Bulked continuous filament carpet yarn

• US 5,549,957 A
• Filed: 06/24/1993
• Issued: 08/27/1996
• Est. Priority Date: 07/08/1992
• Status: Expired due to Fees

• Current Assignee: Nyltec Incorporated
• Original Assignee: Nyltec Incorporated
• Inventors: Kennedy, James R., Negola, Edward J.
• Primary Examiner(s): MORRIS, TERREL H
• Application Number:
  US08/082,222
• Time in Patent Office: 1,160 Days
• Field of Search: 428/92, 428/373, 428/97, 428/370
• US Class Current: 428/92
• CPC Class Codes: D01F 8/06 with at least one polyolefin as constituent
• CPC Class Codes: D01F 8/12 with at least one polyamide as constituent
• CPC Class Codes: D01F 8/14 with at least one polyester as constituent
• CPC Class Codes: D02G 3/445 Yarns or threads for use in floor fabrics floor fabrics A47G27/00; floor coverings on textile basis D06N7/0005
• CPC Class Codes: Y10T 428/23957 Particular shape or structure of pile
• CPC Class Codes: Y10T 428/23993 Composition of pile or adhesive
• CPC Class Codes: Y10T 428/2924 Composite
• CPC Class Codes: Y10T 428/2929 Bicomponent, conjugate, composite or collateral fibers or filaments [i.e., coextruded sheath-core or side-by-side type]

Abstract

A bi-component, multifilament synthetic dyeable carpet face yarn that is manufactured using the sheath-core melt spinning process is constructed so as to include a plurality of individual uniformly sheath-cored filaments having a sheath of virgin polyamide (e.g., nylon) and a polymer core that cannot be dyed using standard atmospheric pressure carpet dyeing methods used to dye the sheath filaments. This yarn is a less expensive substitute for 100% polyamide tufted carpet face yarn.

Claims

1. A carpet tufted with a bulked continuous filament carpet face yarn, wherein said yarn comprises:

a) a bundle of drawn and crimped bi-component filaments;

b) each filament consisting essentially of an outer sheath of nylon surrounding a core consisting of fiber forming polymeric material;

c) said nylon sheath constituting from twenty to fifty percent of the total weight of each filament wherein said polymeric core constitutes the remainder of the total weight of each filament;

d) said nylon sheath being dyed under standard atmospheric pressure using nylon dye techniques and said polymeric core material being undyeable under standard atmospheric pressure using said nylon dye techniques;

e) wherein the percentages of nylon and polymeric material in combination impart the properties of recovery from crushing or compression;

the ability

to be tufted at high speeds;

the ability to apply desired color on conventional dyeing equipment at atmospheric pressure;

strength to resist heavy foot traffic; and

good bulking properties equivalent to those of a bulked continuous filament carpet face yarn consisting of 100% nylon.

2. The carpet according to claim 1 wherein said polymeric core consists of fiber forming material that is a material not ordinarily used in the manufacture of piece-dyable carpet yarn.

3. The carpet face yarn according to claim 1 wherein said polymeric core material is fiber-forming polypropylene.

4. The carpet face yarn according to claim 1 wherein said polymeric core material is fiber-forming polyethelene terephthalate.