US3018521A

US3018521A - Apparatus for making strands, yarns, and the like

Info

Publication number: US3018521A
Application number: US745163A
Authority: US
Inventors: Harmon Carlyle
Original assignee: Chicopee Manufacturing Corp
Current assignee: Chicopee Manufacturing Corp
Priority date: 1958-06-27
Filing date: 1958-06-27
Publication date: 1962-01-30
Anticipated expiration: 1979-01-30

Description

Jan. 30, 1962 c. HARMON 3,018,521

APPARATUS FOR MAKING STRANDS, YARNS, AND THE LIKE Filed June 27, 1958 3 Sheets-Sheet 1 INVENTO -C31 e4 r45 AAM ATTORNEY Jan. 30, 1962 c. HARMON 3,018,521

APPARATUS FOR MAKING STRANDS, YARNS, AND THE LIKE Filed June 27, 1958 3 Sheets-Sheet 2 INVENTOR (54x01: Ame/way MT'M/ ATTORNEY Jan. 30, 1962 c. HARMON 3,018,521

APPARATUS FOR MAKING STRANDS, YARNS, AND THE LIKE ATTORNEY United States Patent 3,018,521 APPARATUS FOR MAKING STS, YARNfi, AND THE LIKE Carlyle Harmon, Scotch Plains, N.J., assignor to Chicopee Manufacturing Corporation, a corporation of Massachusetts Filed June 27, 1958, Ser. No. 745,163 9 Claims. (Cl. 13-150) This invention relates to strands, rovings, yarns, and the like, and more particularly to novel improved apparatus for making the same.

The product of the apparatus of this invention is a strand containing fibers disposed substantially in longitudinal alignment or parallelism and bundled, packed, or consolidated along their lengths. The strand may subsequently be twisted into rovings or yarns; it may then be bonded; or it may be bonded without twisting, as desired or required. An important feature of this product is that the linear density of the strand, roving or yarn is substantially constant and very nearly uniform along the length thereof.

The operation of the apparatus of the present invention involves the application of fluid rearranging forces to a flat, sheet-like layer of fibrous starting material in spaced, parallel areas, referred to herein as deflection zones. As a result of these rearranging forces, the fibrous web starting material is subdivided lengthwise into a plurality of substantially separate, narrow strand-like strips or hands by the displacement of the fibers lying in the deflection zones between the strand-like strips. The fibers in these narrow, strand-like strips are rearranged, packed and consolidated, and are moved substantially into longitudinal alignment or parallelism with the long axis of each strand-like strip by the action of the applied rearranging forces, thus forming a strand. Rearranging forces which are fluid, and most desirably hydraulic, in nature are preferred with the apparatus of this invention.

STARTING MATERIAL WITH WHICH APPARATUS OF THIS INVENTION IS USEFUL In practicing this invention, the starting material is a relatively flat, sheet-like fibrous web or layer containing fibers which arecapable of movement under the influence of applied rearranging forces. In this fibrous web starting material, the individual fibers preferably are aligned generally in the direction of the longitudinal axis of the web. An example of such a fibrous web starting material is a card web in which the fiber alignment has preferably been increased somewhat over the alignment present in the web as it comes directly off a card.

The fibrous web or layer which is processed to form the product of this invention may contain textile length fibers having various lengths, say, from about one-half inch in length up to about two and one-half inches ,or more in length, as well vas various mixtures thereof. For example, the layer of starting material or base web may comprise natural vegetable .and animal fibers such as cotton, silk, wool, alpaca, vicuna, mohair, flax, hemp, sisal, manila, ramie, jute, abaca, .etc.; the synthetic or man- .made fibers such as the cellulosic fibers, notably cuprammonium, viscose, or regenerated cellulose fibers; cellulose ester fibers such as cellulose acetate and cellulose triacetate; the saponified cellulose ester fibers such as Fortisan and For-tisan-B; the polyamide fibers such as nylon 6 (polycaprolactam), nylon 66 (hexamethylene diamine-adipic acid), nylon 6'10 (hexamethylene diaminesebacie acid), nylon 11 (ll-amino undecanoic acid-Rilsan); protein fibers such as zein Vicara and casein 'Aralac; halogenated, hydrocarbon fibers such as Tefing upon the requirements of the finished product. thin web of fibers, as produced by a conventional card,

Patented Jan. 310, 1962 lon (polytetrafluoroethylene); hydrocarbon fibers such as polyethylene, polypropylene and polyisobutylene; polyester fibers such as Dacron; vinyl fibers such as Vinyon and saran; dinitrile fibers such as Darvan; nitrile fibers such as Zefran; acrylic fibers such as dynel, Verel, Orlon, Acrilan, Creslan, etc.; mineral fibers such as glass, metal,; etc.

