Collins Aikman Corporation

Eddie W Scott

Errol N Seltzer

Nelson E Sweezy

A pile fabric is formed of interengaging ground yarns and cut pile tufts. The tufts are formed of wrap yarns extending upwardly from the ground yarns and forming the face of the fabric. Each of the wrap yarns comprises a body strand of untwisted staple fibers and a crimped textured binder strand which has extensible and retractable properties. In the wrap yarn, the binder strand is helically wrapped around the body strand in an axially extended and tensioned condition and is reduced in bulk compared to the condition the binder strand would assume when relaxed. When tufts formed of such wrap yarns are cut to form the face of a cut pile fabric, the binder strands retract and position themselves inwardly away from the face of the pile fabric so as to be hidden among the pile tufts and not visible. The retraction of the binder yarns and the appearance, hand and integrity of the resulting fabric can all be enhanced by various finishing processes.

Wrap yarns having crimped textured binder strands and pile fabrics

A pile fabric is formed from interengaging ground yarns and cut pile tufts formed of wrap yarns extending upwardly from the ground yarns to form the face of the fabric. Each of the wrap yarns comprises a body strand of untwisted staple fibers and a binder strand helically wrapped around the body strand. The binder strands are preferably crimped textured strands and formed of a thermoplastic polymer having heat shrinkable and fusible properties and a relatively low melting point of less than about 300.degree. F. The staple fibers and ground yarns are formed of a material unaffected at the relatively low melting point of the binder strand. When a moderated amount of heat is applied to a cut pile fabric formed from such wrap yarns, the binder yarns shrink and are retractably positioned inwardly away from the face of the pile fabric and are hidden among the pile tufts and not visible. When a greater amount of heat is applied to the pile fabric, the binder strands melt and thereafter resolidify into randomly arranged discrete portions of binder strand material which fusibly interconnect the staple fibers with one another and with the ground yarns. The shrinking, melting and resulting improved properties of the pile fabric can be further enhanced by appropriate finishing steps.

Wrap yarns having low-melt binder strands and pile fabrics formed

In accordance with the invention there is provided a synthetic sewing thread of multifilament construction characterized by its ability to lessen the buildup of heat at the needle of a high speed sewing machine during the operation thereof, even during the sewing of relatively heavy weight fabrics, so as to allow the thread to be utilized as a substitute for the sewing threads conventionally required in high temperature sewing applications, such as cotton spun yarns or cotton sheathed core yarns. The thread is of substantially uniform cross section throughout, devoid of alternating thick and thin areas to provide a smooth more uniform sewing thread. The thread comprises a plurality of texturized continuous synthetic filaments, the filaments having a nonlinear crimped configuration providing bulk to the thread and being entangled with one another along the length of the thread by being directed through a fluid jet under a relatively high pressure of at least 80 p.s.i. and being further bound together by twist. The thread has a heat protective lubricant coating applied thereto and penetrating the filament bundle.

High temperature resistant sewing thread and method of making

In accordance with the invention there is provided a synthetic sewing thread of multifilament construction characterized by its ability to lessen the buildup of heat at the needle of a high speed sewing machine during the operation thereof, even during the sewing of relatively heavy weight fabrics, so as to allow the thread to be utilized as a substitute for the sewing threads conventionally required in high temperature sewing applications, such as cotton spun yarns or cotton sheathed core yarns. The thread comprises a plurality of texturized continuous synthetic filaments, the filaments having a nonlinear crimped configuration providing bulk to the thread and being entangled with one another along the length of the thread and being further bound together by twist. The thread has a heat protective lubricant coating applied thereto and penetrating the filament bundle.

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Mebane, NC, United States of America

Eddie W Scott