High bulk yarn and method of manufacturing thereof
AssigneeAYM Syntex Limited
InventorAbhishek MANDAWEWALA
Life of this patent
Estimating the term…
Abstract
A method of manufacturing high bulk continuous multi-filament yarn comprises a number of distinct steps. In a first step, a plurality of filaments of polymer are melt spun to form a partially oriented yarn (POY). In a second step, the POYs are drawn and textured to form a draw textured yarn, wherein texturing is carried out in a friction texturing process. Subsequently at least two plies of the draw textured yarn are twisted and/or cabled together and subsequently heat set to obtain the high bulk continuous multifilament yarn.
Claims25
A method of manufacturing a high bulk continuous multifilament yarn for use as pile in a floor covering, comprising:
- in a first step, melt spinning a plurality of filaments of polymer to form a partially oriented yarn;
- in a second step, drawing and texturing one or more partially oriented yarns in a friction texturing process to form a draw textured yarn;
- and
- in a third step, twisting or cabling at least two plies of the draw textured yarn together in a range between 30 and 400 twists per meter and heat setting the twisted plies to obtain the high bulk continuous multifilament yarn having a weight of at least 1000 denier, wherein at the end of the second step and prior to the third step, the draw textured yarn is wound to a bobbin or hank.
(canceled)
(canceled)
(canceled)
(canceled)
A high bulk yarn for use as pile in a floor covering comprising a plurality of plies, wherein;
- each ply further comprises at least one draw textured yarn and wherein, the at least one draw textured yarn further comprises continuous filaments of polymer wherein,
- the at least one draw textured yarn is false-twist friction textured;
- the plurality of plies are twisted or cabled together in a range between 30 and 400 twists per meter and heat set in the twisted or cabled state, wherein a weight of the high bulk yarn is at least 1000 denier, and
- the bulk of the high bulk yarn is at least 12 cm3/gm.
A floor covering material comprising:
- a base backing;
- and
- a pile comprising a high bulk yarn that is tufted, knitted, knotted or woven to the base backing,
- wherein the high bulk yarn comprises a plurality of plies of false-twist friction textured yarn formed from continuous filaments of polyester, wherein the plurality of plies are twisted or cabled together in a range between 30 and 400 twists per meter and heat set in the twisted or cabled state, such that a weight of the high bulk yarn is at least 1000 denier and the bulk of the high bulk yarn is at least 12 cm3/gm.
(canceled)
Dependencies are inferred from the claim text.