Patent Application
20230115841
This application relates to fabrics and surface coverings (e.g., floor coverings) comprising such fabrics. In some examples, fabrics can comprise conventional turf yarns and conventional carpet yarns that are associated with a primary backing. Optionally, such fabrics can be colored (e.g., printed with ink, or dyed) in accordance with a color pattern. In some examples, fabrics can comprise unpigmented natural yarns that are associated with a primary backing.
There are several existing approaches to providing color patterns within an artificial turf article. Under one approach, yarns are tufted or woven into fabric using pre-colored yarns. However, this approach requires multiple tufting operations/machines and does not permit usage of high-resolution graphics. In another approach, the face surface of an artificial turf installation can be painted (in the same way a field can be painted). However, this approach can only be used with favorable (cooperative) outdoor weather and is either performed on-site (as is usually the case) or requires pre-assembly indoors, leading to added steps and increased expense.
In yet another approach, turf panels are selectively modified at the site of installation to incorporate graphics or other visual features into the turf. More particularly, turf panels having a uniform face pattern can be cut or positioned to provide openings or other void spaces where other turf panels or turf structures having different color yarns (or other different properties) can be resized and then placed in the void spaces. After the differently patterned turf panels (or other turf structures) are manually placed in a desired configuration, the turf panels are secured together (for example, by gluing or sewing), forming seams at various locations throughout the turf structure. Conventionally, in any region of an artificial turf installation where multiple colors or patterns are required, it is contemplated that a separate panel (or other structure) or separate series of panels is required for each graphical element of the turf installation. These conventional techniques are susceptible to inconsistency in integrity, performance, and appearance, and cutting and gluing (and other installation steps), particularly when extensive, can be inefficient and uneconomical. Further, it is not possible to produce high-resolution graphics using these conventional techniques
Disclosed herein, in one aspect, is a fabric having a primary backing and a first yarn associated with the primary backing. The primary backing has a face surface and an opposing rear surface. The first yarn extends outwardly from the face surface of the primary backing in a direction moving away from the primary backing. The first yarn is a naturally colored yarn with no added pigment. The fabric can be subjected to printing or dyeing processes to impart a color pattern to fabric.
Also disclosed herein, in other aspects, is a surface covering having a backing structure that includes a primary backing. The surface covering also has a face structure and a color pattern that is applied to the face structure. The primary backing has a face surface and an opposing rear surface. The face structure can be defined by at least one yarn associated with the primary backing and extending outwardly from the face surface of the primary backing in a direction moving away from the primary backing.
Further disclosed herein, in various aspects, is a hybrid turf-carpet article having a backing structure and a plurality of yarns associated with a primary backing of the backing structure. The primary backing has a face surface and an opposing rear surface. The plurality of yarns extend outwardly from the face surface of the primary backing in a direction moving away from the primary backing. The plurality of yarns include a first yarn having a plurality of yarn filaments, wherein each yarn filament of the plurality of yarn filaments of the first yarn has a denier ranging from 61 to 3,600 denier per filament (dpf). The plurality of yarns also include a second yarn having a plurality of yarn filaments, wherein each yarn filament of the plurality of yarn filaments of the second yarn has a denier per filament (dpf) ranging from 2 dpf to 60 dpf.
Also disclosed herein, in additional aspects, is a method including forming a face structure of a fabric and applying a color pattern to the face structure of the fabric. Forming the face structure can include securing at least one yarn to a primary backing having a face surface and an opposing rear surface. The at least one yarn extends outwardly from the face surface of the primary backing in a direction moving away from the primary backing. The at least one yarn includes a first yarn that is an unpigmented natural yarn, and the color pattern is applied to the face structure formed by the at least one yarn.
Further disclosed herein, in additional aspects, is a method including forming a face structure of a fabric and applying a color pattern to the face structure of the fabric. Forming the face structure can include securing a plurality of yarns to a primary backing having a face surface and an opposing rear surface. The plurality of yarns extend outwardly from the face surface of the primary backing in a direction moving away from the primary backing. The plurality of yarns include: a first yarn having a plurality of yarn filaments, wherein each yarn filament of the plurality of yarn filaments of the first yarn has a denier ranging from 61 to 3,600 denier per filament (dpf); and a second yarn having a plurality of yarn filaments, wherein each yarn filament of the plurality of yarn filaments of the second yarn has a denier per filament (dpf) ranging from 2 to 60 dpf. The color pattern is applied to the face structure formed by the plurality of yarns.
Additional advantages of the invention will be set forth in part in the description that follows, and in part will be obvious from the description, or may be learned by practice of the invention. The advantages of the invention will be realized and attained by means of the elements and combinations particularly pointed out in the appended claims. It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the invention, as claimed.
It should be understood that the drawings provided herein are not necessarily to scale. Rather, the drawings are formatted to help aid the understanding of certain features disclosed herein. For example, the relative sizes of the depicted tufts and backing materials shown in the figures are not necessarily indicative of what would be seen in the tufted articles disclosed herein.
The disclosed system and method may be understood more readily by reference to the following detailed description of particular embodiments and the examples included therein and to the Figures and their previous and following description.
It is to be understood that the terminology used herein is for the purpose of describing particular embodiments only and is not intended to limit the scope of the present invention which will be limited only by the appended claims.
It must be noted that as used herein and in the appended claims, the singular forms “a,” “an,” and “the” include plural references unless the context clearly dictates otherwise. Thus, for example, reference to “a tuft” includes one or more of such tufts, and so forth.
“Optional” or “optionally” means that the subsequently described event, circumstance, or material may or may not occur or be present, and that the description includes instances where the event, circumstance, or material occurs or is present and instances where it does not occur or is not present.
Ranges may be expressed herein as from “about” one particular value, and/or to “about” another particular value. When such a range is expressed, also specifically contemplated and considered disclosed is the range from the one particular value and/or to the other particular value unless the context specifically indicates otherwise. Similarly, when values are expressed as approximations, by use of the antecedent “about,” it will be understood that the particular value forms another, specifically contemplated embodiment that should be considered disclosed unless the context specifically indicates otherwise. It will be further understood that the endpoints of each of the ranges are significant both in relation to the other endpoint, and independently of the other endpoint unless the context specifically indicates otherwise. Finally, it should be understood that all of the individual values and sub-ranges of values contained within an explicitly disclosed range are also specifically contemplated and should be considered disclosed unless the context specifically indicates otherwise. The foregoing applies regardless of whether in particular cases some or all of these embodiments are explicitly disclosed.
Optionally, in some aspects, when values are approximated by use of the antecedents “about,” “substantially,” or “generally,” it is contemplated that values within up to 15%, up to 10%, up to 5%, or up to 1% (above or below) of the particularly stated value or characteristic can be included within the scope of those aspects.
As used herein, the definition of the term “color” is referenced in terms of the CIELAB color scale, which was created by the International Commission on Illumination (CIE). The CIELAB color scale provides a uniform scale for measuring and comparing the color values of different samples. Three different color measurements are used to determine the CIELAB color value of a given sample: 1) a white-black color measurement; 2) a red-green color measurement; and 3) a yellow-blue color measurement. The white-black color measurement represents the amount of white present in the sample relative to the amount of black present in the sample. The red-green color measurement represents the amount of red present in the sample relative to the amount of green present in the sample. The yellow-blue color measurement represents the amount of yellow present in the sample relative to the amount of blue present in the sample. CIELAB color scale values can be obtained using color measurement instruments known in the art, including, for example, HunterLab color measurement instruments. When two “colors” are referred to as being the same or “substantially” the same or matching or “substantially” matching, it should be understood that each of the three color measurements (in the CIELAB scale) for the colors being compared are equal or substantially equal.
The term “backing structure” as used herein can include both primary backing materials and secondary backing materials. The term “backing structure” refers to any conventional backing material that can be associated with yarn to define a fabric as disclosed herein. Exemplary backings can be a woven material, a non-woven material, a knitted material, a needle punched fabric, as well as a stitch bonded primary backing material or any other fabric formation layer needed to hold yarn in place during the fabric pile formation process. As one skilled in the art will appreciate, materials such as polypropylene, polyesters, hemp, composites, blend, nylons, or cottons can be used to form the backing material. As used herein, the term “primary backing” refers to conventional backing materials that serve as the carrier for yarn. For example, in conventional tufting processes, the backing layer is the component into which pile yarn tufts are inserted by tufting needles. Exemplary primary backing materials include woven or nonwoven polypropylene. Optionally, in woven or knitted surface coverings, it is contemplated that woven or knitted yarns can form a primary backing from which upper pile yarns extend.
The term “yarn” as used herein refers to a continuous strand or bundle of fibers. Such yarns can include, for example and without limitation, monofilament yarns, cut yarns, looped yarns, fibrillated yarns, multifilament yarns, twisted yarns, wrapped yarns, staple yarns, and the like. Optionally, yarns can be textured using conventional methods. “Yarns” as disclosed herein are capable of being independently delivered to a backing structure (for example, via tufting). A yarn can be a single end yarn (single ply yarn) or a multiple end yarn (e.g., a plied yarn) that includes plurality of single end yarns that are entangled or otherwise commingled with one another (for example, by air entanglement, twisting, wrapping, and the like) such that the single end yarns are no longer individually or independently moveable. For example, a plurality of single end yarns can be twisted together to form a plied yarn (e.g., a two-ply yarn can include two single end yarns that are twisted together). In some aspects, the plurality of single end yarns can be air-entangled to form a multiple end yarn. In some aspects, the plurality of single end yarns can be roto-twisted to form a multiple end yarn. In some aspects, the plurality of single end yarns can be air-twisted to form a multiple end yarn. Each single end yarn can be formed from at least one filament (optionally, a plurality of filaments). Thus, within a multiple end yarn, each single end yarn that makes up the multiple end yarn can include a respective filament or plurality of filaments. Further, in some optional aspects, yarns can further be entangled or otherwise commingled with one another (for example, by air entanglement, twisting, wrapping, and the like) in order to form a multiple yarn structure.
