Abstract: A high efficiency method of producing a high quality knit fabricis diclosed. The method includes the steps of drafting a blended sliver of cotton fibers and polyester fibers in a four roll draffing zone in which the nip to nip spacing in the break zone is no more than 2.5 mm longer than the effective fiber length of the polyester fibers, and no more than 1.5 mm greater than the effective fiber length in the intermediate zone, and at least 7 mm greater than the effective fiber length in the front zone, thereafter spinning the drafted sliver into yarn at a take up speed of greater than 150 meters per minute, and thereafter knitting the spun yarn into fabric.

Abstract: A method is disclosed for spinning polyester staple to produce dark dyeing yarns as compared to yarns having an otherwise similar composition. The method includes spinning polyester staple into yarn, in which the polyester includes between about 0.5 and 4 percent by weight of polyethylene glycol, into yarn in a rotor spinning machine at a rotor speed of between about 110,000 and 120,000 rpm and at a tension of between about 2.5 and 3.2 grams/tex. A resulting polyester fiber is also disclosed of between about 1.2 and 2.25 denier per filament, and that contains between about 0.5 and 4 percent by weight of polyethylene glycol, and with a fiber tenacity of 4.7 grams per denier or less.

Abstract: A method is disclosed for spinning polyester staple to produce dark dyeing yarns as compared to yarns having an otherwise similar composition. The method includes spinning polyester staple into yarn, in which the polyester includes between about 0.5 and 4 percent by weight of polyethylene glycol, into yarn in a rotor spinning machine at a rotor speed of between about 110,000 and 120,000 rpm and at a tension of between about 2.5 and 3.2 grams/tex. A resulting polyester fiber is also disclosed of between about 1.2 and 2.25 denier per filament, and that contains between about 0.5 and 4 percent by weight of polyethylene glycol, and with a fiber tenacity of 4.7 grams per denier or less.

Abstract: A spinning apparatus is disclosed according to the invention having a drafting zone comprising at least four roll pairs for drawing a sliver comprising one or more types of staple fibers. The rolls pairs include a back roll pair, intermediate roll pairs and a front roll pair and the distance between the nip of the back roll pair and the nip of the adjacent intermediate roll pair, and the distances between the nips of adjacent intermediate roll pairs is no more than the effective fiber length of the longest staple fiber type in the sliver. The drafted sliver may be spun into yarns at high speeds, such as the speeds used in air jet spinning apparatus to provide yarns having increased strength and reduced defects. The present invention also includes a method of forming high quality and high uniformity yarns by advancing a sliver through a drafting apparatus and thereafter spinning the sliver into yarn.

Abstract: A drafting and spinning apparatus is disclosed that produces highly uniform yarns with improved mechanical properties. The apparatus comprises a plurality of pairs of drafting rolls for drawing a sliver formed of one or more types of staple fibers, each fiber type having a predetermined effective fiber length. The plurality of pairs of drafting rolls comprises at least two pairs of intermediate rolls, with the distances between the nips of adjacent intermediate roll pairs being no more than the effective fiber length of the longest fiber type in the sliver. The apparatus further includes device for spinning the sliver into yarn at a take-up speed of greater than 150 meters/minute.

Abstract: A spinning apparatus is disclosed according to the invention having a drafting zone comprising at least four roll pairs for drawing a sliver comprising one or more types of staple fibers. The rolls pairs include a back roll pair, intermediate roil pairs and a front roll pair and the distance between the nip of the back roll pair and the nip of the adjacent intermediate roll pair, and the distances between the nips of adjacent intermediate roll pairs is no more than the effective fiber length of the longest staple fiber type in the sliver. The drafted sliver may be spun into yarns at high speeds, such as the speeds used in air jet spinning apparatus to provide yarns having increased strength and reduced defects. The present invention also includes a method of forming high quality and high uniformity yarns by advancing a sliver through a drafting apparatus and thereafter spinning the sliver into yarn.

Abstract: A spinning apparatus is disclosed according to the invention having a drafting zone comprising at least four roll pairs for drawing a sliver comprising one or more types of staple fibers. The rolls pairs include a back roll pair, intermediate roll pairs and a front roll pair and the distance between the nip of the back roll pair and the nip of the adjacent intermediate roll pair, and the distances between the nips of adjacent intermediate roll pairs is no more than the effective fiber length of the longest staple fiber type in the sliver. The drafted sliver may be spun into yarns at high speeds, such as the speeds used in air jet spinning apparatus to provide yarns having increased strength and reduced defects. The present invention also includes a method of forming high quality and high uniformity yarns by advancing a sliver through a drafting apparatus and thereafter spinning the sliver into yarn.