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WO2023059897A1 - Tissus, revêtements de surface comprenant ceux-ci, et systèmes et procédés de production de ceux-ci - Google Patents

Tissus, revêtements de surface comprenant ceux-ci, et systèmes et procédés de production de ceux-ci Download PDF

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Publication number
WO2023059897A1
WO2023059897A1 PCT/US2022/046086 US2022046086W WO2023059897A1 WO 2023059897 A1 WO2023059897 A1 WO 2023059897A1 US 2022046086 W US2022046086 W US 2022046086W WO 2023059897 A1 WO2023059897 A1 WO 2023059897A1
Authority
WO
WIPO (PCT)
Prior art keywords
yam
yams
filaments
primary backing
filament
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Ceased
Application number
PCT/US2022/046086
Other languages
English (en)
Inventor
Gregory D. Fowler
Michael Mathis
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Shaw Industries Group Inc
Original Assignee
Shaw Industries Group Inc
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Shaw Industries Group Inc filed Critical Shaw Industries Group Inc
Priority to EP22879338.6A priority Critical patent/EP4413196A4/fr
Priority to CN202280072971.XA priority patent/CN118234904A/zh
Priority to MX2024004065A priority patent/MX2024004065A/es
Priority to CA3233624A priority patent/CA3233624A1/fr
Publication of WO2023059897A1 publication Critical patent/WO2023059897A1/fr
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

Links

Classifications

    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N7/00—Flexible sheet materials not otherwise provided for, e.g. textile threads, filaments, yarns or tow, glued on macromolecular material
    • D06N7/0063—Floor covering on textile basis comprising a fibrous top layer being coated at the back with at least one polymer layer, e.g. carpets, rugs, synthetic turf
    • D06N7/0065—Floor covering on textile basis comprising a fibrous top layer being coated at the back with at least one polymer layer, e.g. carpets, rugs, synthetic turf characterised by the pile
    • D—TEXTILES; PAPER
    • D05—SEWING; EMBROIDERING; TUFTING
    • D05C—EMBROIDERING; TUFTING
    • D05C15/00—Making pile fabrics or articles having similar surface features by inserting loops into a base material
    • D05C15/04—Tufting
    • D05C15/08—Tufting machines
    • D05C15/26—Tufting machines with provision for producing patterns
    • D05C15/34—Tufting machines with provision for producing patterns by inserting loops of different nature or colour
    • D—TEXTILES; PAPER
    • D05—SEWING; EMBROIDERING; TUFTING
    • D05C—EMBROIDERING; TUFTING
    • D05C17/00—Embroidered or tufted products; Base fabrics specially adapted for embroidered work; Inserts for producing surface irregularities in embroidered products
    • D05C17/02—Tufted products
    • D05C17/026—Tufted products characterised by the tufted pile surface
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06P—DYEING OR PRINTING TEXTILES; DYEING LEATHER, FURS OR SOLID MACROMOLECULAR SUBSTANCES IN ANY FORM
    • D06P5/00—Other features in dyeing or printing textiles, or dyeing leather, furs, or solid macromolecular substances in any form
    • D06P5/003—Transfer printing
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06P—DYEING OR PRINTING TEXTILES; DYEING LEATHER, FURS OR SOLID MACROMOLECULAR SUBSTANCES IN ANY FORM
    • D06P5/00—Other features in dyeing or printing textiles, or dyeing leather, furs, or solid macromolecular substances in any form
    • D06P5/30—Ink jet printing
    • E—FIXED CONSTRUCTIONS
    • E01—CONSTRUCTION OF ROADS, RAILWAYS, OR BRIDGES
    • E01C—CONSTRUCTION OF, OR SURFACES FOR, ROADS, SPORTS GROUNDS, OR THE LIKE; MACHINES OR AUXILIARY TOOLS FOR CONSTRUCTION OR REPAIR
    • E01C13/00—Pavings or foundations specially adapted for playgrounds or sports grounds; Drainage, irrigation or heating of sports grounds
    • E01C13/08—Surfaces simulating grass ; Grass-grown sports grounds
    • D—TEXTILES; PAPER
    • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B2503/00—Domestic or personal
    • D10B2503/04—Floor or wall coverings; Carpets
    • D—TEXTILES; PAPER
    • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B2505/00—Industrial
    • D10B2505/20—Industrial for civil engineering, e.g. geotextiles
    • D10B2505/202—Artificial grass

Definitions

  • fabrics and surface coverings comprising such fabrics.