For the purposes of describing the present invention, these textile length fibers are divided into three groups: (1) the long textile-length fibers having a length greater than about 1% inches; (2) the medium textile length fibers having a length from about inch to about 1% inches; and (3) the short textile-length fibers having a length less than about inch and down to about /2 inch. The purpose of this classification will become clear from a consideration of the further description of the invention.

The denier of the synthetic or man-made fibers referred to above is preferably in the range of the approximate thickness of the natural fibers mentioned and consequently deniers in the range of from about 1 to about 3 are preferred. However, where greater opacity or greater covering power is desired, deniers of down to as low as about or even /2 may be employed. Where greater bulk and loft, however, are desired, deniers of up to 5.5, 6, 8, 10, 15, or higher, are suitable. The minimum and maximum denier would, of course, be dictated by the desires or requirements for producing a strand or yarn to be used in making a particular fabric, and by the machines and methods for producing the same.

If desired, the fibrous layer may include a minor proportion, say, less than 50% by weight and preferably less than about 25% by weight, of fibers other than those of textile length. These other fibers may range in length from about A2 inch down to about one-eighth of an inch, for example. These shorter fibers normally are not used in conventional methods of producing strands or yarns.

Illustrative of the shorter length fibers which may be employed are the natural cellulosic fibers such as papermaking wood or wood pulp fibers and cotton linters, mineral fibers such as asbestos, or any of the above-mentione l fibers, if in lengths of less than about one-half inch and down to about one-eighth inch.

It is preferred, however, that the shorter papermaking fibers be unbeaten or substantially unhydrated, if a textile-like fabric is desired as the end pro-duct. In this connection, shorter hydrated woodpulp fibers of a papermaking length, for instance, may be mixed with longer textile length fibers in such a way that the longer fibers will contribute the strength desired in the resulting fabric while the shorter wood fibers will decrease its cost. Good results can also be obtained with a layer of hydrated woodpulp fibers which would introduce elements of a plastic mass into the fibrous sheet.

The fibrous starting material may also contain various types of particulate solids and semi-solids, including materials having potentially adhesive character or capable of providing visual or other sensory interest. If desired, the fibrous layer may also include special fibers, as for example, fibers which are capable of curling, bending, stretching, shrinking or otherwise deforming after the yarn has been produced. The main requirement for these added individual elements of the starting fibrous material is that they also must be capable of movement under the influence of an applied rearranging fluid force.

The weight of the fibrous web or layer of starting material may be varied within relatively wide limits dependmay have a weight of from about 35 to about grains per square yard. Such a thin fibrous web, however, is so fragile that its handling and manipulation is extremely difiicult. In the usual case, therefore, from about 3 to about 12 of these webs are preferably combined and processed in the combined form. In instances where products having a greater weight are desired, total web weights of as high as about 1800 or 2000 grains or more per square yard may be processed. Within the more commercial aspects of the present invention, however, web weights of from about 150 grains per square yard to about 850 grains per square yard are contemplated.

UNIFORM LINEAR DENSITY OF RESULTING PRODUCTS The strand or yarn produced by use of the apparatus of this invention exhibits strikingly uniform linear density. This striking uniformity of linear density is acheved by producing the strand or yarn product from a starting material, such as a card web, that itself possesses a relatively high degree of fiber alignment as well as uniformity in web weight throughout its area.

In contrast to the uniformity of linear density of the strands and yarns of the present invention, conventional staple yarns made by currently popular processes generally exhibit a widely fluctuating linear density. The linear density or the weight per unit length of a short portion of a conventional staple yarn may vary from a value as high as several times the average linear density of the yarn to a value as low as a small fraction of the average linear density. The reason for this fluctuation in linear density is that conventional yarn is usually produced by a process employing several roller drafting steps which unavoidably introduce variations, and these varitaions are unavoidably exaggerated further in subsequent steps of the process.

The disadvantages produced by these linear irregularities in conventional staple yarns are that these marked variations in density increase the tendency of the yarn toward undesirable pilling and fraying which enables the loose fibers to ball up in washing or during use. This produces a less attractive appearance, particularly in woven and knitted fabrics where uniformity of appearance is desired.

DEGREE OF ALIGNMENT OF FIBERS OF STARTING MATERIAL As is evident, when the fibrous starting layer is divided by the fluid rearranging forces of this invention into elongated strand-like strips or bands, the distance separating adjacent resulting strands is determined principally by many factors such as by the physical nature and intensity of the rearranging forces employed, the shape, size and spacing of the deflection zones in which the rearranging forces are applied, the nature and arrangement of the fibers in the starting layer, the nature of the backing member on which the fibrous starting layer is supported, and the freedom of movement of the individual fibers upon the backing member.

