2. Description of Related Art Makers of continuous multifilament nylon yarns sell their product into apparel manufacturing markets where a mix of textured and untextured yarn is consumed.

Untextured yarns are also called flat or fully drawn yarn.

Typically, textured yarn is prepared from a feed yarn, a partially oriented yarn (POY), by draw-twisting and heat setting. Fully drawn or fully oriented yarn (FOY), is prepared by further drawing POY in a split process. Alternatively, FOY is directly spun in a coupled process of spinning and drawing. The terms POY and FOY generally distinguish nylon yarns having an elongation to break of >60% and <60% respectively ; see"LOY MOY POY HOY FOY"by H. Treptow, Man-Made Fiber Year Book (CTI) 1986, page 6.

Well-known processes and apparatus to melt spin nylon multifilament POY at high spin speeds are described by Chamberlin et al. in U. S. Patent No. 4, 646, 514. However, various spinning machine configurations for POY are employed throughout the industry. These POY machine configurations may be"godetless", a most compact apparatus, where the yarn is wound without passing over roll surfaces or with godets. In such a POY machine with godets the yarn passes over multiple roll surfaces prior

to wind-up ; see Chemical Fibers International (CFI) Vol.

46, January 1996, pages 37-40.

Flat yarn or FOY spinning machine configurations are disclosed by McNamara et al. in U. S. Patent No. 4, 123, 492 ; and by Kemp et al. in Swiss Patent No. CH-623 611.

Generally, the FOY process apparatus requires some means to draw or stretch the yarn. A differential roll speed between a feed roll onto which the yarn is wrapped several times and a draw roll, also where multiple yarn wraps occur, serve to effect the stretch or draw. Some means to relax the fully drawn nylon yarn to allow good yarn package build in winding is necessary for high productivity. This yarn relax means may include a steam box as taught in Kemp at al. or a heated roll assembly.

The makers of multifilament nylon yarns usually prepare both POY and FOY for various end uses. The spinning machine asset investment by each maker usually reflects the relative fraction of POY to FOY consumed by the apparel market into which the maker sells product.

However, market demands shift over time as fashion trends may dictate a changing requirement for POY versus FOY consumed in the market. As a result, a fixed machine asset may present certain liabilities. While recognized as a long standing dilemma to the makers of POY and FOY nylon yarns, the ability to shift a POY spinning machine asset to a FOY spinning asset has not been addressed in the literature.

SUMMARY OF THE INVENTION The present invention deals with this situation where a maker of nylon multifilament yarns must respond to a drop in the demand for textured apparel yarns (POY) and a corresponding growing requirement for fully drawn yarn (FOY) consumed in the market.

We have found an effective and economical method to convert a POY machine to spin FOY yarns resulting in a novel apparatus for making fully drawn yarn. This

conversion process of our invention is reversible and may allow spinning assets to"swing"between product types in response to market demands.

A prior art godetless POY machine is shown in Figure 1. Such a prior art machine is readily converted to a FOY machine via the process of our invention. Our incentive to make this conversion resulted largely from space restrictions, both vertical and horizontal, imposed by traditional POY machine design. We have found productivity and investment criteria impose stringent design standards on facilities of POY machines. Often the yarn winding assemblies are less than 300 mm apart (on average). Introducing a typical prior art feed and draw roll assembly to the midsection of closely spaced POY machines would result in undue complexity and be expensive. Moving the winder assemblies father apart to accommodate prior art feed and draw roll mechanisms and a yarn relax means is not a simple and economical option and would inhibit a readily reversible conversion of machines.

Where incentive exists to shift POY spinning assets to FOY spinning assets without substantive modification of winding assemblies, there is a need for a simple, inexpensive, and compact yarn drawing and yarn relaxing assembly to meet the space restriction and investment limitations imposed by an existing POY spinning facility.

The present invention, i. e., a conversion method and an apparatus, and other objects of the invention will be clear from the following description.