  • fabrics can comprise conventional turf yams and conventional carpet yams that are associated with a primary backing.
  • fabrics can be colored (e.g., printed with ink, or dyed) in accordance with a color pattern.
  • fabrics can comprise unpigmented natural yams that are associated with a primary backing.
  • 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 stmctures having different color yams (or other different properties) can be resized and then placed in the void spaces. After the differently patterned turf panels (or other turf stmctures) 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 stmcture.
  • a fabric having a primary backing and a first yam associated with the primary backing.
  • the primary backing has a face surface and an opposing rear surface.
  • the first yam extends outwardly from the face surface of the primary backing in a direction moving away from the primary backing.
  • the first yam is a naturally colored yam with no added pigment.
  • the fabric can be subjected to printing or dyeing processes to impart a color pattern to fabric.
  • a surface covering having a backing stmcture that includes a primary backing.
  • the surface covering also has a face stmcture and a color pattern that is applied to the face stmcture.
  • the primary backing has a face surface and an opposing rear surface.
  • the face stmcture 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.
  • a hybrid turf-carpet article having a backing stmcture and a plurality of yams associated with a primary backing of the backing stmcture.
  • the primary backing has a face surface and an opposing rear surface.
  • the plurality of yams extend outwardly from the face surface of the primary backing in a direction moving away from the primary backing.
  • the plurality of yams include a first yarn having a plurality of yam filaments, wherein each yam filament of the plurality of yam filaments of the first yam has a denier ranging from 61 to 3 ,600 denier per filament (dpf).
  • the plurality of yams also include a second yam having a plurality of yam filaments, wherein each yam filament of the plurality of yam filaments of the second yam has a denier per filament (dpf) ranging from 2 dpf to 60 dpf.
  • 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 yam to a primary backing having a face surface and an opposing rear surface.
  • the at least one yam extends outwardly from the face surface of the primary backing in a direction moving away from the primary backing.
  • the at least one yam includes a first yam that is an unpigmented natural yam, and the color pattern is applied to the face stmcture formed by the at least one yam.
  • a method including forming a face stmcture of a fabric and applying a color pattern to the face stmcture of the fabric.
  • Forming the face stmcture can include securing a plurality of yams to a primary backing having a face surface and an opposing rear surface. The plurality of yams extend outwardly from the face surface of the primary backing in a direction moving away from the primary backing.
  • the plurality of yams include: a first yam having a plurality of yam filaments, wherein each yam filament of the plurality of yam filaments of the first yam has a denier ranging from 61 to 3,600 denier per filament (dpf); and a second yam having a plurality of yam filaments, wherein each yarn filament of the plurality of yam filaments of the second yam has a denier per filament (dpf) ranging from 2 to 60 dpf.
  • the color pattern is applied to the face stmcture formed by the plurality of yams.
  • FIGS. 1A-1C are schematic, cross-sectional views of exemplary fabrics as disclosed herein.
  • FIG. 1 A depicts an exemplary fabric having a plurality of tufts, with two yams being provided within each tuft.
  • FIG. IB depicts an exemplary fabric having first and second pluralities of tufts, with the tufts of the first plurality of tufts being provided at a pile height that is greater than the pile height of the second plurality of tufts.
  • FIG. 1C depicts an exemplary fabric having first and second pluralities of tufts, with the tufts of the first plurality of tufts being provided at a pile height that is less than the pile height of the second plurality of tufts.
  • FIGS. 2A-2B are cross-sectional views of exemplary yams having a plurality of filaments.
  • FIG. 2A depicts the periphery of the yam, which is defined by portions of the outer surfaces of the filaments of the yam.
  • FIG. 2B depicts inner portions of respective filaments that can retain a base color or have a different color than adjacent portions of the yam after application of a color pattern to the yam.
  • FIG. 3 A is a schematic view of a portion of an exemplary yam having a first portion that is colored by a color pattern and a second portion that retains a base color or has a different color than the first portion after application of the color pattern.
  • FIG. 3B is a schematic view of a portion of an exemplary yam having a first portion that is colored by a first color of a color pattern and a second portion that is colored by a second color of the color pattern.
