Appeal 2006-2287
Application 10/631,320
Yarn, preferably synthetic, comprises at least one bundle of
fiber, the fiber being ring spun or wrap spun with a second fiber
. . . comprising a heat-activated binder material, preferably a
fiber, having a melting point range of about 105 to 190°C . . . .
The preferred fiber bundle comprise staple fibers, preferably in
the form of a sliver. . . . The present invention is also an article,
preferably . . . a carpet, made from this yarn. The present
invention is also a process of producing a yarn suitable for
tufting, the process comprising the steps of:
a. forming a bundle of fiber . . . ;
b. ring spinning or wrap spinning the bundle of fiber
with a second fiber comprising a heat-activated binder . . . ;
c. heating the yarn sufficiently to melt the binder
material; followed by
d. cooling the yarn, preferably during twist setting, to
solidify the binder material.
Bowers 3:10-31.
The Examiner contends:
While not explicitly stated, [Bowers] as a whole would have
reasonably suggested to one [sic] in the art that, although it is
desired to use a twist heat-treated yarn as a carpet face yarn,
such is not necessary as evidence from passages on page 3[,]
lines 10-31 . . . . In other words, one [sic] in the art reading
[Bowers] would have reasonably recognized and appreciated
that, twist-free heat-treated yarn of [Bowers] can effectively be
used as a carpet face yarn.
Answer 6. At the same time, the Examiner agrees with Appellant’s
contention that Bowers teaches subjecting the untwisted binder-wrapped
yarn “to a standard twist setting operation under high temperatures” while
the claimed method specifies using untwisted heat-activated wrapped singles
yarn (id. 7-8; Br., e.g., 8; see also Reply Br. 2-4).
We find Bowers would have disclosed to one of ordinary skill in this
art a method of forming a carpet which includes the step of heat treating the
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