Patent ID: 7402217

Claim:
The method of making a Saxony carpet comprising the steps: a. forming an untwisted core strand comprising at least one member selected from the group consisting of a natural or synthetic fiber; b. forming a wrapper yarn comprising at least one base synthetic fiber material, and a heat activated binder fiber having a melting point at least 20° C. lower than the base synthetic fiber; c. wrapping the wrapper yarn about the core strand, forming an untwisted wrapped singles yarn; d. heat setting the untwisted wrapped singles yarn at a temperature sufficient to melt the heated activated binder material, then subsequently cooling and solidifying said melt, thereby constricting the base synthetic fiber component of the wrapper yarn about the core strand and securing it to the core strand; e. incorporating the untwisted heat-treated yarn into a backing material as loops; f. cutting the loops to form vertical tufts; and g. dyeing and finishing.