Apparatus and method for forming coils of yarn and for heat setting the same

An apparatus and method are provided for forming coils of yarn and for heat setting the yarn. The apparatus has a coiler adapted to receive yarn from a yarn source and to form the yarn into a plurality of overlapping loops of a desired size. The coiler preferably includes a supporting frame, a pair of feed rolls mounted on the supporting frame and adapted for feeding yarn from a yarn source, and a rotatable coiler tube positioned downstream from and cooperating with the feed rolls. The coiler also includes a first variable speed drive connected to the pair of feed rolls and adapted for rotating the same at a predetermined speed and a second variable speed drive connected to the coiler tube and adapted for rotating the same at a speed to thereby form loops of yarn of a desired size. The apparatus further has a conveyor positioned below the rotatable coiler tube for receiving overlapping loops of yarn thereon. A heating oven is positioned downstream from the coiler and through which the conveyor extends to thereby effect heat setting of the yarn carried thereon.

FIELD OF THE INVENTION 
This invention relates to an apparatus and method for forming coils of yarn 
and, more particularly, to an apparatus for forming coils of yarn and for 
feeding the coiled yarn into a heat treatment zone to thereby heat set the 
yarn. 
BACKGROUND OF THE INVENTION 
During the production of continuous filamentary or spun yarns, for example, 
the yarns are often conventionally subjected to a drawing or stretching 
process under tension. This stretching process is followed by a partial or 
complete relaxing of the yarn to produce the desired physical 
characteristics, such as a reduced shrinkage propensity in the processed 
yarn or some other effect, i.e., bulking or crimping of the filaments 
forming the yarn. Such yarns may have an inherent tendency to retract into 
a crimped form under low tension. Heat may also be used to assist this 
process. 
Conventionally, the relaxation of yarn has been accomplished by a type of 
batch process wherein the yarn is temporarily collected in some form of 
can or box which allows a degree of contraction to take place such as seen 
in U.S. Pat. No. 3,470,587 by Kincaid titled "Planetary Coiler." Other 
processes are also known such as continuously subjecting the fed yarn to 
treatment with a hot fluid in some form of jet device such as seen in U.S. 
Pat. No. 3,644,968 by Elliott et al. titled "Apparatus For Relaxing 
Yarns." These prior methods, however, involve a relatively slow batch 
process, primarily provide only one pattern or type of crimp in the yarn, 
provide limited production output, and provide little control over the 
production process. 
OBJECTS AND SUMMARY OF THE INVENTION 
It is, therefore, an object of the present invention to provide a versatile 
apparatus and method for forming a plurality of patterns in yarn having 
either a desired crimp or substantially no crimp therein. 
It is also an object of the present invention to provide an apparatus and 
method of coiling yarn that is adaptable to a plurality of sizes of yarns 
and a plurality of rates of production for various yarn patterns. 
The above and other objects and advantages of the present invention are 
achieved in the embodiments described herein by the provision of an 
apparatus and method of forming coils of yarn and for feeding the yarn to 
and through a heating zone so as to effect heat setting of the yarn. The 
apparatus preferably has a coiler, a conveyor cooperating with the coiler, 
and an enclosed heating oven cooperating with the conveyor. The coiler has 
a pair of feed rolls adapted for feeding yarn from a yarn source and a 
rotatable coiler tube positioned adjacent the feed rolls and extending 
vertically downward therefrom. The apparatus also provides first drive 
means for driving the pair of feed rolls of the coiler at a variable speed 
and second drive means for driving the coiler tube of the coiler at a 
variable speed. By providing the combination of these variable speed 
drives for the coiler, for example, in situations where high production 
output of yarn is important, the user of the apparatus can advantageously 
adjust the feed rate of yarn through the coiler to maximize the throughput 
of the yarn on the conveyor fed into and through the heating oven. Also, 
based on the desired throughput, the user can then adjust the drive rate 
of the coiler tube to select a predetermined pattern of loops in the yarn. 
For example, the faster the drive rate of the coiler tube, more 
larger-sized loops are formed in the yarn. The slower the drive rate of 
the coiler tube, fewer larger-sized loops and more smaller-sized loops are 
formed in the yarn. 
