CA2128237A1 - Chain-stitched carpet yarns - Google Patents

Abstract

The present invention relates to carpet yarns having an improved chain-stitch structure, where each component yarn (1, 2) forms a series of tightly held loops along the entire length of yarn. The invention also includes a method for producing such yarns and carpets composed of such yarns.

Description

W093/142s4 2 1 2 ~ 2 ~ 7 PCT/US92/11302 TI~LE
CHAIN--S~ CHED C~RPE'r YARN8 Field of the Invention The present invention relates to carpet yarns composed of multiple component yarns which have been chain-stitched together, and methods for producing such yarns. These yarns are characterized by a uniqu.e stru.c~ure, where each compo~ent yarn forms a series of tigh,~ly held loopg along the entire l~ngth o~ y~rn. The invention also ~ncompasse~ carpets compo~d of such yarns.
Desc ~ o~gu~oD~-~L~s~
l'he most common way for combining two or more component yarns in order to make a larger composite yarn, suit:able for carpets/ is by twisting them together~ For example, in making yarns ~or sax~y-type cut pile carpets, two or more bulked continuou~ filament yarns or staple yarns are twisted in one dir~c~ion individually and then ply--twisted together in the opposite direction. The 2~ compositt~ yarn is then heaked. while at low or no tension to a temperature at which the yarn strands become heat-set in the twisted ~ondition. As a result, the yarns tend to remain twisted when they are inserted into a carpet backing and sub~equently cut to ~orm parallel vertical tuf1:s. However, under continuous wear, the tuft tips gradually lose their twist and filaments of one tuft become entangled with those of neighboring tufts tt~ form a matled surface appearance. Thus, a ~u~t tip structure which retains its integrity during wear would be greatly des:ired.
In preparing the above-d~scribed conventional ply-twisted yarns for cut pile carpets, the plies must be twisted firmly together; otherwise, they will untwist prernaturely 9 To achieY~ acceptable twisting, a i~ 12 ~ 2 3 7 pc~/uss2tl13o2 lubricant solution must be applied to the component yarns in an amount of approximately l~ of the total yarn mass.
The lubricant ingredients are then removed from the yarn when t:he carpets are dyed or sc~ured before sale, thus interiering with the treatment of effluent streams in waste water treatment syst~s of carpet mill communities.
Yarn preparation systems which do not need such lubricants would be a great advantage.
A proposed alternative method for making carpet yarns is a sti~ching op~eration, where the component yarns are enchained t~gether ]by a series of ~ock stitches, as descr:ibed in Parlin, U.S~ Patent 2,82~,605. This operation involves varying the tension applied to the indiv:idual yarn strands, such ~hat each yarn strand forms a ser:ies of tightly h~l~ loops and loosely held loops along its length. The process i~ carried out upon an overedge stitcher provided with a chain-fo~ming mandrel.
However, this type of yarn is not particularly de~irable for making carpets today, due to the presence of loosely held :loops in its structure.
Now, in accordance with this invention, novel chain-stitch yarns having a unique structure which makes them particularly suitable for carpet pile and a method for producing such yarns have been ~ound.
~ ARY O~ TH~ INVENTION
The present invention provides chain-stitched carpet yarns, carpets composed of such yarns, and a method for producing such yarns. The yarn comprises a plurality of componen~ yarns, preferably two component yarnsl characterized by each component yarn formîng a series vf loops, wherein a loop of one component yarn is enchained with a loop of the other component yarn to form a series of chain-stitches evenly spaced along the length of the WO93/142S4 2 1 2 ~ 2 3 7 P~CT/US92/11302 yarn. Each component yarn forms a series of tightly held loops uniformly along the entire length of yarn.
Preferably, ~here are 3 to 16 chain-stitches per inch of yarn. The componen~ yarns may all be of the same color, or they may be of different colors.
Suitable component yarns for this invention include bulked continuous filament yarns and cri:mped staple fiber yarns. These yarns inc~ude, for example, polyolef'n yarns, such as polypropylene yarns, polyamide yarns, such as nylon 6,6 and nylon 6 yarns, polyacryloni~rile yarn~, and polyest~r yarns.
The invention also provide~ a novel proce~s for producing such yarns. The process invslves chain-stitching a plurality of component yarns together, lS such that a loop of one component yarn is enchained with a loop of the other component yarn to ~orm a series of chain-stitches evenly spaced along the l~ngth of the yarn.
During the operatlon, uniform tension is applied along each component yarn such that each component yarn forms a series of tigh~ly held loops uniformly along the entire length of yarn. The yarns may be subsequently heat-set, making them ideal for cut-pile carpets. Furthermore, no yarn lubricant is needed for producing these yarns.
The invention al~o includes carpets, ~uch as those having cut-pile and loop pile surfaces. For cu~-pile carpets, the yarns are preferably heat-set and have two or more chain~stitches per tu~t.
BRI~F D~8CRIPTION OF T~ DR~WIN~
Figure l is a schematic drawing of the 3~ chain-stitshed yaxn of this invention.
~ igure 2A is an enlarged photograph ~about 5X) of conventionally ply-twisted nylon bulked continuous filament ~BCF) yarn tufts in a cut pile carpet before wear testing.

