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 ant 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 the yarn source, and a rotatable coiler tube positioned downstream from the feed rolls. An air blowing device is positioned between the feed rolls and the coiler tube for facilitating the advance of the yarn into and through the coiler tube. A first variable speed drive is connected to the pair of feed rolls and a second variable speed drive is connected to the coiler tube for rotating the coiler tube at a selected 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, and the conveyor extends through an enclosed heating oven for heat setting the loops of 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 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. 
OBJECT AND SUMMARY OF THE INVENTION 
Copending application Ser. No. 08/289,937 discloses an apparatus and method 
for coiling a yarn and then heat treating the coiled yarn, which 
effectively overcomes the disadvantages and limitations of the prior art 
practices as noted above, and it is an object of the present invention to 
provide a further improvement for such apparatus and method. 
It is a more specific object of the present invention to provide an 
apparatus and method of coiling and then heat treating a yarn, which 
permits the yarn to be reliably advanced through a rotating coiler tube 
and without risk of jamming in the tube. 
The above and other objects and advantages of the present invention are 
achieved in the embodiment described herein by the provision of an 
apparatus and method for forming coils of yarn, and which comprises a 
supporting frame, a pair of feed rolls mounted to the supporting frame and 
arranged to feed yarn in a downward direction from a yarn source, and a 
rotatable coiler tube positioned adjacent and below the pair of feed 
rolls. The rotatable coiler tube is vertically positioned and arranged to 
facilitate the travel of yarn from the feed rolls to and through the 
coiler tube. Also, an air blowing device is vertically positioned between 
the feed rolls and the rotatable coiler tube, and the air blowing device 
includes a guide tube having an upper portion positioned closely adjacent 
the feed rolls and a lower portion positioned coaxially within the upper 
confines of the rotatable coiler tube. An air supply duct communicates 
with the interior of the guide tube at a medial location along its length 
and so that the introduced air exhausts from the lower portion of the 
guide tube and into the rotatable coiler tube to thereby assist in the 
movement and guiding of the yarn from the feed rolls to and through said 
rotatable coiler tube. 
The apparatus of the present invention further includes a first variable 
speed drive connected to the pair of feed rolls and arranged to rotate the 
feed rolls at a predetermined speed, and a second variable speed drive 
connected to the rotatable coiler tube and arranged to rotate the same at 
a speed so as to form a plurality of loops of yarn. 
A conveyor is positioned below the rotatable coiler tube and is adapted to 
receive the loops of yarn from the coiler tube, and an enclosed oven is 
positioned downstream of the coiler tube and receives a portion of the 
conveyor therein for heating the loops of yarn carried on the conveyor so 
as to effect heat setting of the yarn while in the looped condition. 
The present invention also involves a method of heat setting a yarn while 
the yarn is supported in overlapping coils, which includes the steps of 
advancing the yarn along a path of travel from a yarn supply source to an 
advancing conveyor belt, and including passing the advancing yarn serially 
(1) between cooperating feed rolls so that the yarn advances downwardly 
therefrom, (2) through a vertically disposed air blowing device, and (3) 
through a vertically disposed and rotating coiler tube which forms 
overlapping coils of the yarn on the advancing conveyor belt. The conveyor 
belt advances through a heat setting oven so as to heat set the yarn which 
is disposed upon said belt.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
The present invention now will be described more fully hereinafter with 
reference to the accompanying drawings in which a preferred embodiment of 
the invention is 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, the illustrated embodiment is 
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 plurality 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 plurality 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 circulating air, such as with a fan, and/or 
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. 5-7, the coiler 50 of the apparatus 20 
preferably includes a supporting plate 101 which is fixed to the frame of 
the apparatus, a pair of feed rolls 31, 32 mounted on the supporting plate 
101 and adapted for feeding yarn Y from the yarn source 21, and a coiler 
tube 51, which is rotatable about a vertical axis 54 as best seen in FIG. 
6, positioned below 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, and which forms an air jet nozzle 24' at its 
downstream end. 
The air jet nozzle 24' is adapted for facilitating the thread up of yarn Y 
from the yarn supply packages 22 to the feed rolls 31, 32, and the nozzle 
has a downwardly directed output end positioned adjacent and immediately 
above the pair of feed rolls 31, 32, as best illustrated in FIGS. 5 and 6. 
The air jet nozzle as illustrated includes a tube collar 25 which defines 
an annular air chamber 25a (FIG. 6), and which communicates with each of 
several inclined bores leading to the interior bore of the tube. An air 
delivery tube 23 having first and second end portions 23a, 23b is 
connected by the second end portion 23b thereof to the collar 25 so as to 
operatively supply air from a compressed air source 28 to the air chamber 
25a and into the nozzle. 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 delivery 
tube 23 to the elongate tube 24. 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 drawing the yarn Y through the elongate tube 
24 during thread-up. 
The pair of feed rolls 31, 32 are preferably positioned closely adjacent 
each other, as best illustrated in FIG. 6 so as to form a nip 34 
therebetween. The feed rolls 31, 32 are also preferably positioned 
downstream from and closely adjacent to output end of the nozzle tube 24'. 