As used herein, the term “denier” refers to the weight in grams of 9,000 meters of yarn. “Denier per filament” refers to the denier (weight in grams of 9,000 meters) of a single filament of a yarn. When the yarn consists of a single end yarn, the “total denier” of the yarn can refer to the combined denier (i.e., the sum of the respective deniers) of all filaments of the single end yarn. When the yarn includes a plurality of yarn ends (a plurality of single end yarns) that are entangled or otherwise commingled with one another such that the yarn ends are no longer individually or independently moveable, then the “total denier” of the yarn can refer to the combined denier (i.e., the sum of the respective deniers) of the plurality of yarn ends (the plurality of single end yarns that define the multiple end yarn).
The total denier, denier per fiber (dpf), and ply information can be used to determine the number of filaments within a given yarn. As a first example, a single-ply yarn can be identified as a 6000/4 dpf yarn. This indicates that the single-ply yarn has a total denier of 6000, and that each filament of the single-ply yarn has a denier (per filament) of 4. The total number of filaments can be determined by dividing the total denier (6000) by the dpf (4), producing a result of 1500 filaments within the yarn. Rather than identifying the yarn as a 6000/4 dpf yarn, it is contemplated that the yarn can instead be identified as a 6000/1500 filament yarn (with the dpf being determined by dividing the total denier (6000) by the number of filaments (1500)).
As another example, consider a two-ply yarn that has the same total denier (6000) but is formed by twisting or otherwise commingling two of the same single-end yarns. Such a yarn can be identified as a 3000×2 yarn, which indicates that the yarn is a two-ply yarn, with each ply corresponding to a single-end yarn having a total denier of 3000. If the dpf of each of the single-end yarns is 15, then the number of filaments of each of the single-end yarns can be calculated by dividing the total denier (3000) by the dpf (15), producing a result of 200 filaments within each of the single-end yarns. Therefore, the total number of filaments within the two-ply yarn can be determined to be 600 (the sum of the number of filaments within the two single-end yarns that make up the two-ply yarn).
In yet another example, consider a yarn formed by twisting or otherwise commingling two different single-end yarns to form a yarn bundle. The yarn bundle can include a first single-end yarn that is a 3000/15 dpf yarn and a second single-end yarn that is a 3000/4 dpf yarn. This indicates that the first single-end yarn has a total denier of 3000, with each filament of the yarn having a denier (per filament) of 15. The second single-end yarn has a total denier of 3000, with each filament of the yarn having a denier (per filament) of 4. Thus, the first single-end yarn has 200 filaments (with each filament having a denier of 15 to provide a total denier of 3000), while the second single-end yarn has 750 filaments (with each filament having a denier of 4 to provide a total denier of 3000).
Unless defined otherwise, all technical and scientific terms used herein have the same meanings as commonly understood by one of skill in the art to which the disclosed apparatus, system, and method belong.
Throughout the description and claims of this specification, the word “comprise” and variations of the word, such as “comprising” and “comprises,” means “including but not limited to,” and is not intended to exclude, for example, other additives, components, integers or steps. In particular, in methods stated as comprising one or more steps or operations it is specifically contemplated that each step comprises what is listed (unless that step includes a limiting term such as “consisting of”), meaning that each step is not intended to exclude, for example, other additives, components, integers or steps that are not listed in the step.
It is to be understood that unless otherwise expressly stated, it is in no way intended that any method set forth herein be construed as requiring that its steps be performed in a specific order. Accordingly, where a method claim does not actually recite an order to be followed by its steps or it is not otherwise specifically stated in the claims or descriptions that the steps are to be limited to a specific order, it is in no way intended that an order be inferred, in any respect. This holds for any possible non-express basis for interpretation, including: matters of logic with respect to arrangement of steps or operational flow; plain meaning derived from grammatical organization or punctuation; and the number or type of aspects described in the specification. Thus, words denoting order, such as “first” or “next,” should be interpreted as optional aspects unless plain meaning or logic dictates otherwise.
Throughout the specification, first and second yarns are described as associated with a backing. Optionally, these yarns can be independently threaded into a single needle and then simultaneously associated with (e.g., tufted through or knit or woven into) the backing. In other aspects, the first and second yarns can be entangled and then pulled through the same needle together as an entangled structure and then simultaneously associated with (e.g., tufted through or knit or woven into) the backing. In still other aspects, the first and second yarns can be tufted through respective needles and then associated with (e.g., tufted through or knit or woven into) the backing.
Disclosed herein, with reference to
In exemplary aspects, and with reference to
In various optional aspects, it is contemplated that the first yarn 30a can be formed into a plurality of yarn tufts 40 that extend through the primary backing 12. Optionally, and with reference to
As shown in
As shown in
Although depicted in the drawings as comprising cut tufts, it is contemplated that the tufts of the fabrics 10 can comprise cut tufts, loop tufts, or combinations thereof. Each tuft 40 of the plurality of tufts can comprise at least one outwardly extending tuft portion 42 (positioned above the primary backing) and a backstitch 44 connected to the at least one outwardly extending tuft portion. In exemplary aspects, when the plurality of tufts comprise cut tufts, each yarn tuft 40 of the plurality of yarn tufts can have at least one pair of outwardly extending tuft portions 42 (positioned above the primary backing and formed by a respective cut) that are joined by a backstitch 44 (positioned beneath or within the primary backing). When a tuft 40 comprises a single yarn, it is contemplated that the tuft can comprise a single pair of tuft portions 42, which are joined by a single backstitch 44. However, when a tuft 40 comprises a plurality of yarns (for example, two or three yarn ends that are delivered concurrently through a backing by a single needle through which each of the two or three yarn ends is threaded), then the tuft can comprise a plurality of pairs of tuft portions 42 (one pair for each yarn), with each pair of tuft portions being joined by a respective backstitch portion.
In further aspects, it is contemplated that the yarn 30 of the fabric 10 can be woven into the primary backing 12 using conventional methods. For example, in these aspects, it is contemplated that first and second yarns 30a, 30b can be woven into the primary backing 12. Thus, rather than defining a plurality of tufts, it is contemplated that woven fabrics can comprise yarn 30 that defines pile structures moving outwardly from the primary backing. Optionally, in woven fabrics, it is contemplated that a portion of the woven yarns can form the primary backing from which upper pile yarns extend.
In still further aspects, it is contemplated that the yarn 30 of the fabric 10 can be knitted into the primary backing 12 using conventional methods. For example, in these aspects, it is contemplated that first and second yarns 30a, 30b can be knitted into the primary backing 12. Thus, rather than defining a plurality of tufts, it is contemplated that knitted fabrics can comprise yarn 30 that defines pile structures moving outwardly from the primary backing. Optionally, in knitted fabrics, it is contemplated that a portion of the knitted yarns can form the primary backing from which upper pile yarns extend.
Although exemplary structures for associating yarn 30 with a primary backing 12 are disclosed herein (e.g., tufting, weaving, knitting), it is contemplated that any conventional mechanical or structural association between the yarn 30 and the primary backing 12 can be employed.
In exemplary aspects, the first yarn 30a can comprise a plurality of yarn filaments 32. In these aspects, each yarn filament 32 of the plurality of yarn filaments of the first yarn 30a can have a denier ranging from 61 to 3600 denier per filament (dpf), such as is typically found in an artificial turf yarn. Optionally, in these aspects, it is contemplated that each yarn filament 32 of the plurality of yarn filaments of the first yarn 30a can have a denier ranging from 61 to 1000 dpf or from 61 to 750 dpf or from 400 to 600 dpf. However, it is contemplated that other dpf values can be used depending on the particular application and desired performance properties.
In further aspects, it is contemplated that the second yarn 30b can comprise a plurality of yarn filaments 32. In these aspects, each yarn filament 32 of the plurality of yarn filaments of the second yarn 30b can have a denier per filament (dpf) ranging from 2 to 60 dpf, such as is typically found in a carpet yarn. Optionally, in these aspects, each yarn filament 32 of the plurality of yarn filaments of the second yarn 30b can have a denier per filament (dpf) ranging from 6 to 60 dpf or from 10 to 40 dpf. Thus, in some aspects, it is contemplated that at least one yarn of the fabric 10 can comprise a turf yarn, while at least one other yarn of the fabric can comprise a carpet yarn. Accordingly, in these aspects, the fabric 10 can function as a hybrid turf-carpet article, providing a combination of the properties offered (separately) by turf and carpet products. For example, it is contemplated that turf yarns can impart desired performance/durability properties, while carpet yarns can impart desired softness and texture properties. As further disclosed herein, it is further contemplated that turf or carpet properties can be selectively emphasized or deemphasized by controlling various properties of the yarns. It is contemplated that the first and second yarns 30a, 30b can comprise any desired number of filaments 32, such as, for example, 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 36, 48, 96, or up to 4000 individual filaments per yarn (for either the first yarn 30a or the second yarn 30b).
Optionally, in some exemplary aspects, it is contemplated that the yarn filaments 32 of the second yarn 30b can have a dpf ranging from 2 to 32. In these aspects, it is contemplated that the second yarn 30b can be a conventional residential carpet yarn as is known in the art.
Optionally, in some exemplary aspects, it is contemplated that the yarn filaments 32 of the second yarn 30b can have a dpf ranging from 22 to 60. In these aspects, it is contemplated that the second yarn 30b can be a conventional commercial carpet yarn as is known in the art.
As described above, in some exemplary aspects, the first and second yarns can be provided within each respective tuft or pile extending through the primary backing of the fabric. In one exemplary process, yarn is hung on a creel and then the two yarn ends 30a, 30b are fed through respective tubes until reaching a guide structure immediately before the needle bar of the tufting machine. At the guide structure, the two yarns are fed together through one guide hole, and both yarns can be delivered at the same rate to each needle of a tufting machine. Two ends per needle can be tufted with adjustments made for tension so that the two yarns will pick up on the hooks for cutting. Optionally, one of the yarns can be straight-set, and one of the yarns can be texturized, so adjustments for tension can be necessary to ensure successful tufting. Alternatively, in other exemplary processes, the two yarns can pass through the same tubes all the way to the needles for tufting. It is contemplated that the needle size and the hole or eye of the needle can be selected based on the gauge and the density that is desired for the final article.