WO93/1425212 8 ~ 3 7 PCT~US92/1130?

Figure 3A is a view o~ the carpet of Figure 2A
after wear testing.
Figure 2B is an enlarged photograph (about 5X) of tufts of chain-stitched yarns of this invention in a cut pile carpet before wear tPsting~
Figure 3B i5 a view of the carpet of Figure 2B
after wear testing.
Figur~ 2C is an enlarged photograph (about 5X) of tufts of chain-stitched yarns of this invention in a cut pile carpet be~ore wear testing.
Figure 3C i8 a view o~ the carpet of Figure 2C
after wear testing.
Figure 2D is an enlarged photograph (about 5X) of tufts of chain-stitched yarns of this invention in a cut pile carpet before wear t~sting.
Figure 3D is the carp~t of Figura 2D af~er wear testing.
Figure 2E is an ~nlarged photograph (about 5X) of tufts of chain-stitched yarns of this invention in a cut pile carpet before wear testing.
Figure 3E is a view of the carpet of Figure 2E
after wear testing.
Figure 4 is a perspective view of a sewing machine capable ~f making the chai~-stitched yarns o~ this invention.
Fi~ure 5 is an enlarged view of the neadle and looper portion of the sewing machine shown in Figure 4.
Figure 6 is a partial view of the opposite side of the sewing machine of Figure 4, showing a pull~r roll device for ,~moving the stitched y~rn ~rom the needle and looper mec~anism.
Figure 7 iB a cross-sectional view of a yarn of this invention under tension.

