Wrap yarns having low-melt binder strands and pile fabrics formed therefrom and attendant processes
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United States of America Patent
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-
May 26, 1987
Grant Date -
N/A
app pub date -
Jul 28, 1986
filing date -
Jul 28, 1986
priority date (Note) -
Expired
status (Latency Note)
Importance
Abstract
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.
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