  • FIG. 4 is a schematic cross-sectional view of an exemplary tuft through a backing structure.
  • the tuft portions above the backing stmcture can be colored by a color pattern, while the back stitch (beneath the backing stmcture) can retain a base color or have a different color than the tuft portions.
  • FIGS. 5A-5B are top views of exemplary surface coverings as disclosed herein.
  • the surface covering can include a color pattern that defines at least a portion of a logo (FIG. 5 A) or a picture or graphical design (FIG. 5B) that includes a plurality of colors.
  • FIG. 6 is a schematic depiction of an exemplary system and method of forming a fabric and applying pigment or other colorant to the fabric and further processing the fabric to form a surface covering as disclosed herein.
  • FIG. 7 is a cross-sectional view of a plurality of yams commingled to form a multiple yam stmcture as disclosed herein.
  • FIG. 8 is a schematic diagram of a system for producing a tufted article as disclosed herein.
  • FIG. 9 is a side view of an exemplary system for producing a tufted article as disclosed herein.
  • 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.
  • 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).
  • 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 instmments 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.
  • backing structure 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 yam 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 yam in place during the fabric pile formation process.
  • materials such as polypropylene, polyesters, hemp, composites, blend, nylons, or cottons can be used to form the backing material.
  • the term “primary backing” refers to conventional backing materials that serve as the carrier for yam.
  • the backing layer is the component into which pile yam tufts are inserted by tufting needles.
  • Exemplary primary backing materials include woven or nonwoven polypropylene.
  • woven or knitted surface coverings it is contemplated that woven or knitted yams can form a primary backing from which upper pile yams extend.
  • yam refers to a continuous strand or bundle of fibers. Such yams can include, for example and without limitation, monofilament yams, cut yams, looped yams, fibrillated yams, multifilament yams, twisted yams, wrapped yams, staple yams, and the like. Optionally, yams can be textured using conventional methods. “Yams” as disclosed herein are capable of being independently delivered to a backing stmcture (for example, via tufting).
  • a yam can be a single end yam (single ply yam) or a multiple end yam (e.g., a plied yam) that includes plurality of single end yams that are entangled or otherwise commingled with one another (for example, by air entanglement, twisting, wrapping, and the like) such that the single end yams are no longer individually or independently moveable.
  • a plurality of single end yams can be twisted together to form a plied yam (e.g., a two-ply yam can include two single end yams that are twisted together).
  • the plurality of single end yams can be air-entangled to form a multiple end yam. In some aspects, the plurality of single end yams can be roto-twisted to form a multiple end yam. In some aspects, the plurality of single end yams can be air-twisted to form a multiple end yam.
  • Each single end yam can be formed from at least one filament (optionally, a plurality of filaments). Thus, within a multiple end yam, each single end yam that makes up the multiple end yam can include a respective filament or plurality of filaments.
  • yams 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 yam stmcture.
  • the term “denier” refers to the weight in grams of 9,000 meters of yam. “Denier per filament” refers to the denier (weight in grams of 9,000 meters) of a single filament of a yam. When the yam consists of a single end yam, the “total denier” of the yam can refer to the combined denier (i.e., the sum of the respective deniers) of all filaments of the single end yam.
  • the “total denier” of the yam can refer to the combined denier (i.e., the sum of the respective deniers) of the plurality of yam ends (the plurality of single end yams that define the multiple end yam).
  • the total denier, denier per fiber (dpf), and ply information can be used to determine the number of filaments within a given yam.
  • a single-ply yam can be identified as a 6000/4 dpf yam. This indicates that the single-ply yam has a total denier of 6000, and that each filament of the single-ply yam 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 yam.
  • the yam can instead be identified as a 6000/1500 filament yam (with the dpf being determined by dividing the total denier (6000) by the number of filaments (1500)).
  • a two-ply yam that has the same total denier (6000) but is formed by twisting or otherwise commingling two of the same single-end yams.
  • Such a yam can be identified as a 3000x2 yam, which indicates that the yam is a two-ply yam, with each ply corresponding to a single-end yam having a total denier of 3000.
  • the number of filaments of each of the single-end yams 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 yams. Therefore, the total number of filaments within the two-ply yam can be determined to be 600 (the sum of the number of filaments within the two single-end yams that make up the two-ply yam).