More particularly, the apparatus, according to the invention, preferably 
has a coiler adapted to receive yarn from a yarn source and to form the 
yarn into a plurality of loops of a desired size. The coiler preferably 
includes a supporting frame, a pair of feed rolls mounted on the 
supporting frame and adapted for feeding yarn from a yarn source, and a 
rotatable coiler tube positioned downstream from and cooperating with the 
feed rolls. The coiler tube is vertically positioned for facilitating the 
travel of yarn from the feed rolls to and through the coiler tube. The 
coiler also includes a first variable speed drive connected to the pair of 
feed rolls and adapted for rotating the same at a predetermined speed, and 
a second variable speed drive connected to the coiler tube and adapted for 
rotating the same at a speed so as to form loops of yarn of a desired 
size. The apparatus further has a conveyor positioned below the rotatable 
coiler tube and adapted for receiving loops of yarn thereon. The conveyor 
extends a predetermined distance from the coiler tube. An enclosed heating 
oven is positioned downstream from the coiler and receives portions of the 
conveyor therein for heating the loops of yarn carried thereon so as to 
effect heat setting of the yarn. 
Also, according to the present invention, an apparatus is provided having a 
series of coilers positioned in a generally side-by-side arrangement and 
adapted for forming loops of yarn. A plurality of yarn supply packages are 
each preferably positioned to feed yarn to a respective one of the series 
of coilers. A series of conveyors extend generally parallel to each other. 
Each of the conveyors is positioned vertically below a respective coiler, 
extends a predetermined distance therefrom, and is adapted for receiving 
loops of yarn thereon. Enclosed heating means is preferably positioned 
downstream from the series of coilers and receives portions of each of the 
series of conveyors therein for heating the loops of yarn carried thereon 
so as to effect heat setting of the yarn. The series of coilers includes a 
common supporting frame having a horizontal plate and a plurality of 
vertical plates extending downwardly therefrom. Each of the coilers of the 
series is adapted to form yarn received from a yarn supply package into a 
plurality of loops of a desired size. Each coiler also preferably includes 
a pair of feed rolls mounted on the horizontal plate of the supporting 
frame and adapted for feeding yarn from the yarn supply package and a 
rotatable coiler tube positioned downstream from and cooperating with the 
feed rolls. The coiler tube is preferably vertically positioned for 
facilitating the travel of yarn from the feed rolls to and through the 
coiler tube. The coiler further includes a first variable speed drive 
connected to the pair of feed rolls and adapted for rotating the same at a 
predetermined speed, and a second variable speed drive connected to the 
coiler tube and adapted for rotating the same at a speed so as to form 
loops of yarn of a desired size. 
Further, according to the present invention, methods of forming coils in a 
yarn are also provided. The method preferably includes the steps of 
providing a first variable speed drive connected to a pair of feed rolls 
and providing a second variable speed drive connected to a rotatable 
coiler tube. The pair of feed rolls and the rotatable coiler tube are then 
rotatingly driven respectively responsive to the first and second variable 
speed drives at such speeds so as to form loops of yarn of a desired size 
deposited on a conveyor.

DETAILED DESCRIPTION OF A PREFERRED EMBODIMENT 
The present invention now will be described more fully hereinafter with 
reference to the accompanying drawings in which typical preferred 
embodiments of the invention are shown. This invention may, however, be 
embodied in many different forms and should not be construed as limited to 
the illustrated embodiments set forth herein; rather, these embodiments 
are provided so that this disclosure will be thorough and complete and 
will fully convey the scope of the invention to those skilled in the art. 
Like numbers refer to like elements throughout. 
FIGS. 1 and 2 schematically illustrate an apparatus, broadly designated at 
20, for forming coils of yarn having a series of coilers 50 according to 
the present invention. FIG. 2 schematically illustrates a side plan view 
of an apparatus 20 for forming coils of yarn Y and for feeding the coiled 
yarn Y to a heating zone, shown in the form of an enclosed heat setting 
oven generally at 80, according to the present invention. FIG. 1 
schematically illustrates in a top plan view an apparatus 20 according to 
the invention having a series of coilers, broadly designated at 50, 
positioned adjacent each other and yet, for example, sharing the same 
enclosed heating means for heating the yarn Y, i.e., the heat setting oven 
80, such as in a production facility or the like. This type of 
configuration can be of particular interest where, for example, a high 
production output of the yarn Y is important to the user of the apparatus 
20. 
