Yarn making process and apparatus

Abstract

The present invention relates to the combination of a tension gate ( 18 ) and an air shield ( 24 ) in the relax zone of a fiber production process. The combination provides a synergistic effect over an air shield ( 24 ) alone, or a tension gate ( 18 ) alone, or the added elect of both a tension gate ( 18 ) and an air shield ( 24 ). The air shield ( 24 ) is a plate like structure with or without perforations. The air shield plates ( 26, 28 ) are placed in close proximity to a pair of rolls ( 20, 22 ) following the tension gate ( 18 ). The plates ( 26, 28 ) are positioned inside of the threadline between the pair of rolls ( 20, 22 ). The tension gate ( 18 ) can be one or more air drag devices, one or more liquid drag devices, or one or more solid surface contact devices, or a combination of any of the above. The apparatus and the process for using the apparatus is disclosed and claimed.

1 . In a yarn making process having a low tension relax zone with at least one pair of relax rolls, comprising: providing a relax zone, where yarn is relaxed; providing a tension gate in said relax zone through which the yarn passes, and providing an air shield adjacent the relax rolls to reduce air buffeting the yarn on the relax rolls.  
     
     
         2 . In the yarn making process of  claim 1 , said tension gate comprising one or more air drag devices, one or more liquid drag devices, one or more solid surface contact devices, or a combination of any of these.  
     
     
         3 . In the yarn making process of  claim 2 , wherein said air drag devices comprise an intermingler or a countercurrent flow of air device.  
     
     
         4 . In the yarn making process of  claim 2 , wherein said liquid drag devices comprise a finished applicator or a pool of liquid in the thread line path.  
     
     
         5 . In the yarn making process of  claim 2 , wherein said solid surface contact devices comprise one or more rolls.  
     
     
         6 . In the yarn making process of  claim 5 , said one or more rolls comprises a turbine driven roll or a free-wheeling roll, or a combination thereof.  
     
     
         7 . In the yarn making process of  claim 1 , wherein said yarn is polyester.  
     
     
         8 . In the yarn making process of  claim 1 , said process comprising: spin drawing, draw-twisting, draw-winding, or draw-bulking process.  
     
     
         9 . In the yarn making process of  claim 1 , wherein said air shield comprises a pair of plates.  
     
     
         10 . In the yarn making process of  claim 9 , wherein said plates are perforated.  
     
     
         11 . In the yarn making process of  claim 9 , wherein said plates are positioned between the relax rolls.  
     
     
         12 . In the yarn making process of  claim 1 , wherein said tension gate creating a tension differential on said yarn of at least five milligrams per denier.  
     
     
         13 . Apparatus for use in a relax zone in a yarn making process, comprising: a pair of spaced apart first rolls, a tension gate positioned after said first rolls in the yarn threadline, a pair of spaced apart relax rolls positioned after said tension gate in the yarn threadline, and an air shield positioned between said relax rolls.  
     
     
         14 . The apparatus of  claim 13 , wherein said tension gate comprises one or more air drag devices, one or more liquid drag devices, one or more solid surface contact drag devices, or a combination of these.  
     
     
         15 . The apparatus of  claim 14 , wherein said air drag devices comprise an intermingler or a countercurrent airflow device.  
     
     
         16 . The apparatus of  claim 14 , wherein said liquid drag devices comprise a finish applicator or a pool of liquid in the thread line path.  
     
     
         17 . The apparatus of  claim 14 , wherein said solid surface contact devices comprise one or more rolls.  
     
     
         18 . The apparatus of  claim 13 , wherein said one or more rolls comprises a turbine driven roll or a free-wheeling roll, or a combination thereof.  
     
     
         19 . The apparatus of  claim 13 , wherein said air shield comprises a pair of plates.  
     
     
         20 . The apparatus of  claim 19 , wherein said plates are perforated.  
     
     
         21 . The apparatus of  claim 19 , wherein said plates are positioned between said pair of relax rolls.  
     
     
         22 . The apparatus of  claim 19 , wherein said plates are positioned about 1 cm. from said relax rolls.  
     
     
         23 . The apparatus of  claim 19 , wherein said plates are spaced apart, positioned between said relax rolls and are within each tangent line connecting the outer surface of each relax roll.  
     
     
         24 . In a yarn making process having a low tension relax zone, comprising: providing a pair of spaced apart first rolls; providing a tension gate positioned after said first rolls in the yarn threadline; providing a pair of spaced apart relax rolls positioned after said tension gate in the yarn threadline; and providing an air shield positioned adjacent said relax rolls.  
     
     
         25 . In a yarn making process of  claim 24 , wherein said air shield comprises a pair of plates.  
     
     
         26 . In a yarn making process of  claim 25 , wherein said plates are perforated.  
     
     
         27 . In a yarn making process of  claim 24 , wherein said plates are positioned between said pair of relax rolls.  
     
     
         28 . In a yarn making process of  claim 27 , wherein said plates are positioned about 1 cm. from said relax rolls.  
     
     
         29 . In a yarn making process of  claim 25 , wherein said plates are spaced apart, positioned between said relax rolls and are within each tangent line connecting the outer surface of each relax roll.