The distance separating adjacent strands in turn affects the length of the individual fibers that may be employed in the starting material, as well as the degree of fiber alignment that should be present in the starting material in order to avoid too many interconnecting cross fibers and to achieve substantially separate strands as the final products of the method. If the individual starting fibers are not substantially longer than the distance separating adjacent strands to be produced by the apparatus of this invention, the degree of alignment or parallelization of the fibers in the starting material is relatively unimportant. However, when the individual fiber length is substantially greater than the distance between adjacent strands to be produced by the apparatus of the invention, the degree of alignment of the fibers of the starting material becomes increasingly important as the length of the fibers increases. If it is desired to achieve substantial separation of adjacent strands without having to sever any large number of interconnecting fibers, the degree of alignment or paral- 4 lelization of the starting fibers must be higher when the fibers are longer.

As stated above, a conventional card web makes a very suitable starting material for the method of this invention, especially after it has been given some additional drafting upon being taken off the carding machine. In a web produced as just described, it is difficult to measure fiber orientation or alignment directly because the individual fibers thereof are curled, hooked and bent, with various segments of the fibers extending in various directions. However, a kind of average orientation which is helpful in describing the physical characteristics of the web may be arbitrarily defined and experimentally measured. This characteristic is called the degree of fiber orientation, degree of fiber alignment, or percent of fiber parallelism. The degree of fiber orientation is determined by bonding the web uniformly with a material such as starch, drying the bonded web, measuring tensile strengths lengthwise and crosswise of the resulting fabric, and then computing the percentage of lengthwise or long strength of the fabric to its total strength. Total strength, for this purpose, is the sum of the tensile strengths in the long and cross directions. Thus, if the long tensile strength in a conventional card web is three times the cross tensile strength, the degree of fiber orientation or degree of fiber alignment is 75 percent. When the quoted terms or similar terms are used in this specification and claims, they have the meaning just indicated.

One skilled in the art who applies the teaching of this specification will therefore be able to examine a given starting fibrous layer and determine whether the method of this invention can be used to produce a satisfactory group of strand-like products connected by a minimum, if any, cross fibers. In making this determination, measurement of the degree of fiber orientation or degree of fiber alignment as defined above will be helpful. If the distance by which the final strands are to be separated is, for example, about A; inch, it has been found that rayon fibers of fairly long textile length (say, over 1% inches), to be rearranged by streams of water applied against the fibers while supported in a narrow space between a foraminous nylon belt and parallel solid rings defining elongated open zones, should display about alignment (9:1) in the longitudinal direction of the starting web in order to form substantially separate strands of fibers. Preferably such starting fibers should have about alignment, and most desirably they should be substantially close to aligned in the longitudinal direction of the starting web. With fibers of medium textile length (say, about 4 inch to about 1% inches) under the conditions specified, a fibrous starting material having about 80% or more alignment will produce satisfactory results. If fibers of short textile length (about /2 inch to about 4 inch) are employed under the same conditions, a starting material of as low as about 70% alignment may be used.

When the fibrous starting material includes a mixture of fibers of various fiber lengths, the fibers of any particular length should be oriented approximately to the degree indicated above for that particular length, and the fibers of any other given length should be oriented approximately to the degree indicated for that length.

Unless otherwise indicated, the distance separating the final strand-like products resulting from the use of the apparatus of this invention is about As inch for the various statements made in this specification, whether in the specific examples or elsewhere.

REARRANGING FLUID The treating fluid which is used to rearrange the fibers in the web in the apparatus of this invention is preferably water, but it may also contain materials which it is desired to incorporate in the strandor yarn-like product. For example, the treating liquid may be an aqueous :liquor containing a binder, dye, a flame-retardant agent, a mothor mildew-proofing material, a wet-strength agent, an insecticide or germicide, a disinfectant, or the like.

If desired, and particularly where the fiber selected is hydrophobic, the water used in the hydraulic rearrangement in accordance with the apparatus of the invention may be heated to facilitate fiber relaxation and rearrangement. Liquids other than water may also be used, either alone or with the water, to facilitate fiber relaxation or simply to modify the wetting action of the water upon the fibers for the purpose of increasing lubricity to thereby facilitate rearrangement by fluid forces.

Methods and apparatus for obtaining the products of the apparatus of this invention from such fibrous webs by such rearranging techniques are fully described in copending commonly-assigned patent application Serial Number 745,010, filed simultaneously herewith on June 27, 1958 in the name of Frank Kalwaites. The methods and apparatus disclosed therein have been found commercially satisfactory and acceptable. However, it is a purpose of the present invention to provide another form of apparatus comprising a different construction which is adaptable in many instances and uses.

Other objects and advantages of the present invention will appear from a consideration of the following description and accompanying drawings wherein there is described and illustrated a preferred design of apparatus embodying the principles of the present invention. It is to be understood, however, that the inventive concept is not to be limited to the particular construction disclosed except as determined by the scope of the appended claims.