As also illustrated in FIGS. 1 and 2, the apparatus 20 preferably includes 
a yarn source 21 which is illustrated as a plurality of yarn supply 
packages 22 and which is positioned to feed yarn Y to be coiled to each of 
the respective coilers 50. Although the invention includes an apparatus 
having one or more coilers 50, the initial description herein will 
generally discuss an apparatus 20 having one coiler 50 and then describe 
an apparatus 20 having a series of coilers 50. The coiler 50 cooperates 
with the yarn source 21 and is adapted for forming coils in the supplied 
yarn Y. The preferred supply path and flow of the yarn Y to and through 
the coiler 50 and the heating oven 80 are schematically illustrated in 
FIG. 2 by the arrows. The supplied yarn Y preferably is either continuous 
filament yarn or spun yarn. 
The apparatus 20 also preferably includes a conveyor 90 positioned below 
the coiler 50 that cooperates with the coiler 50 and the heat setting oven 
80. The conveyor 90 is adapted for receiving loops L of yarn Y thereon and 
feeds the yarn Y from the coiler 50 to and through the enclosed heat 
setting oven 80. The yarn heat setting oven 80 is positioned downstream 
from the coiler 50 (FIG. 1) and receives portions of the conveyor 90 
therein for heating the loops L of yarn Y carried thereon to thereby 
effect a heat setting treatment to the yarn Y. After the yarn Y passes 
through the heat setting oven 80 on portions of the conveyor 90, the yarn 
Y is preferably cooled by exposure to air, other gases, or the like and 
taken-up by yarn take-up means, generally designated at 26, which is 
illustrated as a plurality of rollers and winders for individually winding 
the yarn Y to form individual packages 27 thereof. The yarn take-up means 
26 preferably supplies the needed tension to take-up the yarn Y from the 
conveyor 90 in a smoothly operable manner so that entanglement or other 
problems do not occur when receiving the yarn Y. 
As best illustrated in FIGS. 6-8, the coiler 50 of the apparatus 20 
preferably includes a supporting frame 100, a pair of feed rolls 31, 32 
mounted on the supporting frame 100 and adapted for feeding yarn Y from a 
yarn source 21, and a coiler tube 51, preferably being rotatable as 
illustrated in FIGS. 6-7, positioned downstream from and cooperating with 
the pair of feed rolls 31, 32. The pair of feed rolls 31, 32 cooperate 
with the first yarn source 21 and the coiler tube 51 so as to feed the 
yarn Y supplied from the first yarn source 21 to the coiler tube 51 
preferably by pneumatic means which preferably includes an elongate tube 
24 or the like positioned upstream of the feed rolls 31, 32, as 
illustrated. 
The pneumatic means is adapted for facilitating the movement of yarn Y from 
the yarn supply packages 22 to the feed rolls 31, 32. The elongate tube 24 
preferably has an input end 24a adapted for receiving yarn Y from a yarn 
supply package 22 and an output end 24b positioned adjacent the pair of 
feed rolls 31, 32, as best illustrated in FIGS. 2 and 6-8. The pneumatic 
means is adapted to feed and guide the yarn Y from the yarn source 21 to 
the pair of feed rolls 31, 32. The pneumatic means as illustrated 
preferably also has a tube collar 25 mounted to the elongate tube 24 and 
an opening 25a (FIG. 8) therein positioned at the output end 24b thereof 
adjacent the pair of feed rolls 31, 32. An air vent tube 23 having first 
and second end portions 23a, 23b is connected by the second end portion 
23b thereof to the elongate tube 24 at the opening 25a to operatively 
supply air from a compressed air source 28 to the output end 24b of the 
elongate tube 24. The air source 28 assists in drawing the yarn Y from the 
yarn source 21, through the elongate tube 24, and to the pair of feed 
rolls 31, 32 by supplying air under pressure through the air vent tube 23 
to the elongate tube 24. A plurality of openings in the output end 24b of 
the elongate tube 24 as illustrated cooperate with the air being supplied 
from the air vent tube 23 to form the drawing-type action for the yarn Y. 
A valve 29 cooperates with the air source 28 and an air supply tube 28a so 
that by use of a button-type switch 29a of the valve 29 or the like, i.e., 
on or off control, the air supply process may be regulated for threadably 
drawing the yarn Y through the elongate tube 24. 