The invention relates to a fully oriented yarn spinning machine for making a first and second plurality of fully oriented multifilament yarns, comprising : at least a first spinning assembly having a spin pack containing a spinneret plate for providing a plurality of filaments ; a quench chimney for receiving and cooling the filaments ; a finish applicator and convergence guide for receiving the filaments from the spinneret plate, for applying finish to the filaments, and for converging the

filaments into a first and a second plurality of multifilament yarns ; a first and a second alignment guide for receiving the first and second plurality of the multifilament yarns from the finish applicator and convergence guide ; a first and a second stepped roll assembly for receiving the first and the second plurality of the multifilament yarns from the first and the second alignment guides, respectively, and for drawing the multifilament yarns to increase their length by a fixed amount ; a steam relax unit between the first and the second unheated rotatable stepped feed and draw roll assemblies, the steam relax unit for receiving the multifilament yarns from the unheated rotatable stepped feed and draw roll assemblies and for applying steam to the multifilament yarns to stabilize the multifilament yarns ; a first and a second pre wind-up guide for maintaining the separation of the multifilament yarns ; and a first and a second windup assembly for winding the first and the second plurality of the multifilament yarns into a first and a second plurality of packages.

The fully oriented yarn spinning machine may optionally have an exit guide for maintaining the separation of the multifilament yarns within the steam relax unit and for directing the first and second plurality of the multifilament yarns.

The invention further relates to a yarn spinning machine conversion process for converting a partially oriented yarn spinning machine to a fully oriented yarn spinning machine, the partially oriented yarn spinning machine having a first spinning assembly in a confined space between adjacent spinning assemblies, the process comprising : relocating and/or replacing a first and a second alignment guide for receiving a first and a second plurality of multifilament yarns ; mounting in the confined space a first and a second unheated rotatable stepped feed and draw roll assembly for receiving the first and the second plurality of the multifilament yarns from the first

and the second alignment guides, respectively, and for drawing the multifilament yarns to increase their length by a fixed amount ; installing in the confined space a steam relax unit between the first and the second unheated rotatable stepped feed and draw roll assemblies, the steam relax unit for receiving the multifilament yarns from the unheated rotatable stepped feed and draw roll assemblies and for applying steam to the multifilament yarns to stabilize the multifilament yarns before they are directed to a first and a second windup assembly, respectively, for winding the first and the second plurality of the multifilament yarns into a first and a second plurality of packages.

Optionally the conversion process includes adding an exit guide for maintaining the separation of the multifilament yarns within the steam relax unit.

BRIEF DESCRIPTON OF THE DRAWINGS The invention can be more fully understood from the following detailed description thereof in connection with accompanying drawings in which : Figure 1 is a schematic drawing of a plurality of prior art godetless POY spinning machines ; Figure 2a is a schematic drawing of a plurality of FOY spinning machines converted from those machines represented by the Figure 1 drawing ; Figure 2b is a schematic drawing of a single FOY spinning machine mid-section ; Figure 2c is a schematic drawing of the single FOY machine mid-section as viewed from a right angle to Figure 2b ; Figure 3a is a schematic drawing of one stepped feed and draw roll assembly relative to the steam relax chamber ; Figure 3b is a schematic drawing of an alternative embodiment, one stepped feed and draw roll assembly

relative to the steam relax chamber with a yarn tension let-down step roll ; and Figure 4a and 4b are cut-away schematics drawings of the steam relax chamber at a right angle to one another.

DESCRIPTION OF THE PREFERRED EMBODIMENT (S) Throughout the following detailed description, similar reference characters refer to similar elements in all figures of the drawings.

The invention is a fully oriented yarn (FOY) spinning machine and a yarn spinning machine conversion process for converting a partially oriented yarn (POY) spinning machine to the fully oriented yarn (FOY) spinning machine.

The FOY spinning machine is for making a first and a second plurality of fully oriented multifilament yarns.

The fully oriented yarn spinning machine comprises at least a first spinning assembly, but preferably comprises a plurality of substantially similar spinning assemblies in a row. Figure 2a depicts the first spinning assembly between a second spinning assembly and a third spinning assembly.