,.,~, , 2 i 2 ~ 2 3 7 PCT/US92/11302 W~3/14254 DETAILED pEBCR P~ION OF T~E INVBN~ION
The present invention provides carpet yarns having an improved "rhain-stitoh~' structure, carpets composed o~ such yarns, and a method for producing such yarns. By the term, "chain~stitchl', it is generally meant a structure where component yarns are combined into a series of equally spaced loops of which each loop of one ~omponent yarn is enchained with a loop of the other component yarn or yarns.
In a known process for producing chain-stitch yarns, as described in the aforem~ntionad U.S. Pat nt 2,822,605, a chain-stitch structure may b~ pxoduced upon an overedge stitcher having a needle, an upper and lower looper, a mandrel about which successive stitches are formed, and a device for drawing-off the compl~ted yarn at a predetermined rate. This c:onventional process is governed by a ~lenoid controlled t~nsioning mechanism, where one of the feeding yarn strands is subiected to a high tension, while r~latively low tension is applied to the other strand for a predetermined length along the enchained yarn. At other prede~rmined lengths along the same yarn, the t~nsloning aff~ct on the yarn strands reverses, thus proYiding each yarn strand with a series of tightly held loops (caused by high ten~ion) and a series of loosely held loops (caused by low tansion).
Referring to the drawing~, Figure l shows a chain-stitched yarn of the present invention formed from component carpet yarns ~l) and (2~. The schematic stitch strusture is slightly expanded, to ~how the yarn paths more clear~y. It is understood that the actual str~ct~1res for the yarns o~ this invention are more compact, as shown in Figures 2B-2E and 3B-3E.
As shown in Figure l, the chain-stitches are formed by interlacing and interlooping the loops of 212Sh37 4 PCT/~S9~/1130 component yarn (l) with the loops of component yarn (2).
These stitches are referred to as Stitch-type 401 in United states Federal Standard No. 715A, I'Stitches, Seams, and Stitchings". A stitch is composed of one loop of one component yarn enchained with a loop consisting of one or more second component yarns. Generally, there should be 3 to 16, and preferably ~ to 9~ chain stitches per 1nch of carpet yarn.
The key improvement of the chain-stitched carpet yarns of this invention is a structure~ where each component yarn forms a sPrie~ of tightly held loops along the entire length of yarn. The compo~ant yarns are firmly secured together by the successive tightly held 1GOPS of both component yarns. Since there is no ~ormation of relatively loosely held loops, the carpet yarn does not have a loose flowing appearanceO Rather, the carpet yarn exhibits a tightly looped structure which is hi~hly resilient and less I~kely to lo~e its int~grity.
When a yarn st~ucture of the present invention, as shown in Figures 2B-2E and 3B-3E, is compressed axially, the yarn loops near the upper end o~ the tuft compress and contact ~he loops below~ thus gradually increasing the resistance of the tuft to further compression. The resistance of the loops to bending also assists the resilience of the yarn structure. When the same yarn in a loop pile carpet or when lying on its side in a long cut pile carpet is compre~ed transversely, the stitch structure also supports load and recovers from compression more effectively than conventional ply-twisted yarn.
In contrast, as 5hown in Figure 2A, when tufts in cut pile carpets composed of conventional ply-twisted yarns are compressed axially by foot traffic, the twisted structure opens. This opening, when repeated many times W~ 93/lq254 2 1 2 ~ 2 3 7 PCT/US92/11302 and combined with scuffing of the tuft tip, causes the fibers at the tip to spread apart and tangle with fibers of adjacent tufts, giving a matted appearance r as shown in Figure 3A. These conventional ply-twisted tufts exhibit significantly higher tip flaring than the r-hain-stitched yarns of this invention.
This chain stitch structure, as shown in Figures 2B-2E, compresses the component yarns laterally so that it may de~elop less bulk than the conventional yarn structures of Figure ~A. This is particularly true ~or structures having a high number o~ chain~stitches per inch~ ~ow2ver, the increa~ed bending resilience, as described above, at least partially o~fsets any loss of bulk. Thus, in the present invention, high bulk component yarns may b used, since they contribute added r~silience and load-bearing ability. In contrast, high bulk component yarns are often not us~d in conventional ply-twisted structures because the tufts are too soft and lose their appearance of newness rapidly.
Figures 2E and 3E show cut pil~ yarn ha~ing six chain-stitches per inch tufted into 1~4 inch pile height carpet. It can be seen from Figure 2E tbefore wear testing) that there is only slightly more than one complete sti~ch ~howing, and a~ter wear testing, the stitch structure has largely disappeared (Figure 3E).
Therefore, for best GUt pile wear, the yarn denier, stitches per inch, and pile height should be selected so that the majority of tufts in cut pile carpets have ~wo or more stitches.
T~e unique yarn structure of this invention is obtalned ~y applying uniformi tsnsion along the entire length of each component yarn during the chain-stitching process. The chain-stitches may be formed by sewing machines, Raschel knitting machines, or ~imilar ~12~,2 '~
wo~3/142s~l PCT/US~2/11302 interlooping equipment~ When more than two yarns are employed~ the additional yarn or yarns is preferably added to the looper of a sewing machine or its equivalent.
In Figure 4, feed yarns (20), (21) and (22) are shown being threaded through conventional tensioners (23), (24) and (25), on a Union Special, Model 56100-MZ sewing machine and thence to the needles~ shown more clearly in Figure 5. Yarns (26~, (27) and (28) go through tensioners (29), (30) and (3l) to the loopers.
Referring to Figure 5, yarns (20), (21) and (22) are each thr~aded through the eye of a needle (32), (33 and (34), respectively. Yarns (26), (27) and (~8) are each threaded through looper (3S~, (363 and (37), r~spectively. In operation, needle (32) works with looper (35) to form a chain stitched yarn (38) (see Figure 6) ~rom feed yarns (20~ and (26), needle (33) works with looper (36) to form a chain stitched yarn (39~ from feed yarns (21~ and (27), and needle (34) works with looper (37) to for~ a chain-stitched yarn (40) from feed yarns (22) and (28).
Figure 6 shows the opposite side of the sewing machine from Figures 4 and 5. Chain-stitched yarns (38), (3~) and (40) are moved away from the needle and lsoper mechanisms by puller roll (41) which presses the yarns against the upper surface of the machine table. The puller roll's speed is adj~sted by selecting the diameters of sprockets (42) and (43) which cooperate with cogged belt (44) to maintain a desired number of stitches per inch~ A slower puller speed gives higher stitches per inch and vioe versa. From here, the yarns may ~ach go to a wi:nd u~ ~nd be wound on a packag~.
Although the sewing machine shown in Figures 3-6 has three sets o~ needles and loopers, suitable machines may :be obtained having one to thirty sets or more.

