Multi-color fiber fluff products and method and apparatus for making same

A fabric made by knitting or weaving from a yarn that is spun from a decorative mass of fiber fluff product that in turn is made by a method comprising the steps of:

• (a) providing a source of supply of staple fibers made of natural or synthetic textile fiber and arranged in continuous form as a pattern array of discrete streams of different selected colors with the colors being uniform in each stream and comprising at least one base color and one contrasting color,
• (b) feeding the array stream of fibers into a carding operation wherein the fibers are brushed or carded from their input form into card or brush clothing to thereby only partially intermix fibers of at least two different colors in the bristles or wires of the card or brush clothing,
• (c) removing the accumulated fibers from the clothing to form a pillow or roving having a streaked appearance representative of the original colors with a partial intermixing and blending of the streaks of one color with those of another,
• (d) accumulating and working the pillow or roving into a final fluff product comprising a tangled mass of loosely interlocked fibers somewhat resembling cotton candy and having randomly dispersed bands, streaks and islands of one color softly merging into another color to thereby produce a randomized and interrupted decorative candy-cane like appearance in the cotton-candy like mass of final fiber fluff product, and wherein step (a) comprises providing a generally parallel array of strands of yarn of the selected colors arranged side by side, and step (b) comprises feeding the array of yarns into a carding mechanism comprising two endless brush belts, each carrying card clothing and arranged with mutually adjacent runs in closely spaced parallel orientation with the card clothing on each run slightly intermeshing and wherein the array of strands are fed into the convergence zone where the two adjacent runs converge for travel adjacent one another, wherein the endless card belts are operated to travel at the same linear speed with little or no relative motion between the two mutually adjacent runs of the belt, wherein the endless belts are mounted for relative bodily motion between open and closed positions, the belt motion being stopped to move the belts to open position for unloading of the accumulated mass of carded fibers as an elongated belt from the associated card clothing of each belt to thereby perform step (c), wherein step (a) further comprises providing each of the yarns as a winding on an associated spool from which the yarn may be drawn by unwinding from the spool, wherein step (a) further comprises arranging the spools on spindles and number coding spools to the color code of the selected colors in accordance with a pre-selected coding pattern of input for the decorative mass of fiber fluff to be made by the method, and wherein the individual yarns are drawn from the associated spool winding to a convergence zone wherein an array of yarn is formed in a predetermined feed pattern to thereby provide the pattern array of discrete streams of different selected colors of staple fibers in yarn form with the yarns being fed as an array of closely spaced parallel strands of yarn into the carding operation of step (b).