The first, and preferably each, spinning assembly of Figure 2a has a spin pack (22) fed with molten polymer from polymer manifold (20), a quench chimney (25), a finish applicator and convergence guide (40), a first and a second alignment guide (50), a first and a second stepped roll assembly (90), a steam relax unit (100), an exit guide (116), a first and a second pre wind-up guide (60), and a first and a second windup assembly, not shown in Figure 2a, but illustrated positionally by the location of multiple yarn packages (70) wound on a spindle (72).

The spin pack (22) contains a spinneret plate for providing a plurality of filaments (30). The quench chimney (25) is for receiving and cooling the filaments (30). The finish applicator and convergence guide (40) is for receiving the filaments (30) from the spinneret plate, for applying finish to the filaments, and for converging

the filaments into a first and a second plurality of multifilament yarns (80). There can therefore be 3, 4, 6, 8 or 12 yarns, for example, fed to one alignment guide (50). The first and the second alignment guides (50) are for receiving the first and the second plurality of the multifilament yarns (80) from the finish applicator and convergence guide (40) and for spacing the plurality of multifilament yarns prior to contacting the following roll surfaces.

The first and a second stepped roll assemblies (90) shown in Figure 2a are for receiving the first and the second plurality of the multifilament yarns (80) from the first and the second alignment guides (50), respectively, and for drawing the multifilament yarns to increase their length by a fixed amount.

In one embodiment illustrated by Figures 2b and 2c, the first and the second unheated rotatable stepped feed and draw roll assemblies comprise a first feed roll (94b), a second feed roll (94a), a first draw roll (92a) and a second draw roll (92b). The first feed roll (94a) and second feed rolls (94b) have first diameters (95) and the first and second draw rolls have second diameters (91) greater than the first diameters (95). The first diameter (95) and the second diameter (91) are selected to provide a fixed draw ratio of the multifilament yarns. The first and second unheated rotatable stepped feed and draw roll assemblies are positioned vertically between each of the alignment guides (50) and the pre wind-up yarn guides (60). The first feed rolls (94b) and the first draw rolls (92a) are positioned higher than the second draw rolls (92b). The typical vertical distance between the alignment guide (50) and the pre wind-up guides (60) is 1400 mm, and the typical distance between the axes (96a) and (96b) of the two stepped rolls is about 400 mm.

Axes of rotation (96a) (as shown in Figures 3a and 3b) of the first feed rolls (94b) and the first draw rolls (92a) are positioned in or substantially in a first plane

and locating axes of rotation (96b) of the second feed rolls (94a) and the second draw rolls (92b) are in or substantially in a second plane. In conventional practice the one stepped roll assembly is tilted versus the other assembly in the vertical plane by a tilt angle and skewed versus the other assembly in the horizontal plane by a skew angle. The first feed roll (94b), the second feed roll (94a), the first draw roll (92a) and the second draw roll (92b) are adapted to rotate at the same speed with axes of rotation (96a, 96b) angled, by skew and tilt, to provide advancement of the multifilament yarns (80), from the first feed roll (94b), the second feed roll (94a), the first draw roll (92a) and the second draw roll (92b).

According to Figure 2c, each multifilament yarn end (80), only one end of which is shown, typically wraps the feed rolls (94b, 94a) 1 and % times and wraps the draw rolls (92a, 92b) 2 and % times. Preferably, the first and the second unheated rotatable stepped feed and draw roll assemblies in each spinning assembly are mirror images of one another.

In a second embodiment shown schematically in Figure 3b, each of the unheated rotatable stepped feed and draw roll assemblies is a double stepped roll assembly. A second roll step to smaller diameter on the outside helps to achieve better yarn relaxation, and hence better yarn package formation, by isolating the relax tension from the winding tension. In this Figure 3b embodiment, each of the rotatable stepped feed and draw roll assemblies comprises a first feed roll (94b), a second feed roll (94a), a first draw roll (92a), a second draw roll (92b), a first relax roll (93b) and a second relax roll (93a).