WO93/14254 212 ~ 2 3 7 P~.r~US92/11302 The productivity and speed of the present operat:ion is not limited by centrifugal force as is conven1:ional ply-twisting, and therefore the presen1-ly-existing stitch-forming eguipment is not only faster than ply-twisting but does not have similar limita1:ions on future speed increases.
The simplest ch,ain-stitch structures of this invent:ion require about twice ~he length of feed yarn as ply tw:isting; therefore, a two-feed chain-stitched yarn consumes four times the yarn length and gives a final yarn of about four times the starting yarn denier. To make a two-feed chain-stitched yarn of about 2200 final denier, two ends of about 550 denier each are required. In contrast, in order to produce a 2200 denier ply-twisted yarn t~o ends of ab~ut llO0 denier are re~uired. More comple~ chain-stitch structures may require still ].onger lengths of smaller denier yarns. Large yarns may be made inexpeI1sively by feeding multiple yarns to the looper so that a large yarn is produced in the same machine ~perat.Lng time as a smaller one.
.When two or more compvnent yaxns of different color/ dyeability or other property are used in the present: process, it is found that the composite yarn appearance can be controlled moxe precisely and uni.formly than when employing entangling processes of the prior art.
It is important that the tension applied to each component yarn be uniform along the entire length of yarn.
Tension on the feed yarns may be controlled by the tensioners furnished with the stitch-forming machine, Howevel., for~better control of kension, other types of known tensioners used in yarn processing operatlons may be substit:uted. These tensioners include, e.g., disc tensioners and spring-loaded tensioners/ which are available from Steel Heddle of Greenville, SC~ These WOs3/142s~ 12 8 ~ 3 7 PCT~US92/11302 tensioners are commonly mounted off the stitch-forming machines. The tension in each feed yarn may be more easily measured if tensioners are mounted so that an acc~rate tensiometer may be inserted between the tensioner and the needle or looper.
It is rec~gnized that the tensi~n applied to one component yarn may be different than the ~ension applîed to the other component yarn. In such a case, there will be a change in the proportion of one component yarn to another in the final yarn, with a corr~sponding contrast in the general color e~fect, where two or more component yarns of di.~ferent color are used. It has been found that this colored appearance can be controllad more precisely and uniformly wi~h this method versus known yarn entangling processes.
The effect of yarn tension on the cross-sectional shape of the yarn can be seen in Figure 7, Figure 7 is a cross-sectional vi~w of a yarn of this invention, where dimensions (5~ and (6) are su~stantially equal, which is typical when two component yarns (3) and ~4) of equal properties are chain-stitched ~ogether at equal yarn tensions. A specific dimension will be greater when larger or stiffer yarn is employed or when tension is lower. The ratio of the dimensions is pre~erably no greater than 2:l, more preferably no grsater than l~5:l, because a yarn of elongated cross-section provides less "cover" for hiding the backing of a carpet. Howe~er, yarns having a ratio greater than 2:l may be used ~o obtain unusual visual or mechanic~l propertias in a cut or loop pile c~rpe~.
Suitable component yarns ~or this invention include bulked continuous filament yarns and crimped staple fiber yarns. These yarns include, for example, polyolefin yarns, such as polypropylene yarns, polyamide ~, , , . . ...... ., ; ~ , .

WO ~3/14~54 2 ~ 2 ~ 2 ~ 7 P~/US92tll302 yarns, such as nylon 6, 6 and nylon 6 yarns, polyacrylonitrile yarns, and polyester yarns~
In contrast to conventional ply-twisted yarn where f ilaments can spread in all directions from a tuft 5 tip and entangle with those from neighboring tufts, the nature of the present yarn ~ s st.itch structure holds the cut filament ends closely together. This occ:urs e~en if the chain sti~ch structure starts to s~ightly unravel, such as in cases of heavy wear. Another advantage of the 10 chain-stitc:h structure is that th~ c:ut end is only about one-half the denier of a ply-twisted tuft, therefore having many fewer f ilamerlt ends te~ spread and entangle .
If the yarns of this invention are tQ be used in cut pile carpets, the yarn should be heat-set. Th~
l 5 heat-setting of the stitched yarn greatly retards unraveling in even the most susc~ptible directions. The heat-setting operation may involve passing a yarn through a Superba heat-setting machi3le, which treats the yarn with pressurized saturated steam to heat- set the stitc:hes .
20 Ano~her msthod invol~res passing the yarn through a continuous Suessen heat-setting machine, which treats the yarn with dry heat to heat- set the stitches. For nylon yarns, steam a'c 120 to l40C or dry air at 18û to 210C
is effective. The heat-setting step may be done after the 25 chain-stitched yarns are wound or as the yarn travels from the stitch~forming operation to winding.
I f the yarns of this invention are to be used in loop pile carpets, it is not necessary to heat-set them.
Generally, nylon or other synthetic: staple yarn is not 3 0 commonly us,sd in loop pile carp~ts, because the scuf f ing which the yarn r~c:eives on the tops of the loops from shoes loosens the twisted yarn structure and allows free ends of the staple filaments to protrude from the yarn and be drawn out further to form unsightly fuzz and pills.