  • the yam bundle can include a first single-end yam that is a 3000/15 dpf yam and a second single-end yam that is a 3000/4 dpf yam.
  • the first single-end yam has a total denier of 3000, with each filament of the yam having a denier (per filament) of 15.
  • the second single-end yam has a total denier of 3000, with each filament of the yam having a denier (per filament) of 4.
  • the first single-end yam has 200 filaments (with each filament having a denier of 15 to provide a total denier of 3000), while the second single-end yam has 750 filaments (with each filament having a denier of 4 to provide a total denier of 3000).
  • 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.
  • 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.
  • first and second yams are described as associated with a backing.
  • these yams can be independently threaded into a single needle and then simultaneously associated with (e.g., tufted through or knit or woven into) the backing.
  • the first and second yams can be entangled and then pulled through the same needle together as an entangled stmcture and then simultaneously associated with (e.g., tufted through or knit or woven into) the backing.
  • the first and second yams can be tufted through respective needles and then associated with (e.g., tufted through or knit or woven into) the backing.
  • fabrics 10 having a primary backing 12 and yam 30 (e.g., at least a first yam 30a) associated with the primary backing.
  • the primary backing 12 can have a face surface 14 and an opposing rear surface 16.
  • the yam 30 associated with the primary backing 12 can extend outwardly from the face surface 14 of the primary backing in a direction 35 moving away from the primary backing.
  • at least one yam 30 of the fabric 10 e.g., the first yarn 30a
  • the yam 30 can be subjected to a dyeing or printing process to impart color to the yam.
  • the fabric 10 can comprise a combination of unpigmented natural yam and colored yam. In other aspects, all of the yam of the fabric 10 is pre-dyed yam.
  • one or more yams 30 of the fabric 10 can comprise a plurality of yam filaments 32.
  • each yam filament 32 of the plurality of yam filaments can be an unpigmented natural monofilament.
  • each yam filament 32 of the plurality of yam filaments can be a pigmented natural monofilament.
  • one or more yarns 30 of the fabric can comprise turf tape or monofilament blade yam.
  • the first yam 30a can be formed into a plurality of yam tufts 40 that extend through the primary backing 12.
  • the fabric 10 can further comprise a second yam 30b associated with the primary backing and extending outwardly from the face surface 14 of the primary backing 12 in the direction 35 moving away from the primary backing.
  • the second yam can be an unpigmented natural yam.
  • the first and second yams 30a, 30b can both be unpigmented natural yams.
  • the second yam 30b can be a pre-dyed yam with added pigment.
  • the fabric can comprise both pre-colored yams and unpigmented natural yams.
  • each yam of the fabric can be a pre-colored (e.g., pre-dyed) yam.
  • the first yam when the fabric 10 comprises first and second yams 30a, 30b, the first yam can be formed into a first plurality of yam tufts 40a that extend through the primary backing 12, and the second yam can be formed into a second plurality of tufts 40b that extend through the primary backing.
  • the first plurality of tufts 40a can be tufted at a first gauge spacing (for example, by a first tufting machine)
  • the second plurality of tufts 40b can be tufted at a second gauge spacing (for example, by a second tufting machine or by a second needle bar of the first tufting machine) that is offset from the first gauge spacing.
  • the second gauge spacing can be different than the first gauge spacing to account for differences in yam properties (e.g., density, diameter, etc.)
  • at least one of the first and second gauges can be 3/16 gauge.
  • respective rows of the second plurality of tufts 40b can be axially between sequential rows of the first plurality of tufts 40a.
  • the first plurality of tufts 40a can have a first pile height and the second plurality of tufts 40b can have a second pile height that is different than the first pile height. For example, as shown in FIG.
  • the first pile height can be greater than the second pile height.
  • the first pile height can be less than the second pile height.
  • the first pile height can be equal to the second pile height.
  • the each tuft of the first plurality of tufts can consist of the first yam, and that each tuft of the second plurality of tufts can consist of the second yam.
  • each tuft of the fabric 10 can correspond to a single yam type.
  • the first and second yams 30a, 30b can be formed into a plurality of yam tufts 40 that extend through the primary backing 12.
  • each yam tuft 40 of the plurality of yam tufts can comprise the first yam 30a and the second yam 30b.