The first and second feed rolls (94b, 94a) have a first diameter (95) and the first and second relax rolls (93b, 93a) have a second diameter (97a or 97b) greater than the first diameter (95). The first and second draw rolls (92a, 92b) have a third diameter (91) greater than the second diameter (97a, 97b). The first feed roll (94b),

the second feed roll (94a), the first draw roll (92a), the second draw roll (92b), the first relax roll (93b) and the second relax roll (93a) are adapted to rotate at the same speed with axes of rotation (96a, 96b) angled to provide advancement of the multifilament yarns (80), from the first feed roll (94b), the second feed roll (94a), the first draw roll (92a), the second draw roll (92b), the first relax roll (93b) and the second relax roll (93a) and provide a preselected draw ratio of the multifilament yarns (80) and preselected amount of yarn relaxation prior to winding.

The double sided steam relax unit (100), shown relative to the stepped roll assemblies, variously, in Figures 2a, 2b and 2c, receives the multifilament yarns (80) from the first and the second unheated rotatable stepped feed and draw roll assemblies and applies a steam atmosphere to the yarn. Steam which is introduced to the steam related unit at (102), as shown in Figure 2c, for example, promotes plasticity of the multifilament yarns (80) stabilizing the yarns and effecting tension relaxation of the yarn. The tension relaxation results in stable yarn package formation from lessened yarn retraction forces.

It is common practice in the manufacture of POY and FOY for interlacing to be required for some products.

This may be achieved in a machine of the invention by optionally fitting interlacing jets (120) for example, before the first feed roll (94b) and/or after the steam relax unit (100) as shown schematically in Fig. 2b.

The shared, or double sided, steam application unit (100) implemented here is shown in cut-away detail from two views at right angles to one another in Figure 4a and Figure 4b. This design (100) cuts costs and reduces congestion on the front of the machine and increases space at the back since process, jacket, condensate and extract services are halved by sharing. The shared, or double sided, steam relax unit (100) is between the first and

second unheated rotatable stepped feed and draw roll assemblies. Preferably, the steam relax unit (100) is as close to the final contact of the yarns (80) with the draw rolls as possible to minimize the build up of tension from air drag before the steam relaxation since lower tension encourages more relaxation reducing subsequent retraction on the packages. To accomplish this, preferably, the steam relax unit (100) is vertically between the first draw rolls (92a) and the second draw rolls (92b).

The steam relax unit (100), as viewed in Figure 4a includes a tube (106) through which steam enters leading to a chamber (104) having openings (108). There is also a baffle (110), standing off from the internal steam chamber (107) on pins (112), for blocking the multiple steam outlet openings (108) from impacting directly on the multifilament yarns (80). The steam relax unit (100) is adapted to cause steam to be applied to the multifilament yarns (80) with the multifilament yarns (80) at tensions at or below 0. 2 grams per decitex at or about atmospheric pressure. Preferably, the steam relax unit (100) has halves which are substantial mirror images of one another (Figure 4a). No internal jets or other guides are used ; a double skinned cover (101) for insulation is provided.

Slots (114c) communicating between yarn entrance slots (114a) and exit slots (114b) provide means to string-up the plurality of threadlines. Slots (114a) and (114b) serve further to vent steam to the atmosphere. An exit 20 guide (116) and pins (118) for maintaining the separation of the multifilament yarns (80) within the steam relax unit (100) and for directing the first and second plurality of the multifilament yarns (80) to pre wind-up guides (60) and to the winding unit (74) (shown in Figures 2b and 2c) are the only guides associated with the steam relaxation unit (100).

The first and second pre wind-up guide (60) (as shown in Figure 2c) maintains the separation of the multifilament yarns (80), fanning the first and second

