Patent Number: 6,165,584

Title: Wool-like rugs and processes for making the same

Abstract: 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.

Inventors: Bryant; Christopher S. (Dalton, GA)

Assignee: Shaw Industries, Inc.

International Classification: A47G 27/02 (20060101); B32B 5/02 (20060101); D02G 1/16 (20060101); A47G 27/00 (20060101); D06P 3/79 (20060101); D01F 6/28 (20060101); D01F 6/30 (20060101); B32B 003/02 (); D06P 007/00 ()

Expiration Date: 12/26/2017