  • the first and second yams 30a, 30b are not entangled (e.g., air-entangled) or otherwise directly coupled or secured together prior to delivery of the first and second yams through the primary backing.
  • the fabrics 10 disclosed herein can advantageously provide face stmctures in which the first and second yams 30a, 30b (and other yams of the plurality of yams, when provided) remain capable of independent, individual movement (relative to other yams). More particularly, when the first and second yams 30a, 30b are not commingled together or otherwise directly coupled to one another, the first and second yams 30a, 30b can have independent (and different) responses to further processing steps, such pigment application, steam, heat, and the like. Optionally, the first and second yams 30a, 30b are not commingled together or are only intermittently comingled together (e.g.
  • first and second yams can have independent (and different) responses in order to further permit independent response to further processing steps.
  • the ability of the first and second yams to have independent (and different) responses can allow for improved control and flexibility in the selective modification of the visual appearance and performance properties of the fabric after the yams are associated with the primary backing.
  • the first and second yams can have different shrinkage or bulk responses in response to heat or steam, thereby providing for modification of the relative pile heights of the different yams.
  • multiple end yams that include two different types of single yam ends (for example, those that are joined together by air entanglement, twisting, wrapping, etc.) can require extra manufacturing steps and restrict free movement of the single yam ends within the yam (thereby limiting modification of performance attributes and visual effects within the yam), with the single yam ends joining together to function as a uniform yam bundle that produces a more homogenous visual appearance in the finished surface covering.
  • multiple yams e.g., the first yam 30a, the second yam 30b, and the third yam 30c shown in FIG.
  • first yam 30a or the second yam 30b can consist of a single end yam, thereby providing improved isolation of color and enhancement of pattern outcomes in finished surface coverings as disclosed herein.
  • the first and second yams can represent any two distinct yams associated with the primary backing, with the first yam comprising at least one monofilament (e.g., optionally, a monofilament blade yam or a plurality of monofilaments) and the second yam comprising a conventional carpet or mg yam and the first yam having a larger dpf than the second yam.
  • the first yam comprising at least one monofilament (e.g., optionally, a monofilament blade yam or a plurality of monofilaments)
  • the second yam comprising a conventional carpet or mg yam and the first yam having a larger dpf than the second yam.
  • 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.
  • each yam tuft 40 of the plurality of yam 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).
  • a tuft 40 comprises a single yam
  • the tuft can comprise a single pair of tuft portions 42, which are joined by a single backstitch 44.
  • a tuft 40 comprises a plurality of yams (for example, two or three yam ends that are delivered concurrently through a backing by a single needle through which each of the two or three yam ends is threaded)
  • the tuft can comprise a plurality of pairs of tuft portions 42 (one pair for each yam), with each pair of tuft portions being joined by a respective backstitch portion.
  • the yam 30 of the fabric 10 can be woven into the primary backing 12 using conventional methods.
  • first and second yams 30a, 30b can be woven into the primary backing 12.
  • woven fabrics can comprise yam 30 that defines pile stmctures moving outwardly from the primary backing.
  • a portion of the woven yams can form the primary backing from which upper pile yams extend.
  • the yam 30 of the fabric 10 can be knitted into the primary backing 12 using conventional methods.
  • first and second yams 30a, 30b can be knitted into the primary backing 12.
  • knitted fabrics can comprise yam 30 that defines pile stmctures moving outwardly from the primary backing.
  • a portion of the knitted yams can form the primary backing from which upper pile yams extend.
  • exemplary stmctures for associating yam 30 with a primary backing 12 are disclosed herein (e.g., tufting, weaving, knitting), it is contemplated that any conventional mechanical or stmctural association between the yam 30 and the primary backing 12 can be employed.
  • the first yam 30a can comprise a plurality of yam filaments 32.
  • each yam filament 32 of the plurality of yam filaments of the first yam 30a can have a denier ranging from 61 to 3600 denier per filament (dpf), such as is typically found in an artificial turf yam.
  • dpf denier per filament
  • each yam filament 32 of the plurality of yam filaments of the first yam 30a can have a denier ranging from 61 to 1000 dpf or from 61 to 750 dpf or from 400 to 600 dpf.
  • other dpf values can be used depending on the particular application and desired performance properties.
  • the second yam 30b can comprise a plurality of yam filaments 32.
