Extended length and higher density packages of bulky yarns and methods of making the same

1. A method of making a package of bulked continuous filament yarn wound on a tube core, the tube core having an axis, an inner diameter about said axis, an outer diameter about said axis, an outer circumference and a length; the package having an inner diameter equal to the outer diameter of the tube core, an outer diameter, a circumference, a width less than the length of the tube core and having approximately flat sides on planes normal to the axis of the tube core and separated by said width, the method comprising:

(a) rotating the tube core about its axis;

(b) placing a continuous length of bulked continuous filament yarn in contact with the outer circumference of the tube core at an initial location along the length of the tube core;

(c) winding said yarn around the outer circumference of the tube core such that the yarn is taken up by the tube core and the yarn contact location moves around the tube core;

(d) causing the yarn contact location to move in a reciprocating motion along the length of the tube core as the tube core rotates, so that the yarn contact location becomes a moving point on circumference of the package as the package rotates and the package outer diameter increases, and so that the contact location traverses the entire width of the package from side to side on each traverse stroke, forming a package surface at the package outer diameter;

(e) selecting a desired contact location traverse speed in relation to the rotational speed of the rotating package,

(f) setting a desired contact location traverse speed control point in relation to the rotational speed of the rotating package;

(g) detecting the actual contact location traverse speed;

(h) adjusting the setting for the contact location traverse speed control point so that the actual speed of traverse converges with the desired speed;

(i) selecting a new desired package rotational speed and a new contact location traverse speed after a specific time interval;

(j) setting the new package rotational speed and yarn contact location traverse speed control point at selected time intervals;

(k) detecting the new actual contact location traverse speeds;

(l) adjusting the settings for the new contact location traverse speeds control points so that the actual speeds of traverse converge with the new desired speeds; and

(m) repeating steps (i) through (l) until the package outer diameter reaches a desired value.

2. The method of claim 1 , further comprising selecting a first contact location traverse speed so that the number of package rotations per traverse cycle results in a non-adjacent winding pattern; and selecting additional contact location traverse speeds so that the number of package rotations per traverse cycle is not adjacent until the package outer diameter is from about 130 mm to about 180 mm.

3. The method of claim 1 , further comprising selecting the first contact location traverse speed so that the number of package rotations per traverse cycle is random; and selecting additional contact location traverse speeds so that the number of package rotations per traverse cycle is not adjacent until the package outer diameter is from about 150 mm to about 180 mm.

4. The method of claim 1 , further comprising selecting the first contact location traverse speed so that the number of package rotations per traverse cycle results in a non-adjacent winding pattern; and selecting additional contact location traverse speeds so that the number of package rotations per traverse cycle is not adjacent until the package outer diameter is from about 130 mm to about 180 mm.

5. The method of claim 1 , further comprising selecting the contact location traverse speed so that the number of package rotations per traverse cycle is adjacent but less than an integer or half integer after the package outer diameter is from about 150 mm to about 180 mm.