The pair of feed rolls 31, 32 are preferably positioned closely adjacent 
each other, as best illustrated in FIGS. 6 and 8, so as to form a nip 34 
therebetween. The feed rolls 31, 32 are also preferably positioned 
downstream from and closely adjacent to the elongate tube 24. The pair of 
feed rolls 31, 32 are further preferably mounted to rotate in opposite 
directions about respective core members 35, 36 having a generally central 
axis of rotation as illustrated by the directional arrows. Each of the 
rolls 31, 32 preferably have a respective fluted peripheral portion 31a, 
32a, i.e., gear teeth, positioned to cooperate with the corresponding 
fluted peripheral portion 31a, 32a, i.e., gear teeth, of the other roll 
31, 32 so that the driving of one roll 32 correspondingly drives the other 
roll 31. 
As best illustrated in FIGS. 8-10, the pair of feed rolls 31, 32 are 
adapted to feed the yarn Y from the yarn source 21 during rotation thereof 
so that the yarn Y from the yarn source 21 travels through a trumpet 
member 39 positioned above and between the oppositely rotating rolls 31, 
32, preferably at the nip 34, to the rotatable coiler tube 51. The yarn Y 
from the feed rolls 31, 32 passes or travels therefrom to a make-up guide 
tube assembly, broadly designated at 70, carried by the supporting frame 
100. The make-up guide tube assembly 70 preferably includes a make-up 
guide tube 71 having lower portions depending from the supporting frame 
100, an upper tapered end adapted to facilitate the positioning thereof 
closely adjacent lower portions of the feed rolls 31, 32, and a lower end 
preferably positioned within the confines of an upper end of the rotatable 
coiler tube 51. The make-up guide tube assembly also preferably includes 
adjusting means carried by the make-up guide tube 71 for adjustably 
positioning the tapered upper end thereof closely adjacent lower portions 
of the feed rolls 31, 32. The make-up guide tube 71 is non-rotatably 
mounted to a generally horizontal, structural plate member 101 of the 
supporting frame 100 and a lower portion 72 thereof extends through an 
opening in the structural plate member 101. The make-up guide tube 71 
provides a make-up portion or transition portion for the corresponding 
distance between the feed rolls 31, 32 and the rotatable coiler tube 51 to 
thereby smoothly guide the yarn Y from the feed rolls 31, 32 to the coiler 
tube 51 without interference from the rotating feed rolls 31, 32. 
As illustrated, the adjusting means of the make-up guide tube assembly 70 
also includes an annular ring 76 surrounding a medial portion of the 
make-up guide tube 71 and preferably affixed thereto. The annular ring 76 
extends outwardly from the make-up guide tube 71 so as to overlie the 
structural plate member 101 of the supporting frame 100. The adjusting 
means further has a plurality of leveling adjusters, shown as screws 78, 
which threadably extend through the annular ring 76 and with lower 
portions of the leveling screws 78 bearing against the structural plate 
member 101. Portions of the structural plate member 101 underlying the 
annular ring 76 have threaded bores therein. A plurality of fasteners, 
shown as securing screws 77, extend through the annular ring 76 and into 
the threaded bores to secure the make-up guide tube assembly 70 to the 
structurally supporting plate member 101. 
The rotatable coiler tube 51 preferably has adjoining first and second 
portions. The first portion is positioned adjacent the feed rolls 31, 32 
and extends downwardly therefrom. The second portion is preferably offset 
vertically from the first portion and also extends downwardly therefrom. 
The rotatable coiler tube 51 is therefore preferably angled and preferably 
has a first or upper end 52, a second or lower end 53, and a predetermined 
angle (.theta.), i.e., offset, formed in the tube positioned between the 
first and second ends 52, 53 thereof (see FIG. 6). The yarn Y preferably 
travels through the angled coiler tube 51 between the first and second 
ends 52, 53. The predetermined angle (.theta.) has a preferred range of 
about 5.degree.-20.degree. for various applications of the invention, but 
the range may also vary from about 0.degree.-45.degree. for some 
applications. 