WO 93/14254 21 2 S 2 ~ ~1 P~/US92/11302 However, when a staple yarn is formed in accordance with this invention, particularly at a stitching rate of 6 stitches per inch or greater, the stitch structure c:orlstri ::ts the yarn and allows only small 5 lengths of the :Eibers tc> be exposed t~ scuffing~ The constructions pre~ent fiber ends from protruding and being drawn out to form pills and~fuzz.
It is recognized thak the chain-stitched yarns of this invention can be made from a broad range o~ ~ynthetiG
or natural fiber component yarns and may be u~ed for other purpose~ than as pile in carpets. These yarns may be used as cords or ropas, or they may, for example, be used as craft yarns in hand knitting. They may also be incorporated in warp and circular knits and in woven fabrics, and are especially suited for applications where improved resi~tance to wear is needed.
Testin~ Methods Texture Retention The texture retention of the carpet ~amples was evaluated after wear tests which were conducted in a vetterman drum test apparatu~, Type KSG manufactured by Schoenberg & Co. (Bamberg, Germany). The drum was lined with carpet samples, with the pile facing inwards and contained a steel ball having 14 rubber bu~fers which rolled randomly in~id~ the rotating drum. The drum was rotated in alternating directions. A circular brush within the drum was in light contact with the carpet surface and removed loose pile fibers which were continuously removed by suction. A~ter a period of 30 cycles, the~samples were removed and insp~cted to evaluate texture re~entiorl.
Texkure retention was determined using a scale of l-5 with a rating of 5 corresponding to an untested . . . . . .. ... ..... . . . . . . .

.W093/14254 2 1 2 3 2 3 7 PCT/US92t11302 control sample and l corresponding to an extremely matted control sample.
Measurement_of Chain-Stitches The number of chain-stitches per inch of yarn may be measured by (l) reading the stitch rat~ from a roller puller sprockek table supplied by the stitch forming machine manufacturer when the top or dri~en sprocket and bottom or dri~e sprocket are known, (2) directly from a piece of fabric run through the machine with the help of a puller such that the yarn i5 stitched into the ~abric and a seriec of chain-stitches is formed, or (3) stre ching the yarn uncler minimal t~nsion and manually counting the number of stitches.
The following examples further describe the invention but should not be construed as limiting the scope of the inven~ion.
~X~MPI~8 Carpet A ~Control~
Commercially available, Du Pont llOO Type 746 BCF
(bulked continuous filament~ nylon 6,6 yarns of llOO total denier and comprised of 68 filaments (of trilobal cross-section) were produced by a conventional process.
Two of these yarns were plied and twisted to provide a yarn with a balanced twist of 4.5 turns per inch (tpi).
Plied and twisted yarn was then conve~tionally heat-set in a Superba heat-set apparatus at 270 degrees F with a resulting yarn denier of 2400. A cut pile tufted carpet was constructed from the heat-set yarn to th~ ~ollowing specificatlo~s: 40 oz./sq~yd. weight, ll/l6 inch pile height, 5j3~ inch gauge, and l2.5 stitches per inch. The carpet was dyed to a light blue ~hade on a continuous dye line using the following dye formulation and based on the weight of carpet: 0~0005% "Tectilon" Orange 3G-200 ........ . . , . .. , ~ .. . ...... .. .. . . .