plurality of the multifilament yarns (80). The first (74a) and the second (74b) windup assembly are for winding the first and the second plurality of the multifilament yarns (80) into a first and a second plurality of packages (70). Preferably the first and the second windup assembly (72a, 72b) comprise a double deck windup assembly (74a, 74b) with yarn traversing means (76) for winding the multifilament yarns onto yarn cores mounted on spindle (75) into yarn packages (70). The first and the second windup assemblies (74a, 74b) have a windup spindle or chuck (75) for winding the first and the second plurality : of the multifilament yarns (80) into a first and second plurality of packages (70). A horizontal distance (10) (shown in Figure 2a) between axes of rotation of the windup chuck (72 or 75) in the first windup assembly (74a) in the first spinning assembly and the windup chuck (72 or 75) in the first windup assembly (74a) in the second and the third spinning assemblies is a maximum distance of less than or equal to 1000 mm and preferably less than or equal to 600 mm. The first and the second windup assemblies (74a, 74b) each include a traversing guide (76) for moving the first and the second plurality of the multifilament yarns (80) back and forth transverse to the multifilament yarns for winding the multifilament yarns on cores into the packages (70). The spinning machines of the present invention are capable of spinning yarns of 10 to 250 decitex, of operating at 4, 000 mpm to 6, 000 mpm, in all melt spinning processes for fibers from all polyamides, especially nylon 6, 6, nylon 6, nylon 6, 10 and nylon 6, 12 and polyesters, especially polyethylene terephthalate and polypropylene terephthalate.

The invention is further directed to a yarn spinning machine conversion process for converting a partially oriented yarn spinning machine to the fully oriented yarn spinning machine.

Illustrated schematically in Figure 1 is a plurality of partially oriented yarn spinning machines similar to

those in wide commercial use that can be easily converted to the fully oriented yarn spinning machine of the present invention as shown in Figure 2a. The partially oriented yarn spinning machine is for making a first and a second plurality of partially oriented multifilament yarns. For purposes herein,"partially oriented yarn"or POY means a yarn of greater than 60% elongation to break, whereas, "fully oriented yarn"or FOY means a yarn of less than 60% elongation to break. The POY spinning machine comprises a plurality of substantially similar spinning assemblies in a row, including as illustrated in Figure 1 a first spinning assembly in a confined space between a second spinning assembly and a third spinning assembly. Each spinning assembly has a spin pack (22), a quench chimney (25), a finish applicator and convergence guide (40), a first and a second alignment guide (50), a first and a second pre windup guide (60), and a first and a second windup assembly not shown, but in relative position to where a plurality of yarn packages (70) are wound on tube cores (72). The yarn spinning machine conversion process for converting a POY spinning machine to a FOY spinning machine comprises the following steps in any order. The first and the second alignment guide (50) are relocated and/or replaced such that the relocated or replaced first and second alignment guides (50), in Figure 2a are for receiving the first and the second plurality of multifilament yarns (80) and directing the multifilament yarns to the first and a second unheated rotatable stepped feed and draw roll assemblies (90) in Figure 2a. Guides (50) in Figure 2a now space out the threadlines to contact the feed roll surfaces individually. The first and the second unheated rotatable stepped feed and draw roll assemblies (90) are mounted in the confined space, essentially that space provided between neighboring machines and limited by the fixed difference (10) between the winding axes indicating by distance (10). The first and a second unheated rotatable stepped feed and draw roll

assemblies (94a, 94b and 92a, 92b) are for receiving the first and the second plurality of the multifilament yarns (80) from the first and the second alignment guides (50), respectively, and for drawing the multifilament yarns (80) to increase their length by a fixed amount.

The steam relax unit (100) is installed in the confined space between the first and the second unheated rotatable stepped feed and draw roll assemblies (90). The steam relax unit (100) is for receiving the multifilament yarns (80) from the unheated rotatable stepped feed and draw roll assemblies (90) and for applying steam to the multifilament yarns (80) to stabilize the multifilament yarns (80). The exit guide (116) is added immediately after the steam relax unit (100) for maintaining the separation of the multifilament yarns (80) within the steam relax unit (100) and for directing the first and second plurality of the multifilament yarns (80) to a first and a second windup assembly (74a and 74b), respectively, for winding the first and the second plurality of the multifilament yarns (80) into a first and a second plurality of packages (70).

As a result of using this machine conversion process, a maker of multifilament nylon yarns can convert a POY spinning machine asset base to a FOY machine asset base in response to market demand shifts in the relative fraction of the product, POY versus FOY. The conversion method of the present invention does not require winder relocation for spacing requirements and effectively and economically converts the typical POY machine to spin FOY yarns providing a novel apparatus. Further benefits are realized with the conversion process of our invention by reversibly performing such a conversion. A fiber maker can then"swing"between product types in response to market-demands.