With reference to the accompanying drawings:

FIGURE 1 is a simplified idealized fragmentary perspective view of a portion of a continuous strand of fibers made in accordance with the present invention, a portion of the strand being broken away to reveal the interior thereof;

FIGURE 2 is a simplified schematic view in elevation showing the general principles of operation of the present invention, prior to the rearrangement of the fibers of the web into continuous strands;

FIGURE 2a is a simplified schematic view in elevation, similar to FIGURE 2, showing the general principles of operation of the present invention, subsequent to the rearrangement of the fibers of the web into continuous strands;

FIGURE 3 is a simplified schematic view in elevation, partially in cross-section, showing a preferred physical embodiment of the present invention;

FIGURE 4 is a perspective view, in diagrammatic form, of a preferred embodiment of apparatus for forming strands and yarns in accordance with the present invention;

FIGURE 5 is a fragmentary cross-section of a part of the apparatus illustrated in FIGURE 4, said cross-section being taken through the periphery of the rearranging annular-ring drum at right angles thereto at approximately the one oclock position, as viewed in FIGURE 4, showing the fibrous web starting material in its integral construction;

FIGURE 5a is a fragmentary cross-section of a part of the apparatus illustrated in FIGURE 4, said crosssection being taken through the periphery of the rearranging annular-ring drum at right angles thereto at approximately the three oclock position, showing the plurality of strands being formed from the fibrous web;

FIGURE 5b is a fragmentary cross-section of a part of the apparatus illustrated in FIGURE 4, said crosssection being taken through the periphery of the rearranging annular-ring drum at right angles thereto at approximately the four oclock position, showing the plurality of strands formed from the fibrous web, as well as the construction of the annular ring support roll and FIGURE 50 is a fragmentary cross-section of a part of the apparatus illustrated in FIGURE 4, said cross-section being taken through the periphery of the rearranging drum at right angles thereto, at approximately the nine oclock position, showing the strand construction in substantially completed form.

THE PRODUCT RESULTING FROM THE APPARATUS OF THIS INVENTION FIGURE 1 represents a simplified, fragmentary, perspective view of a continuous strand of fibers made in accordance with the present invention. As can be seen,

substantially all of the individual fibers It) of the strand are arranged in substantially longitudinal alignment or parrallelisrn and are consolidated in closely packed. relatively untwisted relationship. The individual fibers 10 have their longitudinal or medium axes generally parallel to the longitudinal axis of the strand and are generally parallel to one another.

A few meandering fibers If spirally encircle some of the longitudinally aligned fibers 1b, the over-all direction of orientation of the meandering fibers Ill being generally the same as that of the longitudinally aligned fibers 19. A few free ends or tips 12 of some of the surface fibers of the fibrous strand protrude therefrom to form a fuzz or nap on the surface thereof which provides a desirable softness and hand thereto. The fuzz constituted by the fibrous ends 12 is believed to be caused by the curling of the free ends of the unconfined surface fibers during heating, drying or other processing.

SCHEMATIC ILLUSTRATION OF THE PRINCIPLE OF THIS INVENTION The principle of this invention is schematically depicted in FIGURES 2 and 2a, wherein the reference numeral 19 designates a fibrous layer such as a card web containing highly aligned fibers which is carried on a foraminous fluid-permeable supporting member 20, such as a wire or plastic screen. In FIGURE 2, the card web 19 is shown intact in one piece on the foraminous support 2 9. This is the existing situation at the beginning of the rearranging process before a fluid is passed through the card web 19 to rearrange its fibrous structure.

As can be seen in FIGURE 2a, a fluid, which is preferably a liquid, as, for example, water or another aqueous medium, is passed in spaced, generally parallel zones 23 through the card web 19, and then through the foraminous support 2t). The fiow of liquid toward the card web 19 on the foraminous support 2A? is indicated diagrammatically by the directional arrows 21 in FIGURES 2 and 2a and the flow of liquid which has passed through the foraminous support 2b is identified by the directional arrows 22 in FIGURE 211.

Some of the liquid striking the upper surface of the foraminous support it? in the spaced-apart zones 23 is displaced or deflected laterally thereon in directions generally parallel to the median plane of the card Web 19 on the foraminous support it All of the liquid striking foraminous support 2% and so deflected laterally thereon will have components of motion and force parallel to that median plane. The displaced flow of liquid is indicated in FIGURE 2a by the directional arrows 24.

As can be seen from FIGURES 2 and 2a, the card web 19 is separated and divided by the rearranging liquid into fiber bundles 25 which are peripherally packed by the deflected flowing liquid forces 2%. on the foraminous support 20. The fibers constituting each bundle 25 are packed, consolidated and deposited so that the longitudinal axis of each bundle 25 lies approximately midway between the spaced zones 23. The fluid forces 24 acting generally parallel to the median plane of the card web 19 and applied on opposite sides of each fibrous bundle 25 are generally opposite in direction and are in substantial equilibrium. Thus, the fibers It) and II in the card web 1% are rearranged, longitudinally aligned, and formed into a packed bundle 25 under conditions of substantial equilibrium.

