Shaw Industries, Inc.

Christopher S Bryant

David R Kelly

Richard Castle

A rug exhibiting a wool-like appearance made by the process comprising the steps of a. extruding a dyeable polyolefin resin comprising the reaction product of a polypropylene and an ethylene alkyl acrylate copolymer to provide an extruded fiber; b. drawing the extruded fiber by conveying the fiber among a system of unheated and heated godets; c. crimping the drawn fiber by passing the fiber into a texturing jet utilizing hot air; d. twisting at least two separate drawn and crimped fibers to provide a multi-ply carpet face yarn wherein the yarn is from about 1000 to about 8000 denier and has about 2 to about 7 twists per inch; e. heat-setting the multi-ply yarn; f. dyeing the multi-ply yarn using a space-dyeing process; and g. weaving the dyed yarn into a rug; thereby providing a rug with a wool-like appearance. The invention also provides a process for making a rug with a wool-like appearance.

Wool-like rugs and processes for making the same

There is disclosed a process and a composition for dyeing polymeric fibers which have limited dye sites and/or difficult to penetrate chemical structures. Briefly stated, the process comprises the steps of contacting polymeric fibers with a dye composition comprising a disperse dye and a swelling agent. The fibers in contact with said dye composition are then preferably heated to a temperature and for a time sufficient to effect dispersion of a portion of said dye into said polymeric fibers. Subsequently, the fibers are treated to remove residual dye composition.

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Dalton, GA, United States of America

Christopher S Bryant