Extended length and higher density packages of bulky yarns and methods of making the same

Abstract

A method of winding bulked continuous filament yarn is disclosed, which enables superior yarn package formation, including higher density packages with excellent shape and yarn takeoff characteristics. The method uses unique helix angles and winding profiles in a non-adjacent and adjacent yarn pattern, achieved by a unique winding control strategy that constantly monitors spindle speed, desired wind ratio, traverse cam speed, and surface speed.

1 - 12 . (canceled) 
     
     
         13 . A package of bulked continuous filament yarn having a final diameter comprising a packing density of from about 0.4 grams per cm 3  to about 0.6 grams per cm 3 , wherein said package further comprises a non-adjacent winding pattern ending at a package diameter from about 47% to about 65% of said final diameter, and a precision adjacent winding pattern starting at a package diameter of from about 47% to about 65% of said final diameter. 
     
     
         14 . The package of bulked continuous filament yarn of  claim 13 , wherein said non-adjacent winding pattern comprises random winding.\ 
     
     
         15 . The package of bulked continuous filament yarn of  claim 13 , wherein said packing density is from about 0.5 grams per cm 3  to about 0.55 grams per cm 3 . 
     
     
         16 . The package of bulked continuous filament yarn of  claim 13 , further comprising a packing density increase of from about 7% to about 17% over a randomly wound package of said yarn. 
     
     
         17 . The package of bulked continuous filament yarn of  claim 13 , wherein said yarn is Nylon 6,6. 
     
     
         18 - 22 . (canceled) 
     
     
         23 . A package of bulked continuous filament yarn wound according to the method of  claim 13 , said package comprising a packing density increase of from about 7% to about 17% over a randomly wound package of said yarn. 
     
     
         24 - 27 . (canceled) 
     
     
         28 . A package of bulked continuous filament yarn having a final diameter comprising a packing density of from about 0.4 grams per cm 3  to about 0.6 grams per cm 3 , wherein said package further comprises a non-adjacent winding pattern ending at a package diameter to tube core diameter ratio from about 1.6:1 to about 2.3:1, and a precision adjacent winding pattern starting at a package diameter to tube core diameter ratio from about 1.6:1 to about 2.3:1. 
     
     
         29 . (canceled) 
     
     
         30 . A package of bulked continuous filament yarn having a ratio of packing density (measured in grams per cm 3 ) to final package diameter (measured in cm) greater than 0.018:1. 
     
     
         31 . The package of bulked continuous filament yarn of  claim 30 , wherein said ratio is between 0.018:1 to about 0.022:1. 
     
     
         32 . The package of bulked continuous filament yarn of  claim 30 , wherein said ratio is between 0.019:1 to about 0.022:1. 
     
     
         33 . The package of bulked continuous filament yarn of  claim 30 , wherein said ratio is between 0.020:1 to about 0.022:1. 
     
     
         34 . The package of bulked continuous filament yarn of  claim 30 , wherein said ratio is between 0.021:1 to about 0.022:1. 
     
     
         35 - 36 . (canceled)