It will thus be realized from FIGURES 2 and 2a that movement of the card Web 19 through the plane of these FIGURES will cause successive portions thereof to be acted upon by the liquid rearranging forces 24 to cause it to be separated into a plurality of spaced, parallel, continuous strands of substantially aligned fibers formed of successions of fibrous bundles 25.

As used in this specification and in the claims, the term median section of the fibrous layer means the locus of all points midway between the two general boundary surfaces of the layer. The median section of the fibrous layer will often be a plane, and will lie substantially parallel to the plane of the foraminous supporting means.

FIGURE 3 is a diagrammatic sectional view of a preferred physical embodiment of the present invention in which the rearranging fluid 21 is applied to the card web 19 in a pattern wherein the spaced apart zones 23 are physically defined and separated by slotted divider means 30 which extend in a direction generally parallel to the direction of predominant orientation of the fibers in the card web 19. The reference numerals 19 through 25 have the same significance in FIGURE 3 that they had in FIG- URES 2 and 211.

As will be explained below in connection with the preferred embodiment of this invention, the foraminous support 20, the slotted dividing means 30, and the card web 19 being rearranged into continuous bundles or strands 25 preferably move together through the region in which the fluid forces 24 are applied.

In FIGURE 4, which is a perspective diagrammatic view of a preferred embodiment of the apparatus of the present invention, a card web 1 42 coming from a conventional textile card (not shown) passes through conventional drafting means, such as a plurality of drafting rolls 143, wherein the fiber alignment of the card web 142 is increased to a desired degree.

In the event that the fiber alignment of the card web is deemed sufficiently high, which may be possible particularly when the shorter of the textile length fibers are used, the drafting means may be omitted. However, it has been found more practical usually to include one such drafting means between the textile card and the hydraulic rearranging apparatus, as is shown in FIGURE 4.

The total draft of the drafting means will naturally depend on the fibers used, their length, their initial alignment, the degree of fiber alignment desired, and so forth. In most cases, when drafting means are used, a total draft of at least about 1.5 or 2 has been found sufficient.

The aligned card web, now referred to by reference numeral 144, is delivered from the drafting rolls 143 and is placed on the surface of an endless movable, foraminous, fluid-permeable supporting member 134, such as an open mesh wire or plastic screen. This supporting screen 134 carries the aligned card web 144 over the rotatable guide roller 135 and into contact with the periphery of a cylindrical rearranging drum 130 comprising a plurality of spaced annular rings 133.

The number and spacing of the annular rings 133 constituting the rearranging drum 130 depends upon many factors, the most important being the number and the size of the strands desired, as well as the type of fibers and weight of the fibrous web. For a conventional 36" card web, for example, weighing from about 150 grains per square yard to about 850 grains per square yard, as few as about 54 rings and as many as about 324 have been found satisfactory. Within the more comercial aspects of the present invention, however, from about 72 rings to about 216 rings per 36" width have been found most practical. The thickness of each individual ring will vary, depending primarily upon the width of the desired strand and may be as thin as about inch to as thick as about A inch, and preferably Irom about 7 inch to about inch.

A plurality of annular ring supporting rollers 131 are provided to maintain the annular rings 133 in accurately spaced parallel planes whereby the outer peripheries collectively define the outer surface of the rotatable cylindrical drum 130. The supporting rollers 131 are provided with peripheral grooves 132 (see FIGURE 5b) whereby the spaced parallelism and relationship of the annular rings 133 is accurately maintained.

As shown, the annular ring supporting rollers 131 are integral but such is not necessarily so. The rollers could be made of a plurality of separate platelike disks, separated by spacing elements of a desired width, whereby interchangeability of parts and adjustability of the supporting roller construction is provided.

In FIGURE 4, there are three supporting rollers illustrated but such is merely preferred and is not essential to the invention. Depending upon the strength and rigidity of the annular rings 133, the number of rollers may be reduced to two, or increased to four, five or more. However, the area of the annular rings directly opposed to the fluid stream is preferably as open and unobstructed as possible to permit free access of the rearranging fluid.

Consideration of FIGURE 4 will reveal that rotation of the annular rings 133, either by frictional driving contact with any one of the rotatable supporting rolls 131 or by the movable supporting screen 134, will result in a collective cylindrical rotation of the annular rings, thereby resembling a rotatable drum in over-all aspect. The direction of rotation is indicated by the directional arrow 141.

A cross-section of the body of an annular ring 133 is shown in FIGURES 5 through 5c. It is noted that the cross-section is an isosceles trapezoid, that is, a quadrilateral having two sides that are equal and two sides (top and base) which are parallel, with the angles between the sides and the base equal but opposite in direction. Such a configuration is preferred for reasons which will become clear from the further description of the invention.