W093/14254 2 ~ 2 S 2 ~ 7 PCT/US~2/1130~

(C.I.Acid Orange l56), 0.0005% "Tectilon" Red 2B-200 (C.I.Acid Red 361) and 0.0075% "Tectilon" Blue 4R-200 (C.I.Acid Blue 277), (available from Ciba-Geigy Corp.).
After dyeing, the carpet was rinsed, extracted and subsequently treated with a commercial fluorochemical soil repellent in a conventional spray application. Finally the carpet was dried in an oven, latexed and sheared.
Carpet B
BCF nylon 6,6 yarns of 550 total denier and comprised of 34 filaments (o~ trilobal cross secticn) were produced by a conv~ntional process of splitting commercially available, Du Pont nylon yarn of ll00 Type 746. Two of these yarns were chain-stitched together on an industrial type sewing machine, Model No. 56l00-MZ, made by Union Special, to form a chain~stitched composite yarn having 5 stitches per inch. The chain-stitched yarn was then heat-set in a Superba h~at-~et appara~us at 270 degrees F with a resultant total yarn denier of 2800. A
cut pile tufted ca~pet wa~ constructed from the heat-set yarn to the ~ollowing specifications: 40 oz./sq~yd.
weight, ll/6 inch pile heigh~, 5/32 inch gauge, and l0 stitches per inch. This carpet was dyed and finished in the same manner as Carpet A.
Carpet C
The carpet was prepared in the same fashion as Carpet B, except that the yarns were c~,ain-stitched together to form a chain-stitched composite yarn having 8 stitches per inch. The carpet dyeing and finishing were done in ~he same manner as Carpat B.
~ 5~
Commercially available, Du Pont 1100 Type 746 BCF
nylon 6,6 yarns of 1100 deni2r and comprised of 68 filaments (o~ trilobal cro5s-~ection) were produced by a conventional pro~-ess~ Two of these yarns were 2:12~237 WO93/142~4 PCT/US92/11302 chain-stitched together using the samP machine as described above for the yarns in Carpet B to form a chain-stitched composite yarn having 5 stitches per inch.
The chain-stitched yarn was then passed through the stuffer box with 5 p.s.i. ~team pressure prior to heat-setting in a Superba h~at-set apparatus at 270 degrees F. The final "textu~ed" yarn had a total yarn denier of 6300. A cut pile tufted carpet was constructed from the heat-set yarn to the following specifications:
40 oz./sq.yd~ weight, 5/8 inch pile height, 5/32 inch gaugel and 4 stitches pe!r inch. The carpet was dy~d to a light beige shade on a continuous dye line using the following dye formulation and based on the weight of carpet: 0.02% "Tectilon" Orange 3G-200 (C.I.Acid Orange 156), 0.01% "Tectilonl' ~.ed 2B -200 (C.I. Acid Red 3~1) and 0.0l25% "Tectilon'l Blue 4R-200 (C.I.Acld Blue 277)~ After dyeing, the carpet was latexed and ~inish~d in the same manner as Carpet A.
Carpet E
BCF nylon 6,6 yarns o~ 705 total denier and comprised of 42 filaments (of trilohal cros~-section) were produced by a conventional process of splitting Du Pont nylon yarn 14l0 Type 696AS. Two of these yarns were chain-stitched together using the same commercial sewing machines as u~ed in making yarns ~or Carpet B to form a chain-stitched composite yarn ha~ing 6 stitches per inch and the resultant denier of 2900. The yarn was not heat-set. A cut pil tuftad carpet was constructed from these non heat-set yarns to the following specifications:
16 oz.~'s~.yd., weight, l/4 inch pile height, l/g inch gauge, and 6 stitches per inch. This carpet was dyed and finished in the same manner as Carpet A.

WO93/l4254 21 2 ~ 2 3 7 PCT/VS92tll302 _ Yarn Construction Denier~ Final5~1~5~ ~D~L~ .}519D
Fi1s. Yarn Stitches ~ Pi1e Yard Hei~ht Gauge Stit CarPet ~_ends Each Denier /Inch(in.~ (in.L (in.

A(control) 2 1100/68 2400 Ply twis~ 4011/16 5/32 12.5 s 2 550/3~ 2800 5 4011/16 5/32 10 C 2 550/34 2~00 8 4011/16 5/32 10 A1:1 fivP (5) carpets ~Contro1 Carpet A, and carpets using the new invention technique B, C~ D and E) were subjected ~to the wear test for 5000 cyc1es, and eYa1uated for texture retention, ~s out1ined above. The texture of each evalui~ted carpet was rated by 3 different people, and the average o~ tho~e ratings is repor~.ed in Tab1e 2.
Figures 2A and 3A are photog.raphs of Contro1 Carpet A;
Figures 2B and 3B are photographs of Carpet B; Figures 2C
and 3C are photographs of ~a:rpet C; Figures 2D and 3D axe photographs of Carpet D; and Figures 2E and 3E are photographs of Carpet E.