The pair of feed rolls 31, 32 are further preferably mounted to rotate in 
opposite directions about respective core shafts 35, 36 having a generally 
central axis of rotation as illustrated by the directional arrows. Each of 
the rolls 31, 32 preferably has 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. 
The pair of feed rolls 31, 32 is 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 an air blowing device broadly designated at 70, which 
is fixedly mounted to the supporting plate 101. 
The air blowing device 70 comprises a guide tube which is composed of 
interconnected upper and lower sections 71, 72 respectively, and the guide 
tube includes a venturi-like internal bore which defines a constriction 73 
at a medial location along its length. Also, an air supply duct is formed 
within the device and which includes an annular chamber 74 which surrounds 
the internal bore, and an annular entrance opening 75 leading from the 
chamber 74 into the internal bore at the constriction 71. Further, an air 
delivery duct 76 (FIG. 8) tangentially communicates with the annular 
chamber 74, and the air delivery duct 76 is connected to an air source 78, 
which supplies pressurized air to the device at a relatively low pressure 
of about 10 psi under most operating conditions. 
The inlet mouth of the device 70 has a diameter of about one inch, and the 
delivered air tends to flow downwardly from the constriction 73, thereby 
creating a partial vacuum below the nip 34 of the feed rolls 31, 32, which 
facilitates the advance of the yarn. The downward flow of air also passes 
downwardly through the coiler tube 51 after exhausting from the air 
blowing device, and thereby facilitates the downward advance of the yarn 
through the coiler tube 51. 
The rotatable coiler tube 51 is composed of adjoining first and second 
portions. The first portion is mounted for rotation about the vertical 
axis 54 and is positioned to coaxially receive the lower portion of the 
air blowing device 70, and extend downwardly therefrom. The second portion 
is preferably offset from the first portion and also extends in a 
generally downward direction. 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. at a bend formed in the 
tube positioned between the first and second ends 52, 53 thereof (FIG. 5). 
The 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 coiler tube 51 preferably has a relatively straight or first portion 
extending from the first end 52 to the bend and then the second portion 
extends outwardly in a relatively straight path from the bend as 
illustrated. Although a predetermined angle .theta. of about 9.degree. at 
the bend 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 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 is 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 101 (FIGS. 5 and 
7). Each support block 111a, 112a has a respective end member 111, 112 of 
a harness-type member 110 pivotally connected thereto. The first and 
second end members 111, 112 are positioned along respective ends of the 
feed rolls 31, 32 and a rod member 113 extends between the end members 
111, 112 and forms 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 shafts 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 111 a, 112a to provide access to the inlet mouth of the 
air flowing device 70. 
The coiler 50 also 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 101 supporting the first 
variable speed drive 40 and the feed rolls 31, 32. The plate 101 is 
supported by generally vertical rod members 122, 123, 132, 133 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 (not shown) 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 101. The mounting flange 65 is mounted to the plate member 101 by 
fasteners which extend through spacer blocks 68 (FIG. 6). 
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 from the air blowing device 70. The yarn Y then 
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. 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 63 
which is fixed to a collar 55 which coaxially receives and supports the 
tube 51. The collar 55 is in turn rotatably mounted to the mounting flange 
65 for rotation about the vertical axis 54. The mounting flange 65 
includes bearings 66 positioned therein and rotatably cooperates with the 
collar 55 so that the rotation of the drive pulley 63 connected thereto 
rotates the coiler tube 51 at the same speed. The collar 55 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. 
FIG. 3 illustrates 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. FIG. 4 illustrates 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 FIG. 4. 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 n 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 n are formed in the yarn Y. 
The conveyor 90, as best illustrated in FIGS. 2-4, 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 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 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. 3-5 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 plurality 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 is 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 n 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 plurality 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. 
The apparatus 20 having the plurality 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 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 n 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. 
In accordance with the method aspects of the present invention, the yarn Y 
is advanced along a path of travel from the supply packages 22 to the 
advancing conveyor belt 90, and so as to include passing the advancing 
yarn serially (1) between the rotating feed rolls 31, 32 so that the yarn 
advances downwardly therefrom, (2) through the air blowing device 70 which 
imparts a downwardly advancing force to the yarn, and (3) through the 
rotating coiler tube 51. Overlapping loops or coils of the yarn are 
thereby deposited on the advancing conveyor belt, and the belt is then 
advanced through the oven 80 to heat set the yarn disposed upon the belt. 
The air introduced in the air blowing device 70 passes downwardly through 
the rotating coiler tube 51 after exhausting from the air blowing device, 
and thereby assists in the movement and guiding of the yarn from the feed 
rolls 31, 32 to and through the rotating coiler tube 51. Thus, the yarn is 
reliably advanced through the rotating coiler tube without risk of jamming 
in the tube. 
The method of the present invention preferably also 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 separately controllable speeds 
so as to form loops L of yarn Y of a desired size and configuration 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 plurality 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 the preferred embodiment. 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.