Method of producing multicolored yarn, and yarn and carpet made thereby

Abstract

Drawn but undyed synthetic continuous filament yarn is formed into a prefabric, selected portions of the prefabric are dyed while leaving other selected portions free of any dye, the prefabric is raveled, the resulting partially dyed yarn is formed into a partially dyed prefabric, and this partially dyed prefabric is then substantially completely over-dyed to produce a novel over-dyed fabric. This method produces a novel form of crimped and drawn continuous filament synthetic polymeric yarn, a substantial portion of which is undyed, and the balance of which consists of random, intermittent dyed lengths consisting of at least two different colors (A and B) intermittently and randomly arranged along the length of the yarn. When such yarn is formed into a tufted pile carpet, a unique product is provided having a base to which are anchored a plurality of upstanding piles of yarn, which tufts have colors uniquely arranged in the form of randomly shaped coherently colored areas wherein the individual colors appear as individual blocks, and wherein such blocks are randomly shaped and randomly grouped on the carpet.

Dependencies are inferred from the claim text.