In some aspects, when the first and second yarns form respective pluralities of tufts, it is contemplated that the fabric can be tufted using two needle bars with the first and second yarns being fed separately to a respective needle bar. The tufting settings of the first and second yarns can be selectively adjusted up or down to produce desired aesthetics. In exemplary aspects, the tufting machine can comprise dual tufting needle bars with separate needles for each of the two yarns. One needle bar can be tufting a higher pile and the second needle bar can tuft a lower pile in the rows in between the higher tufts.
Optionally, and as further disclosed herein, the first and second yarns are not entangled or otherwise commingled with one another (for example, by air entanglement, twisting, wrapping, and the like) such that the first and second yarns are no longer individually or independently moveable. Thus, in these aspects, it is contemplated that the first and second yarns can optionally be provided from separate yarn cones/packages.
In other aspects, the first and second yarns can be entangled or otherwise commingled with one another (for example, by air entanglement, twisting, wrapping, and the like) to form a multiple yarn structure 60 such that the first and second yarns are no longer individually or independently moveable. Advantageously, in these aspects, the first and second yarn ends can be formed into, and be provided as, a single yarn cone/package. Further, it is contemplated that the multiple yarn structure 60 can be threaded into a single needle. Accordingly, handling (e.g., transportation and threading) of the first and second yarns (and any additional commingled yarns) can be simplified.
Although first and second yarns are described in detail herein, it is contemplated that any desired number of different yarns can be provided within a fabric as disclosed herein. For example, referring to
In some aspects, the first yarn 30a can be a first type of yarn, and the second and third yarns 30b,c can both be a second type of yarn. For example, in some aspects, the first yarn can be or comprise a conventional turf yarn (e.g., monofilament yarn), and the second and third yarns 30b,c can be or comprise conventional carpet yarns (e.g., optionally, having a denier per filament (dpf) ranging from 2 dpf to 60 dpf).
In various optional embodiments, it is contemplated that the second and third yarns 30b,c can be the same type of yarn. Accordingly, in these embodiments, for the sake of conciseness, the disclosure herein describing specific embodiments for the second yarn should be understood as also describing specific embodiments for the third yarn 30c, which is the same type of yarn as the second yarn 30b.
In other optional aspects, the second and third yarns 30b,c can be different types of yarn. Thus, in some optional aspects, each of the first, second, and third yarns 30a,b,c can be a different type of yarn.
Optionally, the first, second, and third yarns 30a,b,c can be entangled or otherwise commingled with one another to form a multiple yarn structure. In other aspects, the first, second, and third yarns are not commingled and, thus, can be independently moveable relative to each other. For example, the first, second, and third yarns 30a,b,c can be threaded through a single needle. In other aspects, each of the first, second, and third yarns 30a,b,c can be independently tufted through, or otherwise associated with, the backing.
In exemplary aspects, it is contemplated that each yarn filament 32 of the first yarn 30a can be a monofilament. Optionally, in these aspects, each yarn filament 32 of the first yarn 30a can be a 100% nylon monofilament. In these aspects, it is contemplated that the nylon of the first yarn can be nylon-6, nylon-6,6, or other conventional forms of nylon. In some optional aspects, it is contemplated that the yarn 30 of the fabric 10 can consist of a single yarn, wherein each filament of the yarn is a monofilament. In some aspects, one or more yarns 30 can be turf tape or monofilament blade yarn.
In other exemplary aspects, the first yarn 30a can consist of nylon. In further exemplary aspects, it is contemplated that each filament 32 of the first yarn 30a can comprise a continuous filament.
As described above, in exemplary aspects, the yarn filaments 32 of the first yarn 30a can optionally be unpigmented natural filaments. In these aspects, it is contemplated that the first yarn 30a can be solution-dyed on a “natural” setting without color pigment added during extrusion. In other aspects, the first yarn 30a can comprise color pigment added during extrusion and/or be dyed (e.g., via solution dying) prior to tufting, knitting, weaving, or otherwise integrating the first yarn with the fabric 10.
In exemplary aspects, it is contemplated that the first yarn 30a can be a 4400/8 monofilament yarn, having a total denier of 4400 and a dpf of 550 (with a total of 8 monofilaments provided within the yarn). In another example, the first yarn 30a can be a 4400/16 monofilament yarn, having a total denier of 4400 and a dpf of 275 (with a total of 16 monofilaments provided within the yarn). In yet another example, the first yarn 30a can be a 4400/32 yarn, with a total denier of 4400 and a dpf of 137.5 (with a total of 32 monofilaments provided within the yarn). In yet another example, the first yarn 30a can be a 6600/8 monofilament yarn, with a total denier of 6600 and a dpf of 825 (with a total of 8 monofilaments provided within the yarn). In yet another example, the first yarn 30a can be a 6600/12 monofilament yarn, with a total denier of 6600 and a dpf of 550 (with a total of 12 monofilaments provided within the yarn). In still another example, the first yarn 30a can be a can be a 6600/24 monofilament yarn, with a total denier of 6600 and a dpf of 275 (with a total of 24 monofilaments provided within the yarn). More generally, it is contemplated that any desired total denier can be used for the first yarn 30a, provided the individual monofilaments of the first yarn have a dpf that is consistent with conventional turf yarns. Optionally, in exemplary aspects, the first yarn can have a total denier ranging from about 1,000 to about 15,000 or from about 3,000 to about 8,000 or from about 4,000 to about 7,000.
It is contemplated that the cross sectional profile of each filament of the first yarn 30a can be any shape that is conventionally used for turf yarns. For example, in some exemplary aspects, each filament of the first yarn 30a can have a cross-sectional profile comprising a diamond shape, a serrated diamond shape, a half-moon shape, or an oval or round shape. However, it is contemplated that any desired cross-sectional profile can be used. It is further contemplated that the first yarn 30a can have desirable durability and colorfastness properties.
As explained above, in exemplary aspects, the yarn 30 of the fabric 10 can comprise a conventional turf yarn (such as first yarn 30a) and a conventional carpet yarn (such as second yarn 30b and, optionally, the third yarn 30c). In exemplary fabrics, the second yarn can comprise nylon (e.g., nylon-6 or nylon-6,6), polyester, or polypropylene. In one example, the second yarn 30b can comprise a 1362/2 ply (1362×2) continuous filament nylon yarn, with a total denier of 2724. As another example, the second yarn 30b can comprise solution dyed nylon 1350/5 ply (1350×5) yarn, with a total denier of 6,750. In these examples, it is contemplated that each ply of the yarns can comprise any desired number of filaments, with the dpf remaining below 60. In various aspects, it is contemplated that each filament 32 of the second yarn 30b can be either a continuous filament or a non-continuous filament.
In some exemplary aspects, it is contemplated that at least one of the first yarn 30a or the second yarn 30b can be a multiple end yarn formed from at least two distinct single end yarns (at least two ply). In these aspects, it is contemplated that at least two distinct single end yarns that form the multiple end yarn can have different dpf values that allow for creating distinct visual effects. For example, it is contemplated that the first yarn can comprise a first yarn end having a 65 dpf value and a second yarn end having a 65 dpf value, wherein both the first and second yarn ends consist of monofilaments. It is further contemplated that the second yarn can comprise a first yarn end having a 2 dpf value and a second yarn end having a 30 dpf value.
In exemplary aspects, it is contemplated that the materials of the yarns 30 of the fabric 10 can be selected based upon the intended use of the fabric. For example, nylon, PP, PE and PET are all suitable for indoor use, but nylon and PET will not hold up as well as PP or PE during outdoor use. However, for printing or dyeing yarns as disclosed herein, it is contemplated that special dyes or paints can be needed to impart color to PP and PE yarns. In some aspects, it is contemplated that one of the yarns can comprise PP and/or PE yarns while another of the yarns can comprise nylon. In these aspects, it is contemplated that during a printing or dyeing process, color can be imparted to the nylon yarn while color is not imparted to the PP and/or PE yarns (due to the absence of the special dyes or paints needed to impart color to PP and/or PE yarns), thereby producing unique face appearances. Thus, in some aspects, the color patterns disclosed herein do not impart color to some of the face yarns, even if paint or dye is applied to those face yarns.
It is contemplated that the cross sectional profile of each filament of the second yarn 30b can be any shape that is conventionally used for carpet yarns. For example, in some exemplary aspects, the filaments of the second yarn 30b can each have a cross-sectional profile having a tri-lobal shape as is known in the art. It is contemplated that the cross-sectional profile of the filaments of the second yarn 30b can be selected to impart desired luster, firmness/softness, resiliency, and other properties. It is contemplated that the yarn density of the fabrics can determine the final surface interactions between the yarns and a ball or a human when the fabric is used in a flooring/playing surface installation. For example, the yarn density can be modified to provide a desired amount of friction when the yarn interacts with shoes. In further aspects, it is contemplated that yarn densities can be varied along the surface of the fabric. For example, in these aspects, it is contemplated that the yarn density can change at locations where the face structure of the fabric changes (e.g., a change in color, yarn type, bulkiness, pile heights, and the like). In exemplary aspects, as further disclosed herein, it is contemplated that a pad (e.g., a polyurethane pad) can be added to the fabric at locations where carpet surface properties change, thereby increasing human safety.
It is contemplated that the first and second yarns 30a, 30b of the fabric 10 can be colored in any desired manner prior to the application of a color pattern as further disclosed herein. For example, as further explained herein, the first yarn 30a can be an unpigmented natural yarn that is not pre-dyed, while the second yarn 30b can be pre-dyed. In another example, both the first yarn 30a and the second yarn 30b can be pre-dyed or solution-dyed. In exemplary aspects, it is contemplated that the first yarn 30a and the second yarn 30b can be dyed the same color to produce a solid look or dyed two different colors to produce a tweed look. As yet another example, it is contemplated that both the first yarn 30a and the second yarn 30b can be unpigmented natural yarns. As yet another example, it is contemplated that both the first yarn 30a and the second yarn 30b can be pigmented yarns.
It is further contemplated that the cross-sectional shapes and/or sizes of the yarns can be selectively varied to modify color and texture as further disclosed herein.
