Enhanced surface coverings, yarns and methods
OwnerJames C. Bridges, David M. Lasseter +3inventors
InventorsJames C. Bridges, David M. Lasseter, W. Augustus Latham, David E. McCarty, Carroll E. Deen JR.
Life of this patent
Estimating the term…
Abstract
A process for forming a carpet, and the carpet formed thereby are provided. The process includes forming a thread comprising low melt fiber and high melt fiber. The thread is then heated above a temperature sufficient to melt the low melt fiber. The thread is tufted in a carpet backing to form a tufted carpet. The tufted carpet is then printed or dyed with an image. A process for forming a low melt content yarn and the yarn formed thereby are provided.
Claims34
A carpet prepared by the process of:
- forming a thread comprising at least one low melt fiber and at least one higher melting point fiber constituent;
- heating said thread above a temperature sufficient to melt said low melt fiber;
- tufting said thread in a carpet backing to form a tufted carpet;
- and
- printing an image on said tufted carpet.
A process for forming printed carpet comprising the steps of:
- forming a thread comprising low melt fiber and a higher melting point fiber constituent;
- heating said thread above a temperature sufficient to melt said low melt fiber;
- tufting said thread in a carpet backing to form a tufted carpet;
- and
- printing an image on said tufted carpet after heating.
A carpet prepared by the process of:
- forming a blended fiber comprising a low melt fiber and a higher melting point fiber constituent;
- forming a thread of said blended fiber;
- heating said thread above a temperature sufficient to melt said low melt fiber;
- tufting said thread in a carpet backing to form a tufted carpet;
- and
- printing an image on said tufted carpet after heating.
A carpet prepared by the process of:
- forming a thread from a first fiber constituent;
- passing said thread through a doubling or winding process wherein a lower melting point fiber or thread is added;
- spinning to form a combined thread;
- heating said combined thread above a temperature sufficient to melt said lower melting point fiber or thread;
- after heating tufting said combined thread in a carpet backing to form a tufted carpet;
- and
- printing an image on said tufted carpet.
A carpet prepared by the process of:
- forming a fiber blend;
- passing said fiber blend through a ring spinning process wherein a lower melting point fiber is added to said fiber blend to form a combined thread;
- heating said combined thread above a temperature sufficient to melt said lower melting point fiber;
- tufting said combined thread in a carpet backing to form a tufted carpet;
- and
- printing an image on said tufted carpet.
A process for forming jet dyed patterned carpet comprising the steps of:
- forming a blended fiber comprising a low melt fiber and a high melt fiber;
- forming a thread of said blended fiber;
- heating said thread above a temperature sufficient to melt said low melt fiber;
- tufting said thread in a carpet backing to form a tufted carpet;
- and
- printing an image on said tufted carpet using a jet dye machine.
In a patterned carpet, the improvement comprising:
- a carpet yarn having a first fiber constituent and at least a second fiber constituent having a melting point less than the first fiber constituent, the carpet yarn having been heated sufficiently to melt at least a portion of the second fiber constituent prior to patterning.
Dependencies are inferred from the claim text.