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US 7,402,217 B2Granted
Untwisted wrapped singles yarns and carpets manufactured therefrom
AssigneeHoneywell International Inc.
InventorCharles Edward Bowers
Life of this patent
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Abstract
The yarns of the invention include untwisted wrapped singles yarns having a core strand and a wrapper yarn. The wrapper yarn is a base synthetic fiber and a heat-activated binder fiber with a melting point substantially below that of the base synthetic fiber. The Saxony carpets of the invention are made from untwisted singles yarn tufts and are possessed of surface appearance, individual tip retention, pile density, resilient hand and wear resistance comparable or superior to conventional Saxony carpets made from multiple plied twist set yarns.
Claims20
The method of making a Saxony carpet comprising the steps:
- a. forming an untwisted core strand comprising at least one member selected from the group consisting of a natural or synthetic fiber;
- b. forming a wrapper yarn comprising at least one base synthetic fiber material, and a heat activated binder fiber having a melting point at least 20° C. lower than the base synthetic fiber;
- c. wrapping the wrapper yarn about the core strand, forming an untwisted wrapped singles yarn;
- d. heat setting the untwisted wrapped singles yarn at a temperature sufficient to melt the heated activated binder material, then subsequently cooling and solidifying said melt, thereby constricting the base synthetic fiber component of the wrapper yarn about the core strand and securing it to the core strand;
- e. incorporating the untwisted heat-treated yarn into a backing material as loops;
- f. cutting the loops to form vertical tufts;
- and
- g. dyeing and finishing.
5 more elements
Dependencies are inferred from the claim text.