In exemplary aspects, the primary backing 12 can comprise any conventional backing materials. Optionally, in these aspects, the primary backing 12 can be formed from polypropylene, PET, woven material, non-woven material, spun-bond material, melt-blown material, air-laid material, air-formed material, or combinations thereof.
In various aspects, a method of forming a surface covering can comprise forming a face structure of a fabric. In these aspects, the method can comprise securing at least one yarn to (or otherwise associating at least one yarn with) the primary backing such that the at least one yarn extends outwardly from the face surface of the primary backing in a direction moving away from the primary backing.
As further described herein, the fabric can optionally comprise a plurality of yarn tufts, which can include cut tufts, loop tufts, or combinations thereof. In exemplary aspects, the step of forming the face structure can comprise passing the at least one yarn through the primary backing to define the plurality of yarn tufts.
As further described herein, the fabric can optionally comprise a woven fabric. Therefore, in exemplary aspects, the step of forming the face structure can comprise weaving the first yarn (optionally, a plurality of yarns) into the primary backing.
As further described herein, the fabric can optionally comprise a knitted fabric. Therefore, in exemplary aspects, the step of forming the face structure can comprise knitting the first yarn (optionally, a plurality of yarns) into the primary backing.
Optionally, at least one yarn of the fabric can comprise a plurality of yarn filaments, wherein each yarn filament of the plurality of yarn filaments is an unpigmented natural yarn as further disclosed herein. In some exemplary aspects, at least one yarn (optionally, a plurality of yarns) of the fabric can comprise (optionally, consist of) yarn filaments that are unpigmented natural filaments. In still other aspects, it is contemplated that at least one yarn of the fabric (optionally, each yarn of the fabric) can be pre-colored (optionally, pre-dyed) prior to formation of the fabric. In still other aspects, it is contemplated that at least one yarn of the fabric can be an unpigmented natural yarn, while at least one other yarn of the fabric can be a pre-colored (optionally, pre-dyed) yarn. As yet another example, it is contemplated that all yarns of the fabric can be pigmented yarns.
As shown in
The backing can be provided on a backing feed roll 214 that is configured to feed the backing through the tufting machine(s). As shown in
One or more controllers 220 can be communicatively coupled to the tufting machine(s) 202. It is contemplated that the controller 220 as illustrated can be embodied as a plurality of controllers, each having a memory in communication with a processor, wherein the plurality of controllers cooperatively control the system 200 to form the tufted articles as disclosed herein. For example, in some aspects, each tufting machine 202 can be in communication with a respective controller 220. Alternatively, it is contemplated that a single controller (with a central memory in communication with a central processor) can be configured to control operation of each tufting machine.
The controller 220 can be configured to cause each tufting machine, which can have at least one respective needle bar supporting a plurality of needles, to selectively control tufting of yarn into the backing to produce the plurality of tuft sequences. Thus, it is contemplated that each needle of the tufting machine can be configured to selectively form a tuft (or a tuft sequence). For example, each needle of the tufting machine can be independently and selectively actuated to penetrate the backing to form a tuft or tuft sequence. While some needles are actuated to deliver yarn through a backing to form respective tuft sequences, other needles of the tufting machine are not instructed to deliver yarn through the backing. Examples of tufting machines having such independently controllable needles are well known and have not been discussed in detail herein. Optionally, the needles 206 can be operatively associated with a conventional needle bar as is known in the art. In alternative aspects, it is contemplated that the needles of a respective tufting machine can be divided among a plurality of needle modules as further disclosed herein. In these aspects, it is contemplated that each needle module of the plurality of needle modules can have a plurality of needles that are independently moveable relative to the needles of other needle modules of the plurality of needle modules, thereby limiting the number of needles that need to move for a given tufting cycle and providing less wear and tear on the tufting equipment. Although not shown herein, it is contemplated that the system 200 can further comprise loopers and/or cutting assemblies as are conventionally used to pull and/or cut tufts. In exemplary aspects, the needle bar assemblies (and, optionally, the looper assemblies) can be controlled by servo motors (optionally, in communication with the controller 220) as are known in the art.
The controller 220 can comprise at least one processor and memory with instructions thereon. The at least one processor can be configured to execute instructions that cause the tufting machine(s) to selectively form tufts that produce a plurality of patterned regions as disclosed herein. For example, the controller can cause each needle of the tufting machine to selectively form tuft sequences or not form tuft sequences as the backing is moved along the first axis 210. In this way, the controller can be configured to cause the tufting device to form a plurality of tuft sequences, with the tufts of each tuft sequence being formed sequentially by a single needle. The controller can be configured to cause the tufting machine(s) 202 to form tuft sequences that are spaced from other along at least one of the first axis 210 and the second axis 212.
In some aspects, the memory of the controller can comprise instructions that when executed by the at least one processor, cause the processor to generate a tufting pattern comprising at least one tufting parameter for a plurality of patterned regions. The parameter(s) can comprise a spacing between adjacent tuft sequences relative to the second axis, a tuft sequence length, a number of tufts per tuft sequence, a tuft pile height, and a yarn type.
In some aspects, the first tufting machine can be rotationally offset from the second tufting machine. For example, each tufting machine can have a longitudinal axis 230 along which each needle is spaced. It is contemplated that the longitudinal dimension of a first tufting machine 202a can optionally be oblique (at an acute or obtuse angle) with respect to the longitudinal axis 230 of a second tufting machine 202b.
It is further contemplated that the plurality of needles 206 of each tufting machine can optionally be spaced relative to each other adjacent needle by a select gauge relative to the longitudinal axis of the tufting machine. It is contemplated that the select gauge of the first tufting machine 202a can be optionally be greater or less than the select gauge of the second tufting machine 202b.
In some optional aspects, it is contemplated that the first tufting machine can be configured to form stitch sequences having stitches of a first stitch length, and the second tufting machine can be configured to form stitches having a second stitch length that is optionally different (i.e., greater than or less than) the first stitch length.
In some optional aspects, it is contemplated that a rotational orientation of the first tufting machine 202a can be offset from a rotational orientation of the second tufting machine 202b by 180 degrees. In these aspects, it is contemplated that the direction of movement of the backing relative to the first tufting machine can be opposite the direction of movement of the backing relative to the first tufting machine.
In some aspects, the system 200 can further comprise a coating machine 240 that is configured to apply a coating (e.g., optionally, polyurethane) on backstitches of the tufted article. After curing, the tufts of the article can be securely locked in place. For example, at least one nozzle 242 (optionally, a plurality of nozzles) can be configured to spray a coating on at least a portion of the backstitches of the tufted article.
In exemplary aspects, the system 200 can further comprise one or more creel assemblies 270 that support yarn packages can be positioned to the sides of or above the plurality of tufting machines. It is contemplated that different sections of the creel assemblies 270 can have different yarn types and/or different color yarns, the distribution of which among the plurality of needles of the tufting machines can be monitored by the controller 220 to determine particular needles or groups of needles that should deliver yarn within a particular tufting zone to achieve a selected tufting pattern. In further aspects, the system 200 can comprise a yarn delivery assembly 260 that is configured to deliver yarn from the creel assemblies 270 to respective needles of the tufting machines. In these aspects, it is contemplated that the yarn delivery assembly 260 can optionally comprise conventional yarn delivery tubes as are known in the art. It is contemplated that the needles of each tufting machine can be configured to receive different yarns than other needles of the same tufting machine. For example, it is contemplated that the needles of at least one tufting machine can comprise a first plurality of needles that receive a yarn having a first color and a second plurality of needles that receive yarn having a second color that is different than the first color. It is contemplated that the selection of yarn color and other yarn color characteristics can vary from needle-to-needle, both within a single tufting machine and among the plurality of tufting machines.
In additional aspects, the tensioning apparatus 250 can comprise a frame, a pair of laterally spaced endless chains, and a plurality of pin rollers that are configured to control application of longitudinal tension to the backing. Optionally, it is contemplated that the plurality of pin rollers can operate independently of one another. It is further contemplated that sets of such pin rollers can be positioned in between each pair of sequential tufting machines (gantries) to maintain a consistent application of tension throughout the tufting process. An exemplary tensioning apparatus can be a tenter apparatus having a frame, endless chains, and gripping pins as disclosed in U.S. Pat. No. 8,695,519, which is incorporated herein by reference in its entirety.
In exemplary aspects, and with reference to
In exemplary aspects, the tensioning apparatus 250 can have an upper level 252, a lower level 254, and a return section 256 that defines a transition between the upper level 252 and the lower level 254. After a tufting process has been completed (when the backing has passed through each tufting machine of the system), the tufted article can be delivered to the coating machine 240 as disclosed herein. As shown in
Although shown as providing a continuous pathway for movement of the backing through the tufting process, it is contemplated that the at least one tensioning apparatus 250 can comprise a plurality of tensioning apparatuses that are each associated with a respective tufting machine.
In use, it is contemplated that the tensioning apparatus 250 can ensure that the operative width of the backing of the fabric 10 remains within a selected tolerance from the start of the tufting process to the finish of the tufting process (after coating has been applied to the backstitches). In exemplary aspects, the selected tolerance can be less than or equal to ⅓ inch. This close control of the operative width of the backing ensures that the alignment of the backing relative to the needles of a first tufting machine is the same or generally the same as the alignment of the backing relative to the needles of a second tufting machine, thereby ensuring that each needle of each tufting machine of the plurality of tufting machines is able to reliably deliver tufts within or substantially within a particular row of tufts within a tufting pattern for a tufted article. For example, a first tufting machine can be programmed to deliver a series of tufts having a first profile (color, pile height, yarn type, and the like) within a given row, and a second tufting machine can be programmed to deliver a second series of tufts having a second profile within the same row, with the first profile being different than the second profile. The reliability and consistency of the operative width of the backing throughout the process can ensure that the second series of tufts is delivered within or substantially within the same row that the first series of tufts was delivered. This principle applies for each row of tufts and across all tufting machines, thereby providing the system with the ability to selectively deliver tufts at any location within any row as the backing passes through each respective tufting machine.
