Process for continuous filament yarn with wool-like hand

Claim 1

A process for producing a self-crimping yarn comprising first and second types of filaments, said process comprising: (a) spinning said first type of filament by (1) forming a first plurality of melt spun filaments by merging molten polyester streams traveling at different extrusion speeds to form thick and thin regions in the merged streams out of phase with other merged streams. (2) quenching said first plurality of merged streams into said first type of filaments having thick and thin regions along their lengths and out of phase from filament to filment; (b) spinning said second type of filament by (1) extruding other streams of molten polymer of fiber-forming molecular weight from orifices selected to give filaments having round cross section with lower shrinkage than said first type of filaments at a common spinning speed; and (2) quenching said other streams into said second type of filament; (c) withdrawing said first and said second types of filaments from said streams at said common spinning speed; and (d) combining said first and said second types of filaments into a yarn; (e) said thick and thin regions in said first plurality of molten streams and said common spinning speed being selected such that said yarn has a crimp pf at least 2%.