Abstract: A method for producing a yarn for constructing non-carpet textile articles which comprises producing a large denier synthetic carpet face yarn by a bulked continuous filament or bulked crimped filament sheath-core extrusion process. The yarn has a denier of at least 300, and preferably around 1400, and is comprised of a plurality of filaments in the denier range of 10-20 denier per filament. Each filament has an outer sheath of nylon or polyester and an inner core of polyolefin, with the sheath comprising 20 to 60% of the total weight of each filament and the core constituting the remainder. The yarn, although very large by the standards applied to non-carpet textile articles, has a silky, soft feel similar to yarns composed of much smaller filaments of homopolymer nylon or polyester, and is thus well suited for the manufacture of non-carpet textile articles, such as upholstery fabrics, sweaters and the like.

Abstract: A carpet is constructed of a face yarn comprised principally of a bulked continuous filament carpet face yarn or a bulk staple carpet face yarn wherein the face yarn comprises principally a bundle of drawn and crimped bi-component filaments, and wherein each such filament consists essentially of an outer lengthwise sheath of a dyeable polymeric material surrounding a core of a different polymeric material, and wherein the two polymeric materials are not dyeable by the same method. A particularly advantageous filament structure comprises a nylon sheath surrounding a polyester core. The nylon sheath may be dyed or pigmented. For automotive and similar usage, a polyester sheath surrounding a core of, for example, polyethylene, may be preferred.