The initial contact between the annular rings 133 and the aligned card web 144 carried by the supporting screen 134 is approximately at the one oclock position of the rearranging drum (as viewed in FIGURE 4) and is schematically shown in detail in FIGURE 5. It is noted that such contact forms a three-layer sandwich in which the annular rings 133 are innermost, the card web 144 is centrally positioned, and the supporting screen 134 is outermost. This three-layer sandwich moves around the periphery defined by the annular rings 133 and it is during a portion of this peripheral movement that the fiber rearrangement takes place.

Within the rotatable drum 130, there is positioned a header or manifold 146 to which a fluid, preferably water, is supplied under a desired pressure. Nozzles or jets 147 are provided on one face of the header 146 and the fluid is projected therethrough under pressure at and through the three-layer sandwich as it is moved on the periphery of drum 130. As seen in FIGURE 4, the fiuid being sprayed through the nozzles 147 is projected at and through the sandwich in a zone extending from about one oclock to about four oclock approximately. This zone will be referred to as the rearranging zone and the rearranging principles described with reference to FIGURES 1 through 3 are applicable thereto.

As shown in FIGURE 5, which is approximately at the one oclock position of the rearranging drum 130, the card web 144 is integral and is positioned between the annular rings 133 and the foraminous supporting screen 134. This position is immediately prior to the initiation of fluid rearrangement.

In FIGURE 5a, which is approximately at the three oclock position of the rearranging drum 130, the rearrangement procedures are well advanced. The card web 144 has been separated and divided by the sprays 21 of fluid into a plurality of strands 148 containing fibers disposed substantially in longitudinal alignment and bundled, packed and consolidated along their lengths. The deflected flowing fluid forces 24 described in particularity with reference to FIGURES 2a and 3 are being applied to the strands during this time.

One of the purposes of the flattened outer edges of the annular rings 133 will become apparent at this time. Inasmuch as the strands 148 are being formed under or adjacent the annular rings 133, the outer surface thereof is in direct contact therewith and controls the formation and shaping of the strands. Flattcned outer surfaces have been found to be most preferable. Other forms of surfaces, such as concave surfaces, however, are also applicable.

It is also to be noted that the annular rings 133 are considerably thicker in a radial direction (from the center of the annulus outwardly) than in an axial direction. This, of course, increases the strength and rigidity of the annular rings whereby a greater number may be present per linear inch of the card web width. Such a configuration also provides for a greater accuracy and preciseness of ring spacing.

In FIGURE 5b, which is approximately at the four oclock position of the rearranging drum 130, the construction of the annular ring supporting roll 131 is clearly illustrated. The preferred shaping of the grooves 132 is to be noted particularly with reference to the angular tapered inner portions of the annular rings 133 which are similar and in supporting contact with the seats of the grooves 132. A smooth rolling contact is thus insured with a minimum of friction between the side walls of the grooves 132 and the sides of the annular rings 133. Such a smooth rolling construction, when combined with the inherent strength of a metallic annular ring having an isosceles trapezoidal cross-section, as described previously, provides for closer control over the accuracy and preciseness of strand formation. This is, of course, highly important when the thickness and weight of an individual strand of fibers is considered.

In FIGURE 5c, which is approximately at the nine oclock position of the rearranging drum 130, the rearrangement procedures are concluded. The plurality of strands 148 are shown in finished form, although still containing .a considerable amount of fluid. These strands 148 are now ready for further processing, as desired or required.

The foraminous supporting screen 134 carries the strands 148 over a rotatable guide roller 139 and then over a vacuum or suction box 149, having an air-withdrawal or suction conduit 150 to exhaust the fluid collected in the vacuum box 149. The foraminous supporting screen 134 then carries the de-watered strands 148 forwardly over a rotatable roller 138 where the strands separate from the supporting screen 134 and are led to a direction-changing roller 151. At this point, the strands are led downwardly to conventional twisting and winding devices 152 such as, for exam-pie, a ring 154 and ring rail 153 capable of twisting the strands into yarns and winding them to form bobbins 155. If desired, bonding may be employed to adhesively bond the fibers of the yarn together. Or if preferred, the adhesive bonding may take place without twisting. An adhesive bond such as viscose or regenerated cellulose is cited as illustrative of many suitable bonding agents.

The foraminous supporting screen 134 having delivered the strands to the twisting and winding devices, and/or bonding apparatus, is led downwardly over rotatable roller 138, around a supporting rotatable roller 137, over a tensioning and tracking rotatable roller 140 and around a supporting rotatable roller 1315 to be returned around supporting rotatable roller 135 to complete its closed continuous cycle.

The invention will be further illustrated in greater detail by the following specific examples. It should be understood, however, that although these examples may describe in particular detail some of the more specific features of the invention, they are given primarily for purposes of illustration and the invention in its broader aspects is not to be construed as limited thereto.

