Method of making a core yarn

#The present invention relates to a method of making a core yarn and, more particularly, a yarn having two core filaments and a mass of a fleece-type fibers completely surrounding these core filaments.

#A core yarn is known having a relatively strong core filament surrounded by a soft mass of fibers. Such a yarn is very soft yet at the same time has considerable longitudinal strength derived from the strong core filament.

#The disadvantage of such a yarn is that very frequently the fiber covering separates from the core. Furthermore the core filament is frequently eccentric to the yarn so that after only a small amount of wear this core filament is exposed.

#The above and other objects, features, and advantages of the invention will become more readily apparent from the following description, reference being made to the accompanying drawing in which:

#FIG. 1 is a cross-section in enlarged scale through a yarn according to this invention;

#FIG. 1A is a perspective view showing the results of the spinning step;

#A core-type yarn 10 is shown in FIG. 1. It comprises a coherent mass 16 formed of fibers such as wool, cotton, rayon, or staple fiber, in which is imbedded a pair of like and spaced-apart filaments 12 and 14 of high-strength synthetic-resin material such as polyester. The mass 16 has a cross-sectional area that is a multiple of that of the filaments 12 and 14. The filaments 12 and 14 can be monofilaments or a tightly wound thread but in any case have a longitudinal strength which is considerably greater than the longitudinal strength of the coherent mass 16. These filaments 12 and 14 are spaced from each other with a portion 16' of the mass 16 between them.

#As shown in FIGS. 2 and 3 this yarn 10 is made in an apparatus having a former 18 constituted by three aligned pairs 20, 22 and 24 of cylindrical rollers which advance a band 26 of slubbing in a direction D. The rollers 20 rotate faster than the rollers 22 which in turn rotate faster than the rollers 24 so that the slubbing 26 is formed into a thin upright band as illustrated in FIG. 3. A pair of guides 28 and 30 feed in the filaments 12 and 14, respectively, to the combining station formed by the rollers 20. FIG. 3 illustrates how these filaments 12 and 14 are fed to opposite sides of the band 26 directly across from each other and both lying in a plane perpendicular to the plane of the band 26 of the combining station.

#In a region 36 between the combining rollers 20 and an eye 32, the slubbing band 26 and filaments 12 and 14 are spun together and then wound up on a ring-type spinner 34 having a spool 42 that is rotated at high speed with the yarn to be spun passing through a traveler 40 on a ring 38 surrounding the spool 42 as described on pages 376 and 377 of The Way Things Work (Simon and Schuster: 1967).