The first or upper end 52 of the coiler tube 51 preferably cooperates with 
lower end portion 72 of the make-up guide tube 71 so that the coiler tube 
51 is positioned over the outer diameter of the make-up guide tube 71 to 
facilitate the transition between the two tubes 51, 71 and so that the 
coiler tube 51 may easily rotate around the lower portion of the make-up 
guide tube 71. The coiler tube 51 preferably has a relatively straight or 
first portion extending from the first end 52 to the angle (.theta.) and 
then the second portion extends outwardly in a relatively straight path 
from the angle (.theta.) as illustrated. Although a predetermined angle 
(.theta.) of about 9.degree. in the coiler tube 51 is preferred, it will 
also be understood that other angles, i.e., greater than 45.degree., and 
shapes of the coiler tube 51 may also be used such as curvilinear shape or 
straight shape in some applications. During operation, however, the 
predetermined angle (.theta.) in the coiler tube 51 generally enables the 
coiler tube 51 to cooperate with the conveyor 90 so that the yarn Y is 
thrown outwardly in a circular pattern from the rotating coiler tube 51 
and to prevent clogging of the yarn Y in the coiler tube 51 such as when 
the yarn Y is being fed from the pair of feed rolls 31, 32 at a 
predetermined speed. 
A first variable speed drive 40 preferably is connected to the pair of feed 
rolls 31, 32 and mounted to the horizontal structural plate member 101. 
The first variable speed drive 40 is adapted for rotating the feed rolls 
31, 32 at a predetermined speed to facilitate the feeding of the yarn Y 
from the yarn source 21 to the coiler tube 51. The first variable speed 
drive 40 preferably includes a first motor 41, such as a variable speed 
motor mounted on a base plate 41a as illustrated, and at least one drive 
pulley, and preferably a first pair of drive pulleys 42, 43 as 
illustrated. The first pair of drive pulleys 42, 43 are respectively 
connected to the motor 41 and at least one of the feed rolls 31, 32. A 
first drive belt 44 is preferably positioned on the drive pulleys 42, 43 
and cooperates with the pair of feed rolls 31, 32 so that driving of the 
first motor 41 rotates the drive pulley 42 connected thereto, the first 
drive belt 44 positioned thereon, and the drive pulley connected to the 
feed rolls 31, 32 to thereby rotate the pair of feed rolls 31, 32 at a 
predetermined speed. 
The first variable speed drive 40 and the feed rolls 31, 32 are preferably 
mounted on various structural support members as illustrated. One feed 
roll 32 is mounted along respective ends thereof to a pair of support 
blocks 111a, 112a fixedly secured to the supporting plate member 101 
(FIGS. 6 and 9). Each support block 111a, 112a has a respective end member 
111, 112 of a harness-type member 110 pivotally connected thereto. The 
harness-type member 110 includes first and second end members 111, 112 
positioned along respective ends of the feed rolls 31, 32 and a rod member 
113 extending between the end members 111, 112 and forming an 
outer-restraining end to the harness-type member 110. A fastener 114 
secures the rod member 113 into an opening 114a in the plate member 101 in 
an operative position. The fastener 114 preferably includes a bolt having 
a spring mounted thereon as illustrated. The feed rolls 31, 32 are 
rotationally mounted on the core members 35, 36 which extend therethrough 
and connect to the respective end members 111, 112. Upon release of the 
fastener 114, the harness-type member 110 pivots about the support blocks 
111a, 112a to provide access to the make-up guide tube 71 and a lower end 
of the feed rolls 31, 32. 
The coiler 50 also preferably has a second variable speed drive 60, shown 
in the form of a second motor 61, also preferably a variable speed motor, 
a mounting flange 65, a second pair of drive pulleys 62, 63 respectively 
mounted to the second motor 61 and the mounting flange 65, and a second 
drive belt 64 that cooperates with the pair of drive pulleys 62, 63 as 
illustrated. The second variable speed drive 60 and the coiler tube 51 
likewise are preferably mounted on various structural support members as 
illustrated. These various structural support members preferably connect 
to and cooperate with the horizontal structural plate member 101 
supporting the first variable speed drive 40 and the feed rolls 31, 32. 
The plate member 101 is supported by generally vertical rod members 122, 
123, 132, 133 (also shown are rod members 142, 152 in FIGS. 5 and 6 which 
cooperate with an adjacent apparatus 20 as illustrated in FIG. 1) and 
transverse beam members 121, 131. The transverse beam members 121, 131 
cooperate with and are further supported by generally vertical beam 
members 125, 135 and transverse base members 136, (not shown), 126 or the 
like. The second motor 61 is preferably mounted to a generally vertical 
base plate 126 secured to and extending generally perpendicular to the 
horizontal plate member 101. The mounting flange 65 is preferably mounted 
to the plate member 101 by fasteners such as the threaded screws 68 
illustrated (FIGS. 7 and 9), but may also be mounted to the vertical base 
plate 126, or other structural support member. 