Example I A 36 carded web of viscose fibers weighing 200 grains per square yard and containing fibers having a length of 1% inches and a denier of 1 /2 is advanced at a velocity of 30 yards per minute through the strand forming machine shown in FIGURE 4. The carded web is first drafted so that immediately prior to rearrangement the fibers thereof are aligned in the direction of travel in a ratio of about 9 to 1 Drum 130 has an external diameter of 12 inches, rings 133 being 43 inch in width and spaced apart a distance of inch, center to center.

A single row of nozzles 147 is employed, spaced at a distance of 4 inches from the fibrous layer. The nozzles are solid cone nozzles providing a uniform spray having a high nozzle velocity. Water is applied to the nozzles at a pressure of about pounds per square inch.

In this fashion, the card web is subdivided into 144 separate strands which are roughly elliptical in cross-section and in which the individual fibers are disposed substantially in longitudinal alignment. The linear density is substantially constant and very nearly uniform along the length of the strand. The strands possess an average dry weight of about 1.4 grains per yard of length, and an average long diameter of about inch. The strands are twisted to about 6 turns per inch and the resulting yarn is used in the manufacture of woven fabrics.

Example II The procedures set forth in Example I are followed substantially as set forth therein with the exception that the starting materials comprise a blend of 50% by Weight of the viscose rayon fibers used in Example I and 50% by weight of cotton having a staple length of 1% inches.

The resulting yarn is comparable to the all-viscoserayon yarn obtained in Example I, taking into account the expected differences due to the substitution of 50% by weight of the viscose rayon by the cotton fibers. The yarn has excellent uniformity along its length and substantially constant linear density.

Example Ill The procedures of Example I are followed substantially as set forth therein with the exception that the viscose rayon fibers have a length of inch and a denier of 1 /2. The degree of fiber alignment is also changed and is about 80%.

The resulting yarn has excellent uniformity and substantially constant linear density. It can be used in the manufacture of Woven fabrics.

Example IV The procedures of Example I are followed substantially as set forth therein with the exception that the thickness of the annular rings 133 is increased to inch, with the spacing between annular rings being 6 inch, center to center. In this way, the card web is subdivided into 108 separate strands (3 per inch) which are approximately elliptical in cross-section. These strands possess an average dry weight of about 1.85 grains per yard of length and an average long diameter of about inch. The strands are twisted to about 4 turns per inch and the resulting yarn can be used in the manufacture of woven fabrics.

Example V The procedures of Example I are followed substantially as set forth therein with the following exceptions: the web weight is reduced to 100 grains per square yard; the annular rings are inch wide and the clear spacing etween annual rings is also ,4 inch; 288 strands are formed with each strand weighing about 0.35 grain per linear yard; the strand is given 14 twists per inch; and is woven into a fabric.

Example VI Example I is repeated utilizing two banks of spray nozzles instead of one, and it is found that the web can be handler at a rate of 50 yards per minute instead of the previous 30 yards per minute.

Example Vll Using three banks of spray nozzles and the same pressures previously set forth, it is found that the 200 grain web can be handled at 70 yards per minute.

Although several specific examples of the inventive concept have been described, the same should not be construed as limited thereby nor to the specific substances or elements mentioned therein but to include various other substances or elements, as set forth in the claims appended hereto. It is understood that any suitable changes, modifications and variations may be made without departing from the spirit and scope of the invention.

What is claimed is:

1. Apparatus for converting a fibrous web containing fibers capable of movement under the influence of an applied fluid force into fibrous strands containing longitudinally aligned fibers which comprises: endless, movable foraminous means for supporting said web and said strands said supporting means having a surface free of obstacles to the movement of fibers therealong under the influence of fluid deflecting forces; spaced annular rotatable separating means adjacent said foraminous means and defining a plurality of elongated open zones; means for positioning a fibrous web between said annular separating means and said foraminous supporting means; means for rotating said foraminous supporting means and said annular separating means with said web supported therebetween; and means to pass a fluid between said annular separating means, through said fibrous web and through said foraminous supporting means, whereby said fibrous web is separated into a plurality of substantially separate fibrous strands.

2. Apparatus for converting a fibrous web containing fibers capable of movement under the influence of an applied liquid force into fibrous strands containing longitudinally aligned fibers which comprises: endless, movable foraminous means for supporting said web and said strands said supporting means having a surface free of obstacles to the movement of fibers therealong under the influence of liquid deflecting forces; spaced annular rotatable separating means adjacent said foraminous means and defining a plurality of elongated open zones; means for positioning a fibrous web between said annular separating means and said foraminous supporting means; means for rotating said foraminous supporting means and said annular separating means with said web supported therebetween; and means to pass a liquid between said annular separating means, through said fibrous web and through said foraminous supporting means, whereby said fibrous web is separated into a plurality of substantially separate fibrous strands. J

3. Apparatus for converting a fibrous web containing fibers capable of movement under the influence of an applied fluid force into fibrous strands containing longitudinally aligned fibers which comprises: endless, movable foraminous means for supporting said web and said strands said supporting means having a surface free of obstacles to the movement of fibers therealong under the influence of fluid deflecting forces; a plurality of spaced annular rotatable separating rings adjacent said foraminous means and defining a plurality of elongated open zones; means to position a fibrous web between said annular separating rings and said foraminous means; means for rotating said foraminous supporting means and said annular separating rings with said web supported therebetween; and means to pass a fluid between said annular separating rings, through said fibrous web and through said foraminous supporting means, whereby said fibrous web is separated into a plurality of substantially separate fib ous strands.