Optionally, in addition to being in communication with the plurality of tufting machines, the controller 220 can be in communication with one or more of the backing feed roll 214, the tensioning apparatus 250, the coating machine 240, or the yarn delivery assembly 260 to selectively control movement of the backing, application of coating material to the backstitches of the tufted article, and/or delivery of yarn to the tufting machines.
In exemplary aspects, a method of manufacturing a tufted article as disclosed herein can comprise tufting the plurality of tufts through the backing. In these aspects, tufting the plurality of tufts through the backing can comprise using a plurality of sequentially positioned tufting machines to tuft respective portions of the plurality of tufts, with each tufting machine defining a respective tufting zone.
In further aspects, each tuft of the plurality of tufts can have a backstitch. In these aspects, and as further disclosed herein, the method can further comprise applying a coating over the backstitches of the plurality of tufts.
Optionally, in exemplary aspects, the tufting zones of the plurality of sequentially positioned tufting machines are positioned along a machine axis corresponding to a direction of movement of the backing through the tufting machines. Optionally, in some aspects, the tufting zone of at least one tufting machine of the plurality of tufting machines can be spaced from the tufting zone of at least one other tufting machine of the plurality of tufting machines along a transverse axis that is perpendicular to a direction of movement of the backing through the tufting machines. In these aspects, the method can comprise shifting the backing along the transverse axis such that at least a portion of the backing passes through the tufting zone of each tufting machine, in either a continuous or non-continuous manner.
In exemplary aspects, when at least one tufting machine comprises a needle bar assembly having a plurality of needle modules, the step of tufting the plurality of tufts can comprise using a selected number of needle modules of said at least one tufting machine to deliver yarn to the backing. In these aspects, it is contemplated that the selected number of needle modules can be less than a total number of needle modules of said at least one tufting machine. It is further contemplated that at least one needle module of the plurality of needle modules of said at least one tufting machine may not deliver yarn to the backing during tufting.
In further exemplary aspects, when each tufting machine of the plurality of sequentially positioned tufting machines comprises a gantry, the method can further comprise using a tensioning apparatus (or a plurality of tensioning apparatuses) to deliver the backing through one or more of the gantries of the plurality of sequentially positioned tufting machines. Optionally, as further disclosed herein, the tensioning apparatus can drive movement of the backing in a serpentine pattern comprising peaks when the backing passes through the gantry of a respective tufting machine and valleys when the backing is in between sequential tufting machines.
In further exemplary aspects, when a controller is communicatively coupled to each tufting machine of the plurality of sequentially positioned tufting machines, the plurality of sequentially positioned tufting machines can form a first tufting pattern using a set of tufting parameters, and the method can further comprise using the controller to modify at least one of the tufting parameters to provide a second tufting pattern that is different from the first tufting pattern. In these aspects, said at least one tufting parameter can comprise at least one of pile height, yarn density, or yarn color. Advantageously, it is contemplated that the controller can modify said at least one tufting parameter without mechanically changing the configuration of the plurality of tufting machines.
Further details of a system for imparting a pattern into a fabric are disclosed in U.S. Application No. 17/476870, filed Mar. 29, 2022, the entirety of which is hereby incorporated by reference herein in its entirety.
In some optional aspects, the pattern can be imparted into the fabric entirely during manufacturing of the article via tufting, knitting, weaving, etc. Accordingly, in some aspects, the method of making the fabric as described herein does not comprise the step of applying a color pattern to the face structure of the fabric.
Although a specific tufting system/machine configuration is disclosed herein, it is contemplated that any suitable tufting machine configuration can be employed. Conventional tufting machine configurations are well known in the art and are not disclosed in detail herein.
Although described above as being formed by tufting, a pattern as disclosed herein can also be imparted into a fabric using conventional knitting or weaving methods as are known in the art. Thus, it is contemplated that patterned fabrics can be formed using knitting and/or weaving machines and equipment as are known in the art.
In further aspects, it is contemplated that the fabric 10 can be subjected to further processing steps (for example, application of color, application of coatings and/or secondary backings, and the like) to produce a surface covering 20, which can optionally function as a floor covering or a wall covering. For example, in exemplary aspects, and as further disclosed herein, it is contemplated that a color pattern can be applied to the fabric 10. Thus, in these aspects, it is contemplated that the surface covering 20 can comprise a face structure 20 defined by the at least one yarn 30 associated with the primary backing 12 and a color pattern applied to the face structure.
In these aspects, the method can further comprise applying a color pattern to the face structure of the fabric. As shown in
In exemplary aspects, applying the color pattern can comprise a pre-steam process that removes or flashes off yarn finishes (that are present in the yarn of the face structure of the previously formed fabrics). Then, the printer or dye applicator apparatus 1200 can be activated to apply ink or dye to the face structure. Steam and/or heat can then be applied to set the color pattern. Jet printers (indirect or direct), air jet printers, bubble jet printers, ink jet printers, and canvas printers, such as those produced by Zimmer Company (e.g., the Chromajet 800 dyeing machine) or Milliken (e.g., the Millitron dye machine) are suitable for performing such printing processes. Heat transfer printing can also be used. Digital printing processes used widely in the hard surface flooring industry are also capable of making images for the applied color patterns disclosed herein. It is contemplated that such digital printing processes can be used to print a logo or image / design over the top of fabric pile yarns that define a face structure of a fabric as disclosed herein. In exemplary aspects, acid based or pre-metalized dyes can be preferred for use with nylon yarns, while disperse dyes can be preferred for use with PP and PET yarns. It is further contemplated that UV activated dyes can be used (e.g., fluorescent dyes along with glow in the dark dyes).
In further exemplary aspects, it is contemplated that the printer or dye applicator apparatus 1200 can comprise one or more controllers that can be configured to receive a user input indicative of an instruction or series of instructions to apply a color pattern to the face structure as disclosed herein. In exemplary aspects, the controller(s) can be communicatively coupled to hardware, such as printer devices (e.g., printer heads, jets, nozzles, piezo printers, and the like), ink/dye sources, and a user interface device where a selected color pattern can be loaded. In these aspects, it is contemplated that the controller(s) can selectively control the delivery of particular ink/dye and the positioning of one or more printer elements to ensure that specific colors are delivered to specific locations on the face structure, thereby producing the desired color pattern.
In various exemplary aspects, and with reference to
Thus, it is contemplated that the disclosed surface coverings 100 can provide complementary, integrated colored graphics, either avoiding the need for securing multiple panels together or minimizing installation requirements to only the adhesion of adjacent, complementary panels that cooperate with one another to define a continuous face pattern (across multiple panels that are only secured together along complementary side edges). Thus, it is contemplated that the disclosed surface coverings can be installed with improved consistency, integrity, and efficiency in comparison to conventional methods. It is further contemplated that the disclosed systems for producing such surface coverings can permit variation of the specifications of the surface covering structures (e.g., panels with an applied color pattern) using purely computerized changes to the system, without the need for operational stoppages. Tufted articles produced by the disclosed systems can have multiple pile lengths and variable yarn density (controlled by the number of stitches), and modifications of these parameters can be driven by changes in yarn type (for example, using multiple needle bars or multiple tufting machines). It is contemplated that the disclosed systems and methods can avoid many of the economic and efficiency issues associated with conventional turf installations by permitting production of a unitary article that results from a single tufting process, without the need for the production of separate tufted articles for each section of the overall installation that has a different color and/or texture.
Optionally, in some exemplary aspects, and with reference to
Optionally, in further exemplary aspects, and with reference to
As another example, as shown in
In further aspects, and as shown in
In still further aspects, it is contemplated that the color pattern can be applied to portions of the face surface of the primary backing, thereby modifying a base color of the primary backing.
In still further aspects, when a fabric comprises tufts that comprise a plurality of yarn types within a tuft (such as, for example, a turf yarn and a carpet yarn as disclosed herein), it is contemplated that the application of a color of the color pattern to the two different yarn types within a single tuft can result in different amounts or rates of yarn uptake among the various yarn types, leading to variations in appearance within the tuft and among adjacent tufts. For example, the turf yarn (e.g., a monofilament yarn) can absorb pigment at a lower rate than the carpet yarn, leading to noticeable differences in the color tones shown by the two yarns.
Optionally, in exemplary aspects, prior to applying dye or ink to the fabric to provide the color pattern, a pre-dyeing process can be completed. In exemplary aspects, the pre-dyeing process can comprise modifying bulk, shrinkage, and/or texture properties of the face yarns of the fabric using conventional methods. More particularly, it is contemplated that bulk levels can be altered with various blends of low or high shrinkage resins / materials, and/or using jet-heat texturizing as is well known in the yarn extrusion industry. Exemplary equipment for texturizing the yarns includes the yarn texturizing equipment manufactured by BARMAG and DEITZ & SCHELL.
In exemplary aspects, following modification of the bulk, shrinkage, and/or texture properties, steam can be applied to prepare the face yarns for dyeing. Following application of the dye to impart pigment to the face yarns, the patterned article can be heated in an oven to finalize the appearance and structure of the article. It is known in the art that different resins react differently to steam and/or heat, and this knowledge can be used to select particular parameters of the texturizing apparatus to create desired visual properties of the yarns.
As further described herein, it is contemplated that the properties of the yarns of the surface coverings can be selected and/or modified to achieve desired aesthetic or performance properties. It is contemplated that one or more of the following properties can be selected to achieve a desired aesthetic or performance property for a particular yarn: total denier; denier per filament; cross-sectional shape; bulk level; resin type (with shrinkage factors and/or heat profiles; dye uptake levels (for example, dye properties of nylon that can be selected to be a light, medium, or deep dye); and/or luster levels (for example, to mute or enhance the visual appearance of the solid or patterned (e.g., tweed, heather, etc.) surface covering. This flexibility allows a fabric designer to customize or tailor a particular fabric for a specific end use by changing out one or multiple yarns for yarns with different properties.