  • each yam filament 32 of the plurality of yarn filaments of the second yam 30b can have a denier per filament (dpf) ranging from 2 to 60 dpf, such as is typically found in a carpet yam.
  • each yam filament 32 of the plurality of yam filaments of the second yam 30b can have a denier per filament (dpf) ranging from 6 to 60 dpf or from 10 to 40 dpf.
  • At least one yam of the fabric 10 can comprise a turf yam, while at least one other yarn of the fabric can comprise a carpet yam.
  • the fabric 10 can function as a hybrid turf-carpet article, providing a combination of the properties offered (separately) by turf and carpet products.
  • turf yams can impart desired performance/durability properties
  • carpet yams can impart desired softness and texture properties.
  • turf or carpet properties can be selectively emphasized or deemphasized by controlling various properties of the yarns.
  • first and second yams 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, orup to 4000 individual filaments per yam (for either the first yarn 30a or the second yam 30b).
  • the yam filaments 32 of the second yam 30b can have a dpf ranging from 2 to 32.
  • the second yam 30b can be a conventional residential carpet yam as is known in the art.
  • the yam filaments 32 of the second yam 30b can have a dpf ranging from 22 to 60.
  • the second yam 30b can be a conventional commercial carpet yam as is known in the art.
  • the first and second yams can be provided within each respective tuft or pile extending through the primary backing of the fabric.
  • yam is hung on a creel and then the two yam ends 30a, 30b are fed through respective tubes until reaching a guide structure immediately before the needle bar of the tufting machine.
  • the two yams are fed together through one guide hole, and both yams 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 yams will pick up on the hooks for cutting.
  • one of the yams can be straight-set, and one of the yams can be texturized, so adjustments for tension can be necessary to ensure successful tufting.
  • the two yams can pass through the same tubes all the way to the needles for tufting, ft 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.
  • the fabric when the first and second yams form respective pluralities of tufts, it is contemplated that the fabric can be tufted using two needle bars with the first and second yams being fed separately to a respective needle bar.
  • the tufting settings of the first and second yams can be selectively adjusted up or down to produce desired aesthetics.
  • the tufting machine can comprise dual tufting needle bars with separate needles for each of the two yams.
  • 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.
  • the first and second yams 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 yams are no longer individually or independently moveable.
  • the first and second yams can optionally be provided from separate yam cones/packages.
  • the first and second yams can be entangled or otherwise commingled with one another (for example, by air entanglement, twisting, wrapping, and the like) to form a multiple yam stmcture 60 such that the first and second yams are no longer individually or independently moveable.
  • the first and second yam ends can be formed into, and be provided as, a single yam cone/package.
  • the multiple yam stmcture 60 can be threaded into a single needle. Accordingly, handling (e.g., transportation and threading) of the first and second yams (and any additional commingled yams) can be simplified.
  • first and second yarns are described in detail herein, it is contemplated that any desired number of different yams can be provided within a fabric as disclosed herein.
  • a third yam 30c can be provided along with first and second yams within each tuft of the plurality of tufts.
  • a third plurality of tufts of a different yam type can be associated with the backing stmcture (in addition to the first and second pluralities of yams).
  • a fourth yam and, optionally, a fifth yam can be provided with first and second yams within each tuft of the plurality of tufts.
  • a fourth plurality of tufts of a different yam type can be associated with the backing stmcture (in addition to the first, second, and third pluralities of yams).
  • the first yam 30a can be a first type of yam
  • the second and third yams 30b, c can both be a second type of yam.
  • the first yam can be or comprise a conventional turf yam (e.g., monofilament yam)
  • the second and third yams 30b, c can be or comprise conventional carpet yams (e.g., optionally, having a denier per filament (dpf) ranging from 2 dpf to 60 dpf).
  • dpf denier per filament
  • the second and third yams 30b, c can be the same type of yam. Accordingly, in these embodiments, for the sake of conciseness, the disclosure herein describing specific embodiments for the second yam should be understood as also describing specific embodiments for the third yam 30c, which is the same type of yam as the second yam 30b.
  • the second and third yams 30b, c can be different types of yam.
  • each of the first, second, and third yams 30a, b,c can be a different type of yarn.
  • the first, second, and third yams 30a, b,c can be entangled or otherwise commingled with one another to form a multiple yam stmcture.