The angled and rotatable coiler tube 51 is preferably positioned in a 
substantially vertical direction above the conveyor 90 and upstream of the 
heating oven 80 so that the first end 52 of the coiler tube 51 is adapted 
to receive the yarn Y passing through the make-up guide tube 71, the yarn 
Y passes through the angled coiler tube 51 and out of the second end 53 
thereof, and impinges on a surface 95 of the conveyor 90 and second 
variable speed drive 60. The driving of the second motor 61 drives, i.e., 
rotates, the drive pulley 62 connected thereto, rotates the second drive 
belt 64, and rotates the drive pulley connected to the mounting flange 65. 
The mounting flange 65 preferably includes bearings 66 positioned therein 
and rotatably cooperates with the rotatable coiler tube 51 so that the 
rotation of the drive pulley 63 connected thereto rotates the coiler tube 
51 in a corresponding relationship, i.e., generally the same relative 
speed. A coiler tube ring member 55, i.e., collar, adjustably cooperates 
with the coiler tube 51, by use of an adjusting fastener 56, and the 
mounting flange 65 so that the coiler tube 51 as illustrated may be 
removed and replaced with other coiler tubes having various other 
predetermined angles formed therein, smaller or larger sized diameters, or 
other shapes or orientations as described. 
FIGS. 3 and 6, for example, illustrate the angled coiler tube 51 being 
rotated at a relatively fast speed so that the yarn Y is thrown out from 
the angled coiler tube 51 and deposited onto the moving conveyor 90 in 
relatively larger-sized diameter loops L. FIGS. 4 and 7, on the other 
hand, illustrate the angled coiler tube 51 being rotated at a relatively 
slow speed so that the yarn Y is thrown out from the angled coiler tube 51 
and impingingly deposited onto the moving conveyor 90 in relatively 
smaller-sized diameter loops L. The plurality of smaller-sized loops L of 
yarn Y are also preferably oriented in a generally larger-sized diameter 
loop pattern which provides a textured appearance as best illustrated in 
FIGS. 4 and 5. The loops L in the yarn Y as described herein will be 
understood to include a shape or pattern of yarn substantially taking the 
form of a length of yarn folded over onto itself with an opening 
positioned therein, as well as other closed or nearly closed shapes or 
patterns in the yarn. 
By providing the combination of these variable speed drives 40, 60 for the 
coiler 50, for example, in situations where high production output of yarn 
Y is important, the user of the apparatus 20 can advantageously adjust the 
feed speed of yarn Y through the coiler 50 to maximize the throughput of 
the yarn Y on the conveyor 90 into and through the heating oven 80. Also, 
based on the desired throughput, the user can then adjust the drive speed 
of the coiler tube 51 to select a predetermined pattern of loops L in the 
yarn Y. For example, the faster the drive speed of the rotatable coiler 
tube 51, more larger-sized loops L are formed in the yarn Y. The slower 
the drive rate of the coiler tube 51, fewer larger-sized loops L and more 
smaller-sized loops L are formed in the yarn Y. 
The conveyor 90, as best illustrated in FIGS. 2-4, preferably includes at 
least two spaced apart drive rolls 91, 92 and a conveyor belt 93 
horizontally extending between and positioned on the drive rolls 91, 92. 
The conveyor 90 also preferably includes a pair of conveyor guide rails 
93a, 93b that provide a guide for the belt 93 as it travels between the 
spaced apart drive rolls 91, 92. An upper surface 95 of the conveyor belt 
93 receives the loops L of yarn Y relatively upstream (FIG. 2) of the 
heating oven 80. The rotation of the conveyor drive rolls 91, 92 then 
feeds the loops L of yarn Y positioned on the conveyor belt 93 to, 
through, and from the heating oven 80. The conveyor belt 93 feeding the 
loops L of yarn Y preferably has a widthwise extent of about 9.125 inches, 
but as will be understood by those skilled in the art various other sizes 
of conveyor belts may also be used according to the invention. The 
apparatus 20 having the series of coilers 50 as illustrated in FIG. 1 
preferably has about 7 inches between the series of conveyors 90 and about 
169/16ths inches from the center of one conveyor 90 to the next. 
