Carpet with self-twisted loop pile and methods for making the same

Abstract

Carpet with self-twisted loop piles that has an appearance and aesthetics similar to cut pile construction with improved durability and methods for making the same are provided.

What is claimed is: 
     
         1 . A carpet comprising single yarn twisted at a higher twist level than typically used stitched through a pre-constructed woven or nonwoven fabric backing to form a loop or a tuft. 
     
     
         2 . The carpet of  claim 1  wherein the single yarn is twisted in the range of 1 to 15 turns per inch (tpi). 
     
     
         3 . The carpet of  claim 1  wherein the single yarn is twisted in the range of 3 to 12 tpi. 
     
     
         4 . The carpet of  claim 1  wherein the single yarn is twisted in the range of 5 to 10 tpi. 
     
     
         5 . The carpet of  claim 1  wherein the single yarn is directly tufted into carpet without a yarn heat setting step. 
     
     
         6 . The carpet of  claim 1  wherein the single yarn comprises any synthetic yarn material, any natural fiber yarn material or any combination thereof. 
     
     
         7 . The carpet of  claim 1  wherein the single yarn comprises polyester, nylon and/or olefin and any combinations thereof. 
     
     
         8 . The carpet of  claim 1  wherein denier of the single yarn ranges from 100 to 10000. 
     
     
         9 . A method for tufting a twisted single yarn without snarling, said method comprising controlling yarn tension as it unwinds from a yarn package on a creel via a tensioning device. 
     
     
         10 . The method of  claim 9  wherein the tensioning device is set so that yarn tension coming off the package is in a range of 0.001 grams per denier to 0.3 grams per denier. 
     
     
         11 . The method of  claim 9  or  claim 10  wherein the tensioning device comprises a tension band around the yarn package. 
     
     
         12 . A method for tufting a twisted single yarn without snarling, said method comprising subjecting the yarn right after unwinding from the package to tension in the range of 0.001 grams per denier to 0.3 grams per denier to remove snarls. 
     
     
         13 . The method of  claim 12  further comprising controlling yarn tension throughout the tufting process to avoid snarling.