Optionally, in exemplary aspects, prior to printing on or dyeing the face yarns of the fabric, the backstitches of tufts of the fabric can be coated using conventional methods (for example, using a coating apparatus 1300 as shown in
It is contemplated that the cross sections and/or sizes of the yarns 30 can be selected or modified to provide any desired color and/or texture combination. It is further contemplated that control of the finished pile heights of the yarns (e.g., the pile heights of yarn tufts) can be controlled by using bulking or shrinkage recipes as are known in the art. Therefore, denier, bulk level, yarn shrinkage, and other properties can be determined as various yarns are extruded, and the yarns can be put together to produce a fabric 10 with desired performance features that are optimized for receiving a color pattern as disclosed herein. The pile heights and bulk and/or shrinkage properties of the lower or upper yarns of each fabric can be selectively controlled and modified to provide a desired finished face fiber profile. More generally, it is contemplated that yarn selection, yarn color, yarn size, pile height, and bulking/shrinkage can be combined to provide any desired face profile that achieves particular performance goals for a specific sport, such as ball bounce, ball roll, ball reaction (e.g., ball spin), fabric stimp rating / speed (e.g., for golf applications), location, etc.
For example, when a first yarn (an “A” turf yarn) and a second yarn (a “B” carpet yarn) are tufted through the primary backing 12, it is contemplated that the denier (i.e., size) of the A yarn or the B yarn can be increased or decreased to change the base level density of the surface covering. Optionally, the denier of the A yarn (e.g., a monofilament turf yarn as disclosed herein) can be increased or decreased, and the bulk levels of the yarns can be controlled, to adjust the amount of the A yarn that serves as an “up blade” that extends above the finished pile height of the second yarn. For example, if no bulk is added, it is contemplated that the first yarn can extend a first distance (e.g., about 3/16″) above the second yarn. A 10% bulk can cause the first yarn to be a second distance (e.g., about ⅛″) higher than the second yarn, a 20% bulk can cause the first yarn to be a third distance (e.g., about 1/16″) above the second yarn, a 30% bulk can cause the first yarn to be a fourth distance (e.g., about 1/32″) above the second yarn, a 40 % bulk can cause the first yarn to be about even with the second yarn, a 50% bulk can cause the first yarn to be below the second yarn by a fifth distance (e.g., about 1/32″), and a 60 % bulk can cause the first yarn to be below the second yarn by a sixth distance (e.g., about ⅛″). At this point, with the first yarn below the second yarn by about ⅛″, it is contemplated that the first yarn can act as a resilient cushion yarn built into the carpet structure by serving as a filler-thatch-spring layer to support the second (upper) yarn (e.g., carpet yarn B). Thus, in some examples, it is contemplated that the first yarn (e.g., the turf yarn) can be lowered to serve as a built-in pad layer that provides fall safety as it is hidden below the upper surface defined by the second (carpet) yarn.
In one example, the first yarn (e.g., a monofilament turf yarn) can be exposed to a 30% bulk process such that the first yarn is at about 30% bulk, causing the pile height of the first yarn to be about 1/32″ above the second yarn (e.g., the carpet yarn), or about 1/64″ above the second yarn, for overdyeing a solid shade or printing a color pattern as further disclosed herein. In exemplary aspects, it is contemplated that the first yarn can dye at a different uptake/strike rate and have a different (e.g., slightly lighter) color than the second yarn. In these aspects, it is contemplated that the variation in dye uptake rate can produce a tweed look. Such a tweed look can be useful at producing the look of a putting green that is groomed close to the ground.
As discussed above, the pile heights of the yarns (e.g., finished pile heights of the tufts) can be selected to achieve various appearance and performance goals. In various aspects, it is contemplated that the pile heights can range from about ¼” to about 1″. However, it is contemplated that any selected pile height can be used. For example, the first yarn (e.g., the carpet yarn, which can optionally comprise a monofilament yarn as disclosed herein) can optionally have a finished pile height ranging from about 2 inches to about 3 inches, while the second yarn has a lower pile height, thereby producing a shag-carpet type look. In some aspects, it is contemplated that by using a higher pile height for the first yarn (e.g., a monofilament yarn) than the second yarn (e.g., a carpet yarn as disclosed herein), a golf ball can be held up (supported) in a desired fashion to provide a better-performing tee-type turf article.
Optionally, with reference to
In exemplary aspects, the surface covering 100 can comprise a multi-layered backing structure. For example, the surface covering 100 can optionally comprise at least one yarn, a primary backing, a back coating to hold the yarn to the primary backings, and a laminate layer of material for attaching a secondary backing or woven, non-woven, spun bond, knitted or plastic sheet or membrane. When provided, it is contemplated that any desired material for the secondary backing can be used. In further aspects, it is contemplated that a cushion layer can be incorporated into the surface covering (either separately or integrally formed) to change the overall fabric performance features for ball bounce, ball roll, underfoot comfort, safety features for ageing in place facilities, or athletic performance features well known in the sports industry by organizations such as the NFL, ASTM, STC, FIFA, Rugby and Field Hockey Sport body governing Organizations. It is contemplated that any conventional cushion materials can be used.
Optionally, the surface covering 100 can comprise an infill. In these aspects, it is contemplated that the infill can comprise a single component or any combination of a plurality of components. When the infill comprises a plurality of components, it is contemplated that the infill material can optionally comprise a plurality of layers, with each layer corresponding to a different infill component or combination of components. Alternatively, it is contemplated that the plurality of components can be provided as a mixture, which can be either homogenous or non-homogenous. In exemplary aspects, it is contemplated that the infill can comprise clay, TPE, EPDM, coconut husks, walnut shells, crushed brick, sand, or combinations thereof. More generally, it is contemplated that the infill can comprise any material that is capable of imparting desired characteristics to a surface covering (e.g., a floor covering) as disclosed herein.
Thus, as further disclosed herein, the disclosed systems and methods can produce a turf carpet using 100% nylon Monofilament yarn with overprinting or secondary dyeing of a solution dyed fiber for solid or multicolored visuals.
As further disclosed herein, the disclosed systems and methods can produce a hybrid turf-carpet article using at least one yarn bundle that is a conventional residential carpet yarn combined with a turf yarn conventional to the turf industry such as Nylon, polypropylene (PP), polyethylene terephthalate (PET), polylactic acid (PLA) or polyurethane (PU) yarns. It is contemplated that at least a portion of the yarns (optionally, the entirety of the yarns) can comprise virgin or recycled resin(s). Monofilament yarns or multi-yarn bundles of blade shapes and/or various cross sections can be used. These yarns can accept dye or be left as their natural color state with selection of ink or dye formulations that will not dye the Turf yarns along with the Residential yarns. Such residential yarns can have small dpf values ranging from 2-32 dpf. As another example, rather than combining with residential carpet yarn, the turf yarn can be provided in combination with a commercial carpet grade yarn, which is typically in the range of 22-60 dpf.
In still further exemplary aspects, a turf carpet (hybrid) article can comprise one or more types of yarns (1, 2, 3, 4, 5, 6 or more types of yarns) that are combined by multiple yarn end-per tuft penetration or by using thread-ups of single or combined ends in a pattern thread up, with distinct types of yarns being combined with each other (e.g., turf yarns being provided with or alongside carpet yarns).
As further disclosed herein, a turf carpet or hybrid turf carpet article can be formed by weaving, knitting, or using cut pile, loop pile or combinations thereof to allow for either solid dye or a printed visual with motifs.
In still further aspects, it is contemplated that the use of carpet yarns and turf yarns together can allow for manufacture of patterned turf carpet articles on a variety of carpet production machines. It is contemplated the combination of both yarn types into a single fabric provides a hybrid fabric product with unique performance properties that neither yarn type can provide on its own. Thus, it is contemplated that a weaving machine, a pattern fabric machine, a tufting machine, a knitting machine, a fusion bonding machine, and any other machine for making a pile fabric can be employed to make the fabrics comprising both yarn types as disclosed herein. It is contemplated that such fabrics can be produced with or without pre-dyed yarns and with or without secondary steps such as printing to make graphic images or other color patterns on the fabric.
Accordingly, various embodiments disclosed herein comprise using all unpigmented yarns, all pigmented yarns, or a combination of pigmented and unpigmented yarns to form a patterned fabric. Said patterned fabric can be formed via weaving, knitting, tufting or any other suitable manufacturing method. In some optional aspects, the pattern can be formed into the fabric partially or entirely during the weaving, knitting, tufting, or other manufacturing process using colored and, optionally, unpigmented yarn. For example, the fabric can have multi-level, multi-bulk / shrinkage yarns that are used to form a specialty surface characteristics using pre-dyed or colored yarns and using a fabric forming machine to impart a desired pattern. In additional or alternative aspects, the pattern can be formed by coloring the fabric 10 itself.
In fitness applications such as exercise facilities and yoga studios, it is contemplated that a softer face surface is desirable. Thus, in these applications, it is contemplated that equal or substantially equal pile heights for the first and second yarns can be used, thereby ensuring that the softness of the second (carpet) yarn provides the desired user experience. It is further contemplated that the pile height of the second yarn can be greater than the first yarn by about 1/64″ to about ⅛″ or about 1/32″ to about ⅛″. It is contemplated that childcare facilities could use similar pile height ranges; however, as the age of the children at the facility increases, it is contemplated that the height of the first yarn (e.g., the monofilament blade yarn) should be increased to provide more realistic looking turf and better footing and durability.
Ball roll properties can be another factor when selecting face yarn properties. It is contemplated that for soccer, field hockey and golf, the higher the pile height of the first yarn (e.g., the “blade” yarn), the slower and less true the ball roll will be. It is contemplated that by using a textured monofilament yarn that has more resiliency and stiffness than the second (carpet) yarn, the first yarn can provide for more resistance and a more natural ball roll / visual. For golf putting applications, it is contemplated that the pile heights of the first and second yarns can be the same or substantially the same. For football or field hockey applications, it is contemplated that the pile height of the first yarn can be greater than the pile height of the second yarn by a selected percentage (for example, about 60% higher than the second yarn). For golf fringe applications, it is contemplated that the pile height of the first yarn can be a selected percentage greater than the pile height of the second yarn (for example, 25%, 50%, or 75% higher than the second yarn). Optionally, in these applications, it is contemplated that the first yarn can be subjected to a low bulk process of about 5 to about 15 percent bulk. In some field hockey applications where water is used during play, it is contemplated that the pile height of the first yarn can be a selected percentage higher (e.g., about 20% higher) than the pile height of the second yarn.
