Carpet Yarn Denier Differential Improvements

Abstract

Different combining techniques are employed for directing multiple denier yarns to be tufted adjacently in a carpet by a tufting machine. Different aesthetic appearances be achieved which provide for many new design opportunities in the marketplace.

Having thus set forth the nature of the invention, what is claimed herein is: 
     
         1 . A method of manufacturing carpet comprising:
 directing first and second distinct yarns to be adjacently tufted beside one another on a tufting machine as directed from a common beam; and   tufting carpet;   wherein the first and second distinct yarns have a denier differential with the first yarn having a denier at least 50 higher than the second yarn.   
     
     
         2 . The method of  claim 1  wherein the first yarn has a denier at least 100 higher than the second yarn, and the directing step further comprises directing the first and second distinct yarns to a single eye of a needle to then perform the tufting carpet step. 
     
     
         3 . The method of  claim 1  wherein the first yarn has a denier at least 150 higher than the second yarn. 
     
     
         4 . The method of  claim 1  wherein the first yarn has a denier at least 200 higher than the second yarn. 
     
     
         5 . The method of  claim 1  wherein the first yarn has a denier at least 250 higher than the second yarn. 
     
     
         6 . The method of  claim 1  wherein the first yarn has a denier at least 300 higher than the second yarn. 
     
     
         7 . The method of  claim 1  wherein the first denier is above 1000 and the second denier is below 1000. 
     
     
         8 . The method of  claim 2  wherein the step of directing the first and second distinct yarns further comprises directing a third yarn from the common beam to the single eye of the needle. 
     
     
         9 . The method of  claim 8  wherein the third yarn has a different denier than the first and second yarns. 
     
     
         10 . A method of manufacturing carpet comprising:
 directing first and second distinct yarns to single eye of a needle of a tufting machine; and   tufting carpet using the single needle;   wherein the first and second distinct yarns have a denier differential with the first yarn having a denier at least 120% of the second yarn.   
     
     
         11 . The method of  claim 10  wherein the first yarn has a denier at least 125% of the second yarn, and the directing step further comprises directing the first and second distinct yarns from a common beam. 
     
     
         12 . The method of  claim 10  wherein the first yarn has a denier at least 133% of the second yarn. 
     
     
         13 . The method of  claim 10  wherein the first yarn has a denier at least 150% of the second yarn. 
     
     
         14 . The method of  claim 10  wherein the first denier is above 1000 and the second denier is below 1000. 
     
     
         15 . The method of  claim 10  wherein the first denier is above 1000 and the second denier is below 1000. 
     
     
         16 . The method of  claim 10  wherein the step of directing the first and second distinct yarns further comprises directing a third yarn from the common beam to the single eye of the needle. 
     
     
         17 . A method of manufacturing carpet comprising:
 directing first and second distinct yarns to single eye of a needle of a tufting machine from a common beam; and   tufting carpet using the single needle;   wherein the first distinct yarn has a denier less than 1000 and the second distinct yarn has a denier over 1000.   
     
     
         18 . The method of  claim 17  wherein the first and second distinct yarns have a denier differential with the first yarn having a denier at least 50 higher than the second yarn. 
     
     
         19 . The method of  claim 17  wherein the first and second distinct yarns have a denier differential with the first yarn having a denier at least 120% of the second yarn. 
     
     
         20 . The method of  claim 17  wherein the step of directing the first and second distinct yarns further comprises directing a third yarn from the common beam to the single eye of the needle.