Heathered helix yarns

Abstract

A process is provided for the manufacture of an effect yarn, such as heathered helix yarns, for use in carpets, floorcoverings, and textile articles. The effect yarns contain patterned alternating sections of twisted multiple singles yarns and sections of entangled multiple singles yarns. More particularly, these effect yarns may comprise a plurality of S-direction twist sections, a plurality of Z-direction twist sections, and a plurality of non-twisted entangled sections interspersed between the S-direction twist sections and the Z-direction twist sections.

What is claimed is: 
     
         1 . A process for producing an effect yarn comprising:
 (a) providing an unmixed yarn bundle comprising a plurality of continuous filament singles yarns;   (b) entangling said continuous filament singles yarns of said unmixed yarn bundle to thereby form an entangled yarn bundle; and   (c) twisting said entangled yarn bundle in a twist jet assembly having a first twisting jet and a second twisting jet so as to twist said continuous filament singles yarns of said entangled yarn bundle about each other in alternate S-directions and Z-directions to thereby produce an effect yarn comprising a plurality of S-direction twist sections, a plurality of Z direction twist sections, and a plurality of non-twisted entangled sections interspersed between said S direction twist sections and said Z direction twist sections,   wherein the average length of said non-twisted entangled sections is greater than the average lengths of said S-direction twist sections and said Z-direction twist sections.   
     
     
         2 . The process according to  claim 1 , wherein said S-direction twist sections and said Z-direction twist sections have a substantially same length. 
     
     
         3 . The process according to  claim 1 , wherein said providing of step (a) comprises:
 drawing said continuous filament singles yarns to thereby form a plurality of drawn singles yarns;   (ii) crimping each of said drawn singles yarns to thereby form drawn and crimped singles yarns;   (iii) entangling said drawn and crimped singles yarns to thereby form drawn, crimped, and entangled singles yarns; and   (iv) converging said drawn, crimped, and entangled singles yarns to thereby form said unmixed yarn bundle.   
     
     
         4 . The process according to  claim 3 , wherein said entangling of step (iii) occurs in an air-jet entangler. 
     
     
         5 . The process according to  claim 1 , further comprising conveying said effect yarn to a wind-up device. 
     
     
         6 . The process according to  claim 1 , wherein the average length of said non-twisted entangled sections are at least  50  percent greater than the average lengths of said S-direction twist sections and said Z-direction twist sections. 
     
     
         7 . The process according to  claim 1 , wherein the length of said non-twisted entangled sections are in the range of 25 to 150 inches and the length of said S-direction twist sections and said Z-direction twist sections are in the range of 15 to 75 inches. 
     
     
         8 . The process according to  claim 1 , wherein said effect yarn comprises 4 to 12 polymeric continuous filament singles yarns. 
     
     
         9 . The process according to  claim 1 , wherein each of said polymeric continuous filament singles yarns making up said effect yarn is of a different color. 
     
     
         10 . The process according to  claim 1 , wherein said polymeric continuous filament singles yarns are formed from a polyamide. 
     
     
         11 . An effect yarn manufactured by said process of  claim 1 . 
     
     
         12 . An effect yarn comprising a plurality of S-direction twist sections, a plurality of Z-direction twist sections, and a plurality of non-twisted entangled sections interspersed between said S-direction twist sections and said Z-direction twist sections,
 wherein the average length of said non-twisted entangled sections is greater than the average lengths of said S-direction twist sections and said Z-direction twist sections.   
     
     
         13 . The effect yarn according to  claim 12 , wherein said S-direction twist sections and said Z-direction twist sections have a substantially same length. 
     
     
         14 . The effect yarn according to  claim 12 , wherein the average length of said non-twisted entangled sections are at least 50 percent greater than the average lengths of said S-direction twist sections and said Z-direction twist sections. 
     
     
         15 . The effect yarn according to  claim 12 , wherein the length of said non-twisted entangled sections are in the range of 25 to 150 inches and the length of said S-direction twist sections and said Z-direction twist sections are in the range of 15 to 75 inches. 
     
     
         16 . The effect yarn according to  claim 12 , wherein said effect yarn comprises 4 to 12 polymeric continuous filament singles yarns. 
     
     
         17 . The effect yarn according to  claim 16 , wherein each of said polymeric continuous filament singles yarns making up said effect yarn is of a different color. 
     
     
         18 . The effect yarn according to  claim 16 , wherein said polymeric continuous filament singles yarns are formed from a polyamide. 
     
     
         19 . The effect yarn according to  claim 12 , further comprising a fire-retardant additive. 
     
     
         20 . A flooring product comprising said effect yarn according to  claim 12 .