In further aspects, it is contemplated that within a horizontal plane that intersects the face structure, the ratio between the surface area occupied by the carpet fiber and the surface area occupied by the turf fiber can vary depending upon the desired properties of the face structure. For color patterns that include printed visuals, it is contemplated that the pile heights of the second (carpet) yarn can be near the heights of the first (turf) yarn to provide optimal clarity. In some exemplary aspects, it is contemplated that providing the first (turf) yarn at a higher pile height can produce a three-dimensional (3D) visual look after dyeing or printing and can provide a soft edge look on various patterns. It is contemplated that some printed patterns can be too perfect, making the use of such soft edge looks advantageous.
The density of the surface covering can also be selectively modified depending upon the intended application. For example, for an indoor soccer field or for a rug for a child’s bedroom, a more open gauge of tufting machine can be used for a higher and less dense fabric design. Softer yarns can also be employed.
It is contemplated that the disclosed methods are unlimited in potential color and design applications within a full fabric, such as, for example, a 180 inch wide fabric. It is contemplated that the pattern length can effectively be infinite. It is contemplated that multiple panels of 15 ft wide surface coverings can be printed so that an entire field (e.g., an entire football field) can be produced with unlimited graphics, lines, numbers, etc. It is contemplated that the disclosed systems can be used to print team logos. As another example, it is contemplated that the disclosed systems can be used to print a full-scale putting green with fringe, sand traps, cup and flag, bushes around to simulate landscape or even an image of their favorite famous golfer putting or driving on a golf course scene. It is further contemplated that the disclosed systems and methods can be used to produce wall murals as well as full scale or miniature scale Golf Courses. In further aspects, it is contemplated that the disclosed systems and methods can be used to produce small-scale soccer or baseball fields or other sports fields where multi-color elements (e.g., lines, markings, etc.) or graphics are used to define a portion of a playing area and/or to distinguish a playing area from an out-of-bounds area. In further exemplary aspects, it is contemplated that the disclosed systems and methods can be used to produce a surface covering that defines an area for playing a children’s game or board game. In still further exemplary aspects, it is contemplated that the disclosed systems and methods can be used to produce a hanging vertical structure (such as those used in golf simulators) or a wall covering.
In exemplary aspects, surface coverings as disclosed herein can achieve complicated or small-scale graphics, which are not possible using conventional turf fabrics. It is contemplated that the combination of carpet and turf yarns as disclosed herein can create a realistic simulated grass surface that is capable of receiving patterns by overprinting the yarns and/or using solid colors (if desired) within the same dye run.
In exemplary aspects, a turf carpet article as disclosed herein can be designed and engineered to withstand the rigors of Fitness Center abuse such a sled machines, agility courses with quick pivoting by the end user, and other fitness equipment. At the same time, it is contemplated that such articles can provide more comfort than typical turf fabrics can deliver due to the addition of Residential or Commercial standard carpet yarns. Also, in these aspects, it is contemplated that the turf carpet article can incorporate the imagery of the fitness equipment, exercises performed in a particular floor space where the imagery or themed pattern defines the workout space, training process, fitness logos and imagery, sports imagery and any other desired graphic into the flooring installation. This color pattern can be integrally incorporated into the turf and not require cutting/attachment or painting on the installation. It is contemplated that the turf yarns can provide the high traffic performance while the addition of the conventional carpet yarns can provide the surface area for absorbing and holding the dyestuffs, thereby allowing for a clear pattern design
In exemplary applications, it is contemplated that the disclosed surface coverings can be in any installation, particularly installations where it is useful to incorporate graphics into the installation. For example, the surface coverings can be provided as mats, pads, flooring, or platforms that are suitable for use in a wide range of applications, such as, for example and without limitation, fitness applications, weight-lifting, wrestling, martial arts, gymnastics, cheerleading, yoga, and the like. As another example, it is contemplated that the disclosed surface coverings can be provided as modular turf structures that are optimized for indoor applications. In each of these examples, it is contemplated that the surface coverings can comprise color patterns that provide logos, images, text, arrows, markers, or other information that is intended to be received by users of the facilities where the surface coverings are installed.
In further exemplary aspects, it is contemplated that the disclosed surface coverings can be optimized for use in applications where the properties of a turf yarn (e.g., a first yarn as disclosed herein) are emphasized (optionally, emphasized relative to a carpet yarn (e.g., a second yarn as disclosed herein)). For example, in some aspects, it is contemplated that the disclosed surface coverings can be used to form at least a portion of an indoor or outdoor running track, with portions of the yarns being colored or patterned to define running lanes, finish lines, and other boundaries. Optionally, such running tracks can further comprise team logos and other graphical elements. In another example, it is contemplated that the disclosed surface coverings can be used to form at least a portion of a baseball field, such as, for example, a batter warm-up area, a first or third base area (an infield “corner”), and the like. In this example, it is contemplated that sections of the baseball field can be removed and replaced periodically in response to wear/usage. Optionally, these sections of the baseball field can comprise base path markings and/or color changes representing transitions from grass to dirt areas. As an example, it is contemplated that a plurality of first base areas can be formed from a surface covering as disclosed herein, with one of the first base areas being replaced by a second one of the first base areas after the first surface covering is worn. It is still further contemplated that the disclosed sections of the field can comprise logos that are formed by color differences among the yarns or by a color pattern as disclosed herein.
In view of the described products, systems, and methods and variations thereof, herein below are described certain more particularly described aspects of the invention. These particularly recited aspects should not however be interpreted to have any limiting effect on any different claims containing different or more general teachings described herein, or that the “particular” aspects are somehow limited in some way other than the inherent meanings of the language literally used therein.
Aspect 1. A hybrid turf-carpet article comprising:
Aspect 2. The article of aspect 1, wherein the yarn filaments of the second yarn have a dpf ranging from 2 to 32.
Aspect 3. The article of aspect 1, wherein the yarn filaments of the second yarn have a dpf ranging from 22 to 60.
Aspect 4. The article of any one of aspects 1-3, wherein the plurality of yarns are tufted through the primary backing to define a plurality of yarn tufts, wherein each tuft of the plurality of tufts comprises the first yarn and the second yarn, and wherein the first yarn is not entangled with the second yarn.
Aspect 5. The article of any one of aspects 1-3, wherein the first yarn is tufted through the primary backing to define a first plurality of yarn tufts, and wherein the second yarn is tufted through the primary backing to define a second plurality of yarn tufts, wherein each tuft of the first plurality of yarn tufts consists of the first yarn, and wherein each tuft of the second plurality of yarn tufts consists of the second yarn.
Aspect 6. The article of aspect 1, wherein each yarn filament of the first yarn is a monofilament.
Aspect 7. The article of any one of aspects 1-6, further comprising a color pattern applied to the plurality of yarns.
Aspect 8. The article of aspect 7, wherein at least one yarn tuft of the plurality of yarn tufts comprises:
Aspect 9. The article of any one of aspects 1-8, wherein the plurality of yarns further comprises a third yarn having a plurality of yarn filaments, wherein each yarn filament of the plurality of yarn filaments of the second yarn has a denier per filament (dpf) ranging from 2 to 60 dpf.
Aspect 10. The article of aspect 9, wherein the third yarn is commingled with the first and second yarns.
Aspect 11. The article of aspect 9, wherein the third yarn is commingled with the first and second yarns.
Aspect 12. A method comprising:
Aspect 13. The method of aspect 12, wherein the yarn filaments of the second yarn have a dpf ranging from 2 to 32.
Aspect 14. The method of aspect 12, wherein the yarn filaments of the second yarn have a dpf ranging from 22 to 60.
Aspect 15. The method of any one of aspects 12-14, further comprising:
tufting the plurality of yarns through the primary backing to define a plurality of yarn tufts, wherein each tuft of the plurality of tufts comprises the first yarn and the second yarn.
Aspect 16. The method of any one of aspects 12-14, further comprising:
Aspect 17. The method of any one of aspects 12-16, wherein each yarn filament of the first yarn is a monofilament.
Aspect 18. The method of any one of aspects 12-18, wherein the first yarn comprises a plurality of yarn filaments, wherein each yarn filament of the plurality of yarn filaments is unpigmented prior to application of the color pattern.
Aspect 19. The method of any one of aspects 12-18, wherein applying the color pattern comprises applying dye to the face structure.
Aspect 20. The method of any one of aspects 12-18, wherein applying the color pattern comprises printing ink onto the face structure.
Aspect 21. The method of any one of aspects 12-20, wherein the color pattern consists of a single color.
Aspect 22. The method of any one of aspects 12-20, wherein the color pattern comprises a plurality of colors.
Aspect 23. The method of aspect 22, wherein the color pattern comprises a logo or a picture.
Aspect 24. The method of any one of aspects 12-23, further comprising:
applying a coating to the rear surface of the primary backing.
Aspect 25. The method of aspect 24, wherein the plurality of yarns are tufted through the primary backing, and wherein coating is applied over backstitches formed by the plurality of yarns
Aspect 26. The method of aspect 24 or aspect 25, further comprising applying a secondary backing to the coating.
Aspect 27. The method of any one of aspects 12-23, wherein at least a portion of the plurality of yarns are positioned on a rear side of the primary backing, and wherein method comprises melting said at least a portion of the plurality of yarns that is positioned on a rear side of the primary backing.
Aspect 28. The method of aspect 27, wherein the plurality of yarns are tufted through the primary backing, and wherein said at least a portion of the plurality of yarns comprises backstitches formed by the plurality of yarns.
Aspect 29. A surface covering comprising:
Aspect 30. The surface covering of aspect 29, wherein the color pattern is applied to the face structure.
Aspect 31. The surface covering of aspect 29 or aspect 30, wherein the color pattern is imparted at least in part by tufting, knitting or weaving the at least one yarn.
Aspect 32. The surface covering of any one of aspects 29-31, wherein the at least one yarn comprises a first yarn comprising a plurality of yarn filaments, wherein each yarn filament of the plurality of yarn filaments of the first yarn is a monofilament.
