Untwisted wrapped singles yarns and carpets manufactured therefrom
View Patent ↗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.
1. A Saxony carpet untwisted wrapped singles yarn comprising:
a. a core strand comprising a member selected from the group consisting of a sliver and a bulked continuous filament yarn; and
b. a wrapper yarn comprising a member selected from the group consisting of a spun staple yarn and a continuous filament yarn;
wherein said wrapper yarn comprises at least one base synthetic fiber material selected from the group consisting of polyester, polyolefin, polyamide, and a heat activated binder fiber having a melting point at least 20° C. lower than the base synthetic fiber.
2. A Saxony carpet manufactured from an untwisted wrapped singles yarn, wherein the untwisted wrapped singles yarn comprises:
a. a core strand comprising a member selected from the group consisting of a sliver and a bulked continuous filament yarn; and
b. a wrapper yarn comprising a member selected from the group consisting of a spun staple yarn and a continuous filament yarn;
wherein said wrapper yarn comprises at least one base synthetic fiber material selected from the group consisting of polyester, polyolefin, polyamide, and a heat activated binder fiber having a melting point at least 20° C. lower than the base synthetic fiber.
3. The untwisted wrapped singles yarn of claim 1 wherein the wrapper yarn is a continuous filament yarn of about 20 to 200 denier.
4. The untwisted wrapped singles yarn of claim 1 wherein the wrapper yarn is a continuous filament yarn of about 40 to 80 denier.
5. The untwisted wrapped singles yarn of claim 1 wherein the wrapper yarn contains about 5 to 95 weight percent of the heat activated binder fiber.
6. The untwisted wrapped singles yarn of claim 1 wherein the wrapper yarn contains about 15 to 85 weight percent of the heat activated binder fiber.
7. The untwisted wrapped singles yarn of claim 1 wherein the wrapper yarn contains about 25 to 75 weight percent of the heat activated binder fiber.
8. The untwisted wrapped singles yarn of claim 1 wherein the wrapper yarn makes about 2 to 10 wraps per inch about the core strand.
9. The untwisted wrapped singles yarn of claim 1 wherein the wrapper yarn makes about 3 to 5 wraps per inch about the core strand.
10. The untwisted wrapped singles yarn of claim 1 wherein the core strand is a sliver of about 0.8 to 6 cotton count.
11. The untwisted wrapped singles yarn of claim 1 wherein the core strand is a sliver of about 1 to 5 cotton count.
12. The untwisted wrapped singles yarn of claim 1 wherein the core strand is a sliver of about 1 to 3 cotton count.
13. The untwisted wrapped singles yarn of claim 1 wherein the core strand is a bulked continuous filament yarn of about 900 to 6000 denier.
14. The untwisted wrapped singles yarn of claim 1 wherein the core strand is a bulked continuous filament yarn of about 1000 to 5300 denier.
15. The untwisted wrapped singles yarn of claim 1 wherein the core strand is a bulked continuous filament yarn of about 1000 to 3000 denier.
16. The untwisted wrapped singles yarn of claim 1 wherein the core strand is comprised of at least one member selected from the group consisting of textile fibers of cotton, wool, polyester, polyolefin, and polyamide.
17. The untwisted wrapped singles yarn of claim 1 wherein the core strand contains about 0-12 weight percent of a heat activated binder fiber having a melting point at least about 20° C. lower than the textile fiber constituents.
18. The untwisted wrapped singles yarn of claim 1 wherein the core strand contains about 0 to 6 weight percent of a heat activated binder fiber having a melting point at least about 20° C. lower than the textile fiber constituents.
19. The untwisted wrapped singles yarn of claim 1 wherein the core strand contains about 0 to 3 weight percent of a heat activated binder fiber having a melting point at least about 20° C. lower than the textile fiber constituents.
20. The untwisted wrapped singles yarn of claim 1 wherein the total content of heat activated binder fiber is 0.05-2.5 weight percent of the total yarn.