Process for forming a tufted pile fabric formed from spun and filament space-dyed yarn

• US 5,503,096 A
• Filed: 04/24/1995
• Issued: 04/02/1996
• Est. Priority Date: 01/26/1994
• Status: Expired due to Fees

• Current Assignee: Milliken Research Corporation
• Original Assignee: Milliken Research Corporation
• Inventors: Willey, Richard C.
• Primary Examiner(s): LEWIS, PAUL
• Application Number:
  US08/426,705
• Time in Patent Office: 344 Days
• Field of Search: 112/80.01, 112/80.7, 112/475.23, 112/410, 428/85, 428/92, 428/97, 8/483, 8/929, 8/149, 8/478, 8/481, 156/72, 156/435
• US Class Current: 112/475.23
• CPC Class Codes: D04H 11/00 Non-woven pile fabrics layered products forming non-woven pile fabrics B32B
• CPC Class Codes: D05C 11/24 incorporating devices for dyeing or impregnating the threads
• CPC Class Codes: D05C 15/34 by inserting loops of different nature or colour
• CPC Class Codes: D05C 17/026 characterised by the tufted pile surface
• CPC Class Codes: D06N 2201/0263 Polyamide fibres
• CPC Class Codes: D06N 2203/042 Polyolefin (co)polymers
• CPC Class Codes: D06N 2209/0823 within the layer by addition of a colorant, e.g. pigments, dyes
• CPC Class Codes: D06N 2209/083 Multi-coloured
• CPC Class Codes: D06N 7/0065 characterised by the pile
• CPC Class Codes: Y10T 428/23957 Particular shape or structure of pile
• CPC Class Codes: Y10T 428/23993 Composition of pile or adhesive

Abstract

The fabric of the present invention includes a pile portion comprising spun yarn tufted in alternating arrangement with bulk continuous filament yarn through a base layer. The spun yarn includes a space-dyed component and a stock-dyed component. The bulk continuous filament yarn is also space-dyed. A process and apparatus for producing the pile fabric of the present invention are also provided.

Claims

1. A process for forming a pile fabric from space-dyed yarn, comprising the steps of:

(a) forming a bulk continuous filament yarn;

(b) space dyeing the bulk continuous filament yarn formed in step (a);

(c) spinning singles yarn from stock dyed staple;

(d) spinning singles yarn from undyed staple;

(e) space-dying the singles yarn spun in step (d)

(f) twisting a multi-ply spun yarn from singles yarn spun in step (c) and space-dyed in step (e); and

(g) tufting the bulk continuous filament yarn space-dyed in step (b) in alternating relation with the multi-ply yarn twisted in step (f).

2. The process as in claim 1, wherein in the twisting step (f) the multi-ply spun yarn is a two ply spun yarn twisted from one space-dyed singles yarn and one stock-dyed singles yarn.