Aspect 33. The surface covering of aspect 32, wherein the at least one yarn further comprises the second yarn having a plurality of yarn filaments, wherein each yarn filament of the plurality of yarn filaments of the second yarn has a denier per filament (dpf) ranging from 2 to 60 dpf.
Aspect 34. The surface covering of aspect 33, wherein the plurality of yarns comprises further at a third yarn having a plurality of yarn filaments, wherein each yarn filament of the plurality of yarn filaments of the second yarn has a denier per filament (dpf) ranging from 2 to 60 dpf.
Aspect 35. The surface covering of aspect 34, wherein the third yarn is commingled with the first and second yarns.
Aspect 36. The surface covering of aspect 34, wherein the third yarn is commingled with the first and second yarns.
Aspect 37. A fabric comprising:
Aspect 38. The fabric of aspect 37, wherein the first yarn comprises a plurality of yarn filaments, and wherein each yarn filament of the plurality of yarn filaments is an unpigmented monofilament.
Aspect 39. The fabric of aspect 37 or aspect 38, wherein the first yarn is formed into a plurality of tufts that extend through the primary backing.
Aspect 40. The fabric of any one of aspects 37-39, further comprising a second yarn associated with the primary backing and extending outwardly from the face surface of the primary backing in the direction moving away from the primary backing.
Aspect 41. The fabric of aspect 40, wherein the second yarn is an unpigmented natural yarn.
Aspect 42. The fabric of aspect 40, wherein the second yarn is a dyed yarn with added pigment.
Aspect 43. The fabric of any one of aspects 40-42, wherein the first yarn is formed into a first plurality of yarn tufts that extend through the primary backing, and wherein the second yarn is formed into a second plurality of tufts that extend through the primary backing.
Aspect 44. The fabric of any one of aspects 40-42, wherein the first and second yarns are formed into a plurality of yarn tufts that extend through the primary backing, wherein each yarn tuft of the plurality of yarn tufts comprises the first yarn and the second yarn.
Aspect 45. The fabric of any one of aspects 40-44, wherein the first yarn comprises a plurality of yarn filaments, wherein each yarn filament of the plurality of yarn filaments of the first yarn has a denier ranging from 61 to 3600 denier per filament (dpf), and
wherein the second yarn comprises a plurality of yarn filaments, wherein each yarn filament of the plurality of yarn filaments of the second yarn has a denier per filament (dpf) ranging from 2 to 60 dpf.
Aspect 46. The fabric of aspect 45, wherein each yarn filament of the plurality of yarn filaments of the first yarn is a continuous filament, and wherein each yarn filament of the plurality of yarn filaments of the second yarn is a continuous filament.
Aspect 47. The fabric of any one of aspects 40-46, further comprising a third yarn associated with the primary backing and extending outwardly from the face surface of the primary backing in the direction moving away from the primary backing.
Aspect 48. The fabric of aspect 47, wherein the third yarn is commingled with the first and second yarns.
Aspect 49. The fabric of aspect 48, wherein the first yarn comprises a plurality of yarn filaments, and wherein each yarn filament of the plurality of yarn filaments is an unpigmented monofilament, wherein the second yarn comprises a plurality of yarn filaments, wherein each yarn filament of the plurality of yarn filaments of the second yarn has a denier per filament (dpf) ranging from 2 to 60 dpf, and wherein the third yarn comprises a plurality of yarn filaments, wherein each yarn filament of the plurality of yarn filaments of the third yarn has a denier per filament (dpf) ranging from 2 to 60 dpf.
Aspect 50. The fabric of aspect 47, wherein the third yarn is not commingled with the first and second yarns.
Aspect 51. A surface covering comprising:
Aspect 52. The surface covering of aspect 51, wherein the first yarn comprises a plurality of yarn filaments, wherein each yarn filament of the plurality of yarn filaments of the first yarn is a monofilament.
Aspect 53. The surface covering of aspect 52, wherein each yarn filament of the plurality of yarn filaments of the first yarn is a 100% nylon monofilament.
Aspect 54. The surface covering of any one of aspects 51-53, wherein the first yarn is formed into a plurality of yarn tufts that extend through the primary backing.
Aspect 55. The surface covering of aspect 54, wherein each yarn tuft of the plurality of yarn tufts comprises at least one outwardly extending tuft portion and a backstitch, and wherein the backstitch has a different color than the at least one outwardly extending tuft portion.
Aspect 56. The surface covering of aspect 55, wherein the color pattern does not impart color to the backstitch.
Aspect 57. The surface covering of any one of aspects 51-56, wherein the at least one yarn comprises a first yarn and a second yarn.
Aspect 58. The surface covering of aspect 58, wherein the first yarn is formed into a first plurality of yarn tufts that extend through the primary backing, and wherein the second yarn is formed into a second plurality of tufts that extend through the primary backing.
Aspect 59. The surface covering of aspect 57, wherein the first and second yarns are formed into a plurality of yarn tufts that extend through the primary backing, wherein each yarn tuft of the plurality of yarn tufts comprises the first yarn and the second yarn.
Aspect 60. The surface covering of aspect 57, wherein the first and second yarns are woven into the primary backing.
Aspect 61. The surface covering of aspect 57, wherein the first and second yarns are knitted into the primary backing.
Aspect 62. The surface covering of any one of aspects 51-61, wherein the color pattern comprises a plurality of colors.
Aspect 63. The surface covering of aspect 62, wherein at least two colors of the plurality of colors of the color pattern are applied to a first yarn of the at least one yarn.
Aspect 64. The surface covering of aspect 62, wherein the color pattern comprises a picture or logo.
Aspect 65. The surface covering of any one of aspects 51-64, wherein the color pattern comprises a single color.
Aspect 66. The surface covering of any one of aspects 51-65, wherein the first yarn of the at least one yarn has a base color, wherein the first yarn comprises:
Aspect 67. The surface covering of any one of aspects 51-66, wherein the first yarn of the at least one yarn comprises a plurality of yarn filaments, each yarn filament having an outer circumferential surface, wherein portions of the outer circumferential surfaces of the plurality of yarn filaments cooperate to define a periphery of the first yarn, wherein the second portion of the first yarn is at least partially defined by portions of the outer circumferential surfaces that face away from the periphery of the first yarn.
Aspect 68. The surface covering of any one of aspects 58-67, wherein each yarn tuft of the plurality of yarn tufts has at least one outwardly extending tuft portion and a backstitch, and wherein the backstitch has a different color than the at least one outwardly extending tuft portion.
Aspect 69. The surface covering of any one of aspects 58-68, wherein the backing structure further comprises a secondary backing.
Aspect 70. The surface covering of any one of aspects 57-69, wherein the at least one yarn further comprises a third yarn.
Aspect 71. The surface covering of aspect 70, wherein the third yarn is commingled with the first and second yarns.
Aspect 72. The surface covering of aspect 70, wherein the third yarn is not commingled with the first and second yarns.
Aspect 73. The surface covering of any one of aspects 57-72, wherein the first yarn is an unpigmented natural yarn.
Aspect 74. The surface covering of any one of aspects 57-72, wherein the first and second yarns are pigmented.
Aspect 75. The surface covering of any one of aspects 57-74, wherein the first and second yarns are pigmented associated with the backing in an arrangement to form a pattern.
Aspect 76. A method comprising:
Aspect 77. The method of aspect 76, wherein forming the face structure comprises passing the at least one yarn through the backing structure to define a plurality of yarn tufts.
Aspect 78. The method of aspect 76, wherein forming the face structure comprises weaving the at least one yarn into the backing structure.
Aspect 79. The method of aspect 76, wherein forming the face structure comprises knitting the at least one yarn into the backing structure.
Aspect 80. The method of any one of aspects 76-79, wherein the first yarn comprises a plurality of yarn filaments, wherein each yarn filament of the plurality of yarn filaments is unpigmented prior to application of the color pattern.
Aspect 81. The method of any one of aspects 76-80, wherein applying the color pattern comprises applying dye to the face structure.
Aspect 82. The method of any one of aspects 76-80, wherein applying the color pattern comprises printing ink onto the face structure.
Aspect 83. The method of any one of aspects 76-83, wherein the color pattern consists of a single color.
Aspect 84. The method of any one of aspects 76-82, wherein the color pattern comprises a plurality of colors.
Aspect 85. The method of aspect 83 or aspect 84, wherein the color pattern comprises a logo or a picture.
Aspect 86. The method of any one of aspects 76-85, further comprising:
Aspect 87. The method of any one of aspects 76-86, wherein the first yarn is an unpigmented natural yarn.
Aspect 88. The method of any one of aspects 76-87, wherein the first yarn is turf tape or monofilament blade yarn.
Aspect 89. The surface covering of any one of aspects 51-74, wherein the at least one yarn of the face structure comprises turf tape or monofilament blade yarn.
Aspect 90. The hybrid turf-carpet article of any one of aspects 1-11, wherein the first yarn comprises turf tape or monofilament blade yarn.
Aspect 91. The method of any one of aspects 12-28, wherein the first yarn comprises turf tape or monofilament blade yarn.
Aspect 92. The surface covering of any one of aspects 29-36, wherein at least one of the at least one yarn comprises turf tape or monofilament blade yarn.
Aspect 93. The fabric of any one of aspects 37-51, wherein the first yarn comprises turf tape or monofilament blade yarn.
Although several embodiments of the invention have been disclosed in the foregoing specification and the following appendices, it is understood by those skilled in the art that many modifications and other embodiments of the invention will come to mind to which the invention pertains, having the benefit of the teaching presented in the foregoing description and associated drawings. It is thus understood that the invention is not limited to the specific embodiments disclosed herein, and that many modifications and other embodiments are intended to be included within the scope of the appended claims. Moreover, although specific terms are employed herein, as well as in the claims which follow, they are used only in a generic and descriptive sense, and not for the purposes of limiting the described invention, nor the claims which follow.
This application claims the benefit of the filing date of U.S. Provisional Pat. Application No. 63/253,697, filed Oct. 8, 2021, the entirety of which is hereby incorporated by reference herein.
| Number | Date | Country | |
|---|---|---|---|
| 63253697 | Oct 2021 | US |
