Patent ID: 7559121

Claim:
A process for converting continuous filament fiber into discontinuous filament yarn, which process comprises a plurality of functional zones at least including (1) breaking all the continuous filaments in a first break zone between cylindrical entrance nip rolls and exit nip rolls, by increasing the fiber speed within the first break zone to create a discontinuous filament fiber, the first break zone including drafting the fiber, (2) breaking the discontinuous filaments in a second break zone between cylindrical entrance nip rolls and exit nip rolls, by increasing the fiber speed within the second break zone, the second break zone including drafting the fiber, and (3) consolidating the discontinuous filaments to form a yarn, wherein the improvement comprises: (a) arranging the path of the discontinuous filament fiber at the exit of the first break zone, and at the entrance and exit of the second break zone, (i) to first contact the fiber to an electrically conductive nip roll before contacting the fiber to an electrically non-conductive nip roll, and (ii) to only separate the fiber from an electrically non-conductive nip roll by first separating the fiber from the electrically non-conductive nip roll before separating it from an electrically conductive nip roll to thereby minimize static buildup in the fiber as it passes through the nip rolls; and (b) withdrawing the yarn from the process at a speed more than four times the input speed of the fiber to the process to reduce the discontinuous filament yarn to less than 500 filaments in any cross-section of the yarn.