The conveyor 90 preferably has a motor 96, preferably the third motor of 
the apparatus 20, mounted positionally below the conveyor belt 93. The 
motor 96 has a drive pulley 97 mounted thereto. One of the drive rolls 92 
also has a drive pulley 98 mounted thereto and a drive belt 99 extends 
between the pair of drive pulleys 97, 98 so that the motor 96 drives the 
drive pulley 97 mounted thereto, the drive pulley 97 rotates the drive 
belt 99, and the drive belt 99, in turn, drives the drive pulley 98 
mounted to the drive roll 92. The driving of the drive pulley 98 rotates 
the drive roll 92 which then drives the conveyor belt 93 generally as 
illustrated in FIGS. 2-4. The driving of the drive roll 92 having the 
conveyor belt 93 positioned thereon and cooperating therewith then drives, 
i.e., rotates, the other drive roll 91 to thereby feed or move the yarn Y 
positioned on the conveyor belt 93 from the coiler 50 downstream to the 
heating oven 80 and the yarn take-up means 26. The conveyor 90 is also 
preferably structurally supported by various generally vertical and 
transverse structural support members as best illustrated in FIGS. 3-4 and 
6-7 and as previously described above. 
The angled coiler tube 51 is also preferably positioned in a substantially 
vertical direction or orientation above the conveyor 90 so that the first 
end 52 of the angled coiler tube 51 receives the uncoiled yarn Y, the yarn 
Y passes through the angled coiler tube 51, and yarn received from the 
second tube end 53 is deposited onto a surface 95 of the conveyor 90. The 
surface 95 of the conveyor preferably has a textured pattern, such as the 
crisscross pattern illustrated, so that the yarn Y can easily cooperate 
with various machinery cooperating therewith, i.e., coiler 50, heating 
oven 80, yarn take-up means 26 and so that air, gases, or the like can 
more easily move or circulate around the yarn Y positioned thereon. 
The loops L of yarn Y are preferably formed and received on the surface 95 
of the conveyor 90 and then fed to the heating oven 80, preferably by the 
conveyor 90. The yarn heat setting oven 80 is preferably positioned to 
cooperate with the conveyor 90 and to substantially surround the conveyor 
belt 93 as it passes through the heating oven 80. The enclosed heating 
oven 80 is preferably adapted to receive the yarn Y on the conveyor belt 
93 through a first opening 81 in the oven 80 (FIG. 2). The conveyor belt 
93 feeds the yarn Y through the oven 80, and the yarn Y then passes from a 
second opening 82 in the oven 80. The yarn Y is conveyed through the 
heating oven 80 so that the yarn Y is heat set so as to maintain at least 
some of the predetermined shape therein. The yarn Y is cooled as it leaves 
the heating oven 80 and is fed to the yarn take-up means 26 for take-up 
and the individually packaging thereof. 
As best illustrated in FIGS. 1 and 2, an apparatus 20 for forming coils of 
yarn Y and for heat setting the same may also include a series of coilers 
50 positioned in a generally side-by-side arrangement and a plurality of 
supply packages 22 of yarn Y. Each of the yarn supply packages 22 are 
preferably positioned to feed yarn Y to a respective one of the series of 
coilers 50. A series of conveyors 90 extend generally parallel to each 
other. Each of the conveyors 90 is preferably positioned vertically below 
a respective coiler 50, extends a predetermined distance therefrom, and is 
adapted for receiving loops L of yarn Y thereon. An enclosed heating 
means, i.e., common heat setting oven 80, is positioned downstream from 
the series of coilers 50 and receives portions of each of the series of 
conveyors 90 therein for heating the loops L of yarn Y carried thereon so 
as to effect heat setting of the yarn Y. Each of the coilers 50 of the 
series is adapted to form yarn Y received from a yarn supply package 22 
into a plurality of loops L of a desired size and preferably have the same 
structural and functional features as described above herein. The 
apparatus 20 having the series of coilers 50 may share a common heating 
oven 80, as best illustrated in FIGS. 1 and 2, and may share a common 
supporting frame 100, as best illustrated in FIGS. 5-7. 