  • the first, second, and third yams are not commingled and, thus, can be independently moveable relative to each other.
  • the first, second, and third yams 30a, b,c can be threaded through a single needle.
  • each of the first, second, and third yarns 30a, b,c can be independently tufted through, or otherwise associated with, the backing.
  • each yam filament 32 of the first yam 30a can be a monofilament.
  • each yam filament 32 of the first yam 30a can be a 100% nylon monofilament.
  • the nylon of the first yam can be nylon-6, nylon-6, 6, or other conventional forms of nylon.
  • the yam 30 of the fabric 10 can consist of a single yam, wherein each filament of the yam is a monofilament.
  • one or more yams 30 can be turf tape or monofilament blade yam.
  • the first yam 30a can consist of nylon. In further exemplary aspects, it is contemplated that each filament 32 of the first yam 30a can comprise a continuous filament.
  • the yarn filaments 32 of the first yam 30a can optionally be unpigmented natural filaments.
  • the first yam 30a can be solution-dyed on a “natural” setting without color pigment added during extmsion.
  • the first yam 30a can comprise color pigment added during extmsion and/or be dyed (e.g., via solution dying) prior to tufting, knitting, weaving, or otherwise integrating the first yam with the fabric 10.
  • the first yam 30a can be a 4400/8 monofilament yam, having a total denier of 4400 and a dpf of 550 (with a total of 8 monofilaments provided within the yam).
  • the first yam 30a can be a 4400/16 monofilament yam, having a total denier of 4400 and a dpf of 275 (with a total of 16 monofilaments provided within the yam).
  • the first yam 30a can be a 4400/32 yam, with a total denier of 4400 and a dpf of 137.5 (with a total of 32 monofilaments provided within the yam). In yet another example, the first yam 30a can be a 6600/8 monofilament yam, with a total denier of 6600 and a dpf of 825 (with a total of 8 monofilaments provided within the yam). In yet another example, the first yam 30a can be a 6600/12 monofilament yam, with a total denier of 6600 and a dpf of 550 (with a total of 12 monofilaments provided within the yam).
  • the first yam 30a can be a can be a 6600/24 monofilament yam, with a total denier of 6600 and a dpf of 275 (with a total of 24 monofilaments provided within the yam). More generally, it is contemplated that any desired total denier can be used for the first yam 30a, provided the individual monofilaments of the first yam have a dpf that is consistent with conventional turf yams.
  • the first yam 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.
  • each filament of the first yam 30a can be any shape that is conventionally used for turf yams.
  • each filament of the first yam 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.
  • any desired cross-sectional profile can be used.
  • the first yam 30a can have desirable durability and colorfastness properties.
  • the yam 30 of the fabric 10 can comprise a conventional turf yam (such as first yam 30a) and a conventional carpet yam (such as second yam 30b and, optionally, the third yam 30c).
  • the second yam can comprise nylon (e.g., nylon-6 or nylon-6, 6), polyester, or polypropylene.
  • the second yam 30b can comprise a 1362/2 ply (1362x2) continuous filament nylon yam, with a total denier of 2724.
  • the second yam 30b can comprise solution dyed nylon 1350/5 ply (1350x5) yam, with a total denier of 6,750.
  • each ply of the yams can comprise any desired number of filaments, with the dpf remaining below 60.
  • each filament 32 of the second yam 30b can be either a continuous filament or a non-continuous filament.
  • At least one of the first yam 30a or the second yam 30b can be a multiple end yam formed from at least two distinct single end yams (at least two ply).
  • at least two distinct single end yams that form the multiple end yam can have different dpf values that allow for creating distinct visual effects.
  • the first yam can comprise a first yam end having a 65 dpf value and a second yam end having a 65 dpf value, wherein both the first and second yam ends consist of monofilaments.
  • the second yam can comprise a first yam end having a 2 dpf value and a second yam end having a 30 dpf value.
  • the materials of the yams 30 of the fabric 10 can be selected based upon the intended use of the fabric.
  • 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.
  • special dyes or paints can be needed to impart color to PP and PE yams.
  • one of the yams can comprise PP and/or PE yams while another of the yams can comprise nylon.
  • color can be imparted to the nylon yam while color is not imparted to the PP and/or PE yams (due to the absence of the special dyes or paints needed to impart color to PP and/or PE yams), thereby producing unique face appearances.
