knit fabric is about a 44 gauge construction having a fabric weight of about 9 to about 16 ounces per square yard.  
     
     
         30 . The textile material as recited in  claim 12 , wherein at least a portion of said discrete color segments have a length less than about 0.5 inches.  
     
     
         31 . A textile material comprising: a plurality of multi-filament polyester yarns forming an outer face surface, wherein at least a portion of said yarns comprise multi-colored yarns including a plurality of discrete color segments of finite length less than 2 inches long arranged in predefined spaced relation along said multi-colored yarns such that portions of said discrete color segments form discontinuous spots of color at discrete visible locations across the outer face surface, said multi-colored yarns making up not more than about 5% to about 40% by weight of the textile material and having a linear density in the range of about 70 to about 250 denier.  
     
     
         32 . A space dyed yarn comprising a plurality of discrete color segments arranged in a predefined spaced relation along said yarn wherein said yarn has a linear density less than 500 denier and wherein at least a majority of said color segments have lengths in the range of less than 2 inches.  
     
     
         33 . An apparatus for applying dye to a yarn, the apparatus comprising: 
 at least one dye nozzle adapted to deliver a coordinated stream of dye along a normal stream path adjacent to said yarn; and    an intermittently activatable gas nozzle projecting towards said stream of dye such that upon activation of said gas nozzle, a stream of gas impinges said stream of dye thereby diverting said stream of dye across said yarn whereby a first band of color is applied across said yarn and such that upon deactivation of said gas nozzle, the stream of dye passes back across said yarn and resumes travel along said normal stream path adjacent to said yarn whereby a second band of color is applied across said yarn.    
     
     
         34 . A process for applying dye to a yarn, the process comprising: 
 conveying said yarn to at least a first dye application station    delivering a coordinated stream of dye from said dye station in a normal stream path adjacent to said yarn; and    intermittently activating and deactivating a gas nozzle projecting towards said stream of dye such that upon activation of said gas nozzle, a stream of gas impinges said stream of dye thereby diverting said stream of dye across said yarn whereby dye impacts and colors said yarn and such that upon deactivation of said gas nozzle, the stream of dye passes back across said yarn whereby dye impacts and colors said yarn.    
     
     
         35 . The process as recited in  claim 34 , wherein the gas nozzle is repeatedly activated and deactivated over a prolonged period and wherein the period between activation and deactivation is sufficiently short such that a substantially uninterrupted dyed segment is produced along the yarn.  
     
     
         36 . The process as recited in  claim 34 , wherein a period of time elapses between activation and deactivation of the gas nozzle such that that a pattern of separate dye segments is produced along the yarn.  
     
     
         37 . The process as recited in  claim 34  further comprising delivering the yarn to a second dye application station downstream of said first dye application station, whereat a second coordinated stream of dye is delivered along a normal stream path adjacent to said yarn, said second dye application station including an intermittently activatable gas nozzle projecting towards said second coordinated stream of dye such that upon activation of said gas nozzle, a stream of gas impinges said second coordinated stream of dye thereby diverting said second coordinated stream of dye across said yarn whereby dye from the second dye application station impacts and colors said yarn and such that upon deactivation of said gas nozzle, the second coordinated stream of dye passes back across said yarn whereby dye from the second dye application station impacts and colors said yarn.  
     
     
         38 . The process as recited in  claim 37 , wherein at least a portion of the dye from the second dye application station impacts and colors said yarn at locations along said yarn previously colored by dye from said first dye application station such that dye from said first dye application station and from said second dye application station is intermixed at said locations along said yarn whereby mixed coloration is achieved.