The apparatus 20 having the series of coilers 50 according to the present 
invention, however, is also preferably adapted so that at least two of the 
series of rotatable coiler tubes 51 of the series of coilers 50 are 
adapted to be variably driven at different desired speeds. This thereby 
provides an apparatus 20 wherein one of the series of rotatable coiler 
tubes 51 may be driven at a relatively slow speed responsive to the second 
variable speed drive 60 connected thereto while forming a clustered mass 
of relatively small loops L of yarn Y on a corresponding one of the series 
of conveyors 90 vertically positioned below the slowly rotating coiler 
tube 51 by impingingly depositing loops L of yarn Y onto the corresponding 
conveyor 90 at successively closely spaced areas. Also, either the same or 
a different one of the series of rotatable coiler tubes 51 of the series 
of coilers 50 may also be driven at a relatively fast speed responsive to 
the second variable speed drive 60 connected thereto. This allows the 
coiler 50 to form relatively large loops L of yarn Y on a corresponding 
one of the series of conveyers 90 vertically positioned below the fast 
rotating coiler tube 51 with substantially no undulations therein by 
depositing loops L of yarn Y onto the corresponding conveyor 90 at 
successively closely spaced areas. 
Also, according to the present invention, methods of forming coils in a 
yarn Y as also described above herein are provided. A method of forming 
loops L of yarn Y deposited onto a moving conveyor 90 in preparation for 
heat setting to obtain a desired pattern of undulations is also provided. 
The method preferably includes the steps of providing the first variable 
speed drive 40 connected to the pair of feed rolls 31, 32, providing the 
second variable speed drive 60 connected to the rotatable coiler tube 51, 
and rotatingly driving the pair of feed rolls 31, 32 and the coiler tube 
51 respectively responsive to the first and second variable speed drives 
40, 60 at such speeds so as to form loops L of yarn Y of a desired size 
deposited on the conveyor 90. The second variable speed drive 60 connected 
to the rotatable coiler tube 51 may rotatingly drive the rotatable coiler 
tube 51 at a relatively slow speed to thereby form a clustered mass of 
relatively small loops L of yarn Y on the moving conveyor 90 by 
impingingly depositing loops L of yarn Y onto the moving conveyor 90 at 
successively closely spaced areas (FIG. 4). According to this method, an 
enclosed heating oven 80 is preferably positioned downstream from the 
coiler tube 51 and adapted to receive portions of the moving conveyor 90 
therein (FIG. 2). The clustered mass of relatively small loops L of yarn Y 
positioned on portions of the moving conveyor 90 is received by the 
heating oven 80 and heated to thereby effect heat setting of the yarn Y so 
that the yarn Y emanating from the heating oven 80 has a substantially 
high degree of undulations therein as effected by the clustered mass of 
heat set yarn Y. The method also may include the step of rotatingly 
driving the rotatable coiler tube 51 at a relatively fast speed responsive 
to the second variable speed drive 60 connected thereto while forming 
relatively large loops L of yarn Y on the moving conveyer 90 with 
substantially no undulations therein by depositing loops L of yarn Y onto 
the moving conveyor 90 at successively closely spaced areas and likewise 
conveying the loops L of yarn Y to the enclosed heating setting oven 80 to 
thereby effect heat setting of the yarn Y (FIG. 3). The yarn Y emanating 
from the heating oven 80 is thereby substantially devoid of any 
undulations. 
Further, as described in the apparatus 20 having the series of coilers 50, 
for example, another method of forming loops L of yarn Y deposited onto 
the moving conveyor 90 in preparation for heat setting to obtain a desired 
pattern of undulations according to the present invention is also 
provided. This method preferably includes the step of rotatingly driving a 
first rotatable coiler tube at a relatively slow speed responsive to a 
variable speed drive connected thereto while forming a clustered mass of 
relatively small loops L of yarn Y on a first moving conveyor by 
impingingly depositing loops L of yarn Y onto the first moving conveyor at 
successively closely spaced areas (FIG. 4). The method preferably further 
includes the step of rotatingly driving a second rotatable coiler tube at 
a relatively fast speed responsive to a variable speed drive connected 
thereto while forming relatively large loops L of yarn Y on a second 
moving conveyer with substantially no undulations therein by depositing 
loops L of yarn Y onto the second moving conveyor at successively closely 
spaced areas (FIG. 3). The first and second conveyors also preferably 
convey the loops L of yarn Y positioned thereon to a common enclosed heat 
setting oven 80 such as illustrated in FIGS. 1 and 2. 
In the drawings and specification, there has been disclosed typical 
preferred embodiments of the invention and, although specific terms are 
employed, the terms are used in a descriptive sense only and not for the 
purposes of limitation. The invention has been described in considerable 
detail with specific reference to various illustrated embodiments. It will 
be apparent, however, that various modifications and changes can be made 
within the spirit and scope of the invention as described in the foregoing 
specification and defined in the appended claims.