High wear resilient soft yarn

Abstract

Various implementations include a method of forming a bulked continuous filament (BCF) yarn. The method includes providing N molten streams of polymer, providing M spinnerets, and spinning the N molten streams of polymer through the M spinnerets. At least a first group of filaments and a second group of filaments are spun through the M spinnerets. The first group of filaments each have a first average denier per filament along a length of the filaments and the second group of filaments each having a second average denier per filament along a length of the filaments, the first and second average denier per filament being different. The method further includes combining the filaments from the M spinnerets together and texturizing the spun filaments.

1 . A method of forming a bulked continuous filament (BCF) yarn comprising:
 providing N molten streams of polymer, wherein N is an integer and is greater than or equal to 1;   providing M spinnerets, wherein M is an integer and is greater than or equal to one;   spinning the N molten streams of polymer through the M spinnerets, wherein at least a first group of filaments and a second group of filaments are spun through the M spinnerets, the first group of filaments each having a first average denier per filament along a length of the filaments and the second group of filaments each having a second average denier per filament along a length of the filaments, the first and second average denier per filament being different;   combining the filaments from the M spinnerets together; and   texturizing the spun filaments.   
     
     
         2 . The method of  claim 1 , further comprising winding the BCF yarn after the spun filaments are texturized. 
     
     
         3 . The method of  claim 2 , wherein spinning the N molten streams of polymer through M spinnerets consists of spinning a first group of the plurality of filaments having a first average denier per filament and a second group of the plurality of filaments having a second average denier per filament, the first average denier per filament and the second average denier per filament being different. 
     
     
         4 . The method of  claim 3 , wherein the average denier per filament of the first group of filaments and the average denier per filament of the second group of filaments vary less than 10% along the lengths of the filaments. 
     
     
         5 . The method of  claim 4 , wherein the average denier per filament of the first group of filaments and the average denier per filament of the second group of filaments vary 5% or less along the lengths of the filaments. 
     
     
         6 . The method of  claim 5 , wherein each filament in the first group of filaments and the second group of filaments have a wavelike axial cross-sectional shape along the lengths of the filaments. 
     
     
         7 . The method of  claim 6 , wherein the first average denier per filament is greater than the second average denier per filament. 
     
     
         8 .- 17 . (canceled) 
     
     
         18 . A bulked continuous filament (BCF) yarn comprising a plurality of filaments, each filament having an average denier along its length, the plurality of filaments comprising a first group of a plurality of filaments having a first average denier per filament, and a second group of a plurality of filaments having a second average denier per filament, the first average denier per filament and the second average denier per filament being different. 
     
     
         19 . The BCF yarn of  claim 18 , wherein the average deniers of the filaments in the BCF yarn vary between 2 denier per filament and 25 denier per filament. 
     
     
         20 . The BCF yarn of  claim 19 , wherein the first average denier per filament and the second average denier per filament vary less than 10% along the lengths of the filaments. 
     
     
         21 . The BCF yarn of  claim 20 , wherein the average denier per filament of the first group of filaments and the average denier per filament of the second group of filaments vary 5% or less along the lengths of the filaments. 
     
     
         22 . The BCF yarn of  claim 21 , wherein the plurality of filaments comprising the first group of the plurality of filaments and the plurality of filaments comprising the second group of the plurality of filaments have a wavelike axial cross-sectional shape along the lengths of the filaments. 
     
     
         23 . The BCF yarn of  claim 22 , wherein the first average denier per filament is greater than the second average denier per filament. 
     
     
         24 . The BCF yarn of  claim 23 , wherein the first average denier per filament is at least 1.5 times larger than the second average denier per filament. 
     
     
         25 . The BCF yarn of  claim 24 , wherein the first group of filaments are between 2% and 33% of a total number of filaments of the BCF yarn. 
     
     
         26 . (canceled) 
     
     
         27 . The BCF yarn of  claim 25 , wherein the filaments have the same radial cross-sectional shape. 
     
     
         28 . The BCF yarn of  claim 25 , wherein the first group of the plurality of filaments has a first radial cross-sectional shape, and the second group of the plurality of filaments has a second radial cross-sectional shape, wherein the first and the second radial cross-sectional shapes are different. 
     
     
         29 . (canceled) 
     
     
         30 . A carpet having a pile formed from a BCF yarn, the BCF yarn comprising a plurality of filaments, each filament having an average denier along its length, the plurality of filaments comprising a first group of a plurality of filaments having a first average denier per filament, and a second group of a plurality of filaments having a second average denier per filament, the first average denier per filament and the second average denier per filament being different. 
     
     
         31 . The carpet of  claim 30 , wherein the average deniers of the filaments in the BCF yarn vary between 2 denier per filament and 25 denier per filament. 
     
     
         32 . The carpet of  claim 31 , wherein the first average denier per filament and the second average denier per filament vary less than 10% along the lengths of the filaments. 
     
     
         33 . The carpet of  claim 32 , wherein the average denier per filament of the first group of filaments and the average denier per filament of the second group of filaments vary 5% or less along the lengths of the filaments. 
     
     
         34 .- 73 . (canceled)