Direct spinning process for stretch-breaking continuous filaments to form entangled yarn

Claim 1

In a direct spinning process wherein parallel synthetic organic continuous filaments are stretch-broken and drafted between input rolls and delivery rolls in a drafting zone to form a yarn of discontinuous fibers, the improvement which comprises supplying continuous synthetic organic filaments having a break elongation of less than 70 percent to the drafting zone, stretch-breaking the filaments with an imposed draft of 5 to 100X with a vertical spacing of 65 to 130 centimeters between the input rolls and the delivery rolls in which the filaments are unsupported while avoiding accumulation of static charges on the filaments to provide discontinuous fibers having a number average fiber length of 18 to 60 centimeters, with a distribution of fiber lengths such that at least 5 percent of the fibers are no longer than 12.7 centimeters, 50 percent to 93.5 percent of the fibers are longer than 12.7 centimeters and no longer than 76 centimeters, and at least 1.5 percent of the fibers are longer than 76 centimeters, removing the fibers from the drafting zone over an apertured delivery roll with an aspirating jet and next entangling the fibers with an entangling jet to form an entangled yarn of fibers which are randomly intermingled along the length of the yarn to maintain the unity of the yarn by frictional constraint between the fibers, the yarn having an entanglement pin count of 3 to 25 millimeters and a nep count value below about 75.