WO 93/14254 2 1 2 S 2 3 7 PCrtUS92/~1302 .

Texture Retent i on Sample Ratinq REMARKS
Carpet A 3 . 5 Open and fuzæed tuft tips; pile ( Control ) matted .
carpet B 4 . 3 Better tuft definition; less matting than c:ontrol Carpet A.
Carpet C* 3 . 5 Better tuft retention compared to other textured pr~ducts in a similar con~:truction made by c:onv~ntional ply-twisting techniques.
Carpet D 4 . 7 Extremely well defined tufts;
appear almost like not wear tested.
Superior texture retention when compared with control Carpet A.
Carpet E* 1. 9 Matted, but better appearans: e ( c:ru h resi~tance ) than other zarpets in a similar construction made by conv~ntional ply-~wisting techni~es.

*NOTE: Carpet C is compared wi~h a textured residential carpet in a similar c:onstruction and Carpet E i5 ~ompared with an automotive ::arpet in a simi.lar corlstruction using a non-heat~et yarn.

W~93/142~ 1 2 8 2 ~ 7 PCT/U~9~/1130 BXAM~E 2 Two ends of commer~ially available, Du Pont 1245 denier BCF solution dyed nylon 5,6 ~NTRON LUMENA were chain-stitched at g, 7.5 and 6 stitches per inch (spi) to yield separate yarns ha~ing deniers of 7964, 6821 and 7214, respectively (-3X imput fe~d yarn deniers). These yarns were used to make carpets by tu~ting them as bands on a 1/8 gauge loop pila ~ufter at 0.188 inch pile height and 6.75 stitches per inch (spi) to approximately 32 oz/sq.yd. The 0 loop pile carpet~ were topiGally treated with 0.9%
anti-soil ~luorochemical ~ollow~d by latexing/drying.
These carpets, along with control carpets co~posed of conventional air-entangled yarnsl were exposed to 110,000, 220,000 and 339,000 cycles in the Ve~terman drum and ranked lS on a l-S scale, as described above. The carpet ratings are shown in Tabl~ 3.
EXAMP:LB 3 Three ~nds of commercially a~ailable, Du Pont 1245 denier BCF solut~on dyed nylon 6, 6 ANTRON LUMENA were 20 chain-stitched at 9, 7.5 and 6 spi to yield separate yarns having deniers of 12122, 11477, and 13563, respec:tively, (-3x imput feed yarn deniers). These yarns were used to make carpets by tufting them as bands on a 1/8 gau~e loop pile tufter at O .188 inch pile height and 7 . 25 spi to 49, 25 4 1 and 44 oz/sq. yd., respectively. The loop pile carpets were treated with the finishing agent described in Example 2. These carpets were exposed to 110~000, 220,000, and 330,000 cycles in the Vetterman drum and ranked on a 1-5 scale, as described above. The carpet ratings were similar 3 0 to the rat~ngs ~or the carpets of E~PLE 2 .
BXAMP:t E: 4 Two ends of 622 denier (produced by splitting the threadline of Du Pont ANTRON 1245 denier 13CF piee-dye WO()3/14254 2 1 2 ~ 2 ~ 7 PCT/US92/11302 lg h~llow filament yarn on the commercial spinning machine) - yarns were chain-stitched at 9, 7.5 and 6 spi to yield separate yarns having deniers of 4017, 3703 and 3553, respectively (-3X input eed yarn deniers). These yarns were tufted as bands on a 1/8 gauge loop pile tufter at 0.188 inch pile and 13 spi to 31, 32, and 34 oz/sq. yd., respectively. The loop pile carpet amples were beck dyed using 0.0115% "Tectilon" orange 3G~V, 0.0165% I'Tectilon' Red 2B-V, 0.1100% "Tectilon" Blue 4R, and 1% Du Pont 10'IAlkanol" ND. These carpets were exposed to 110,000, 220,000, and 330,000 cycles in the V~tterman drum and ranked on a 1-5 s~ale, as described above. The carpet ratings were similar to the ratings for the carpets of EXAMPLE 2.
1513XAMPI,E 5 Three ends of 950 denier polypropylene were chain-stitched to yield a yarn having a denier of 10,000.
The yarn was tufted on a 1/8 gauge table top tufter at 0.188 inch pile and 5 spi to 33 oæ./sq. yd. .The l~op pile carpet was latexed and dried. The finished carpet had unique visuals and ex~ellent Vetterman drum performanre after 22,000 cyclesr WO ~3/14254 ~ 1 2 ~ ~ 3 7 P~/US9~/1130 _A8~E 3 CHAIN-STITCHES VETTERMAN TEXTURE RETENTION