4. Apparatus for converting a fibrous web containing fibers capable of movement under the influence of an applied fluid force into fibrous strands containing longitudinally aligned fibers which comprises: an endless, movable foraminous fluid permeable screen for supporting said web and said strands said supporting screen having a surface free of obstacles to the movement of fibers therealong under the influence of fluid deflecting forces; a plurality of spaced, rigid, rotatable annular separating rings adjacent said foraminous fluid permeable screen and defining a plurality of elongated open zones; means to position a fibrous web between said annular separating rings and said foraminous fluid permeable screen; means for rotating said foraminous supporting screen and said annular separating rings with said web supported therebetween, and means to pass a fluid between said annular separating rings, through said fibrous web and through said foraminous fluid permeable screen, whereby said fibrous web is separated into a plurality of substantially separate fibrous strands.

5. Apparatus as defined in claim 4 wherein the annular separating rings have a flattened portion in contact with the fibrous web.

6. Apparatus as defined in claim 4 wherein the annular separating rings are isosceles trapezoidal in cross section.

7. Apparatus for converting a fibrous Web containing fibers capable of movement under the influence of an applied fluid force into fibrous strands containing longitudinally aligned fibers which comprises: an endless, movable foraminous fluid permeable screen for supporting and transporting said web and said strands said foraminous screen having a suface free of obstacles to the movement of fibers therealong under the influence of fluid deflecting forces; a plurality of rotatable, rigid annular separating rings adjacent said foraminous fluid permeable screen and movable therewith for defining a plurality of elongated open zones; a plurality of rotating suppo ting rolls, each of said rolls having parallel grooves circumferentially positioned on its exterior surface to receive and support the annular separating rings; means to position a fibrous web between said annular separating rings and said foraminous fluid permeable screen; means for rotating said foraminous screen and said annular separating rings with said web supported therebetween; and means to pass a fluid between said annular separating rings, through said fibrous web and through said foraminous fluid permeable screen, whereby said fibrous web is separated into a plurality of substantially separate fibrous strands.

8. Apparatus for converting a fibrous web containing fibers capable of movement under the influence of an applied liquid force into fibrous strands containing longitudinally aligned fibers which comprises: an endless movable foraminous liquid permeable screen for supporting and transporting said web and said strands said foraminous screen having a surface free of obstacles to the movement of fibers therealong under the influence of liquid deflecting forces; a plurality of rotatable, rigid annular separating rings adjacent said foraminous liquid permeable screen and movable therewith for defining a plurality of elongated open zones; a plurality of rotating supporting rolls, each of said rolls having parallel grooves circumferentially positioned on its exterior surface to receive and support the annular separating rings; means to position a fibrous web between said annular separating rings and said foraminous liquid permeable screen; means for rotating said foraminous screen and said annular separating rings with said web supported therebetween; and means to pass a liquid between said annular separating rings, through said fibrous web and through said foraminous liquid permeable screen, whereby said fibrous Web is separated into a plurality of substantially separate fibrous strands.

9. Apparatus for making fibrous strands containing longitudinally aligned fibers from a fibrous Web containing fibers capable of relative movement within the web under the influence of applied fluid forces, said apparatus comprising a series of similar circular members of the same diameter spaced along and mounted for rotation about a common central axis, a traveling foraminous fluid permeable web supporting member having a surface free of obstacles to the movement of fibers therealong under the influence of fluid deflecting forces and arranged to convey a fibrous web supported thereby in close proximity to and around a substantial portion of the periphery of the circular members during rotation of the latter, and means for directing fluid between said circular members and against a fibrous web supported by the foraminous web supporting member and thence through said foraminous member to deflect the fibers of the Web out of first Zones on the foraminous web supporting member determined by the space between the circular members and into second zones on the foraminous web supporting member intermediate the first Zones, whereby said fibrous web is separated into a plurality of substantially separate fibrous strands.

References Cited in the file of this patent UNITED STATES PATENTS 1,765,571 Edison et al June 24, 1930 2,274,424 Miller Feb. 24, 1942 2,274,425 Miller Feb. 24, 1942 2,862,251 Kalwaites Dec. 2, 1958 FOREIGN PATENTS 17,199 Great Britain of 1903 21,915 Great Britain of 1902 24,136 Great Britain of 1902 25,629 Denmark Feb. 18, 1920