Honeywell International Inc.

Alliedsignal Inc.

Charles Edward Bowers

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.

Untwisted wrapped singles yarns and carpets manufactured therefrom

Yarn suitable for tufting comprises a base fiber ring spun or wrap spun with a second fiber at least partially comprising a heat-activated adhesive material such that the yarn includes from 0.1 to 12, preferably 0.25 to 10, weight percent adhesive material having a melting point within the range of 105&#xb0; to 190&#xb0; C., more preferably 165&#xb0; to 190&#xb0; C. A preferred base fiber is a synthetic staple fiber bundle. A preferred wrapping or insert fiber comprises copolyamide material, including ternary copolyamides of the 6/66/12 type. When the yarn is twist set by conventional processes and then tufted into carpet, the resulting carpet displays enhanced wear and appearance properties.

Yarn with heat-activated binder material and process of making

Yarn suitable for tufting comprises a base fiber ring spun or wrap spun with a second fiber at least partially comprising a heat-activated adhesive material such that the yarn includes from 0.1 to 12, preferably 0.25 to 10, weight percent adhesive material having a melting point within the range of 105&deg; to 190&deg; C., more preferably 165&deg; to 190&deg; C. A preferred base fiber is a synthetic staple fiber bundle. A preferred wrapping or insert fiber is a copolyamide fiber, including ternary copolyamides of the 6/66/12 type. When the yarn is twist set by conventional processes and then tufted into carpet, the resulting carpet displays enhanced wear and appearance properties.

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Hopewell, VA, United States of America

Charles Edward Bowers