9 llOM* 4.5 Slight crushing 9 220M 4.5 51ight crushing 9 33OM 4 Modest crushing Superior performance Versus Controls (~4X Traffics) 7.5 llOM 3.5 Moderate crushing 7.5 2~0M 305 Moderate crushing 7.5 330~ 3 Noticeable crushing Superior to Controls (>3X Traffics) 6 lloM 3 Noticeable crushing 6 220M 3 Noticeable crushing 6 330M 2.5 Very noticeabIe crushing (>2X Traffics) Air-Entangled "Rooster-Tail"
Controls llOM 3 Noticeable crushing " 220M 2~5 Very noticeable crushing " 330M 2 Slightly severe crushing "Gilbos"
Air Entangled Controls ,~ 3 01M l . 5 Savere crushing "Texalor"
Air-Entangled Controls 330M 1 Very severe crushing *M a thousand

Claims (24)

1. In a carpet yarn comprising a plurality of component yarns characterized by each component yarn forming a series of loops, wherein a loop of one component yarn is enchained with a loop of the other component yarn to form a series of chain-stitches evenly spaced along the length of the yarn; the improvement comprising, each component yarn forming a series of tightly held loops uniformly along the entire length of yarn.

2. The carpet yarn of claim 1, wherein there are two component yarns.

3. The carpet yarn of claim 1, wherein there are 3 to 16 chain-stitches per inch of yarn.

4. The carpet yarn of claim 1, wherein all of the component yarns have the same color characteristics.

5. The carpet yarn of claim 1, wherein the component yarns have at least two different color characteristics.

6. The carpet yarn of claim 1, wherein the component yarns are bulked continuous filament yarns.

7. The carpet yarn of claim 1, wherein the component yarns are crimped staple fiber yarns.

8. The carpet yarn of claim 6 or 7, wherein the component yarns are selected from the group consisting of polyamide, polyolefin, polyester and polyacrylonitrile yarns.

9. The carpet yarn of claim 8, wherein the component yarns are nylon 6,6 yarns.

10. The carpet yarn of claim 8, wherein the component yarns are nylon 6 yarns.

11. The carpet yarn of claim 8, wherein the component yarns are polypropylene yarns.

12. A carpet, comprising the carpet yarns of claim 1.

13. The carpet of claim 12, wherein the carpet has a cut-pile surface of yarn tufts and the yarns have been heat-set.

14. The carpet of claim 13, wherein each tuft has at least two chain-stitches.

15. The carpet of claim 12, wherein the carpet has a loop pile surface.

16. In a process for producing a carpet yarn, comprising chain-stitching a plurality of component yarns together, such that a loop of one component yarn is enchained with a loop of the other component yarn to form a series of chain-stitches evenly spaced along the length of the yarn; the improvement comprising the step of:
applying uniform tension along each component yarn such that each component yarn forms a series of tightly held loops uniformly along the entire length of yarn.

17. The process of claim 16, further comprising the step of heat-setting the yarn.

18. The process of claim 16, wherein there are two component yarns.

19. The process of claim 16, wherein the yarns are chain stitched together at a rate of 3 to 16 stitches per inch.

20. The process of claim 16, wherein the component yarns are bulked continuous filament yarns.

21. The process of claim 16, wherein the component yarns are crimped staple fiber yarns.

22. The process of claim 20 or 21, wherein the component yarns are selected from the group consisting of polyamide, polyolefin, polyester and polyacrylonitrile yarns.

23. In a yarn comprising a plurality of component yarns characterized by each component yarn forming a series of loops, wherein a loop of one component yarn is enchained with a loop of the other component yarn to form a series of chain-stitches evenly spaced along the length of the yarn;
the improvement comprising, each component yarn forming a series of tightly held loops uniformly along the entire length of yarn.

24. In a process for producing a yarn, comprising chain-stitching a plurality of component yarns together, such that a loop of one component yarn is enchained with a loop of the other component yarn to form a series of chain-stitches evenly spaced along the length of the yarn; the improvement comprising the step of:
applying uniform tension along each component yarn such that each component yarn forms a series of tightly held loops uniformly along the entire length of yarn.