  • the color patterns disclosed herein do not impart color to some of the face yams, even if paint or dye is applied to those face yams.
  • each filament of the second yam 30b can be any shape that is conventionally used for carpet yams.
  • the filaments of the second yam 30b can each have a cross-sectional profile having a tri-lobal shape as is known in the art.
  • the cross- sectional profile of the filaments of the second yam 30b can be selected to impart desired luster, firmness/softness, resiliency, and other properties.
  • the yam density of the fabrics can determine the final surface interactions between the yams and a ball or a human when the fabric is used in a flooring/playing surface installation.
  • the yam density can be modified to provide a desired amount of friction when the yam interacts with shoes.
  • yam densities can be varied along the surface of the fabric.
  • the yam density can change at locations where the face stmcture of the fabric changes (e.g., a change in color, yam type, bulkiness, pile heights, and the like).
  • a pad e.g., a polyurethane pad
  • a pad can be added to the fabric at locations where carpet surface properties change, thereby increasing human safety.
  • the first and second yams 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.
  • the first yam 30a can be an unpigmented natural yam that is not pre-dyed, while the second yam 30b can be pre-dyed.
  • both the first yam 30a and the second yam 30b can be pre-dyed or solution-dyed.
  • the first yam 30a and the second yam 30b can be dyed the same color to produce a solid look or dyed two different colors to produce a tweed look.
  • both the first yam 30a and the second yam 30b can be unpigmented natural yams. As yet another example, it is contemplated that both the first yam 30a and the second yam 30b can be pigmented yams.
  • cross-sectional shapes and/or sizes of the yams can be selectively varied to modify color and texture as further disclosed herein.
  • the primary backing 12 can comprise any conventional backing materials.
  • 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.
  • a method of forming a surface covering can comprise forming a face stmcture of a fabric.
  • the method can comprise securing at least one yam to (or otherwise associating at least one yam with) the primary backing such that the at least one yam extends outwardly from the face surface of the primary backing in a direction moving away from the primary backing.
  • the fabric can optionally comprise a plurality of yam tufts, which can include cut tufts, loop tufts, or combinations thereof.
  • the step of forming the face stmcture can comprise passing the at least one yam through the primary backing to define the plurality of yam tufts.
  • the fabric can optionally comprise a woven fabric. Therefore, in exemplary aspects, the step of forming the face stmcture can comprise weaving the first yam (optionally, a plurality of yarns) into the primary backing.
  • the fabric can optionally comprise a knitted fabric. Therefore, in exemplary aspects, the step of forming the face stmcture can comprise knitting the first yam (optionally, a plurality of yarns) into the primary backing.
  • At least one yam of the fabric can comprise a plurality of yam filaments, wherein each yarn filament of the plurality of yam filaments is an unpigmented natural yam as further disclosed herein.
  • at least one yam (optionally, a plurality of yams) of the fabric can comprise (optionally, consist of) yam filaments that are unpigmented natural filaments.
  • at least one yam of the fabric (optionally, each yam of the fabric) can be pre-colored (optionally, pre-dyed) prior to formation of the fabric.
  • At least one yam of the fabric can be an unpigmented natural yam, while at least one other yam of the fabric can be a pre-colored (optionally, pre-dyed) yam.
  • all yams of the fabric can be pigmented yams.
  • a system 200 for manufacturing the fabric 10 can comprise one or more tufting machines 202.
  • Each tufting machine 202 can define a respective tufting zone 204.
  • Each tufting machine can comprise a plurality of needles 206 that are configured to deliver yam into the backing 12 to form a plurality of tufts that extend through the backing.
  • each tufting machine 202 of the plurality of tufting machines can comprise a gantry.
  • the backing can have a length along the first axis 210 and a width along a second axis 212 that is perpendicular to the first axis.
  • 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 FIGS. 7-8, the backing feed roll can provide the backing to at least one tensioning apparatus, which is configured to guide the backing through the plurality of tufting machines while applying tension to the backing.
  • 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 yam into the backing to produce the plurality of tuft sequences.
  • each needle of the tufting machine can be configured to selectively form a tuft (or a tuft sequence).
  • 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 yam through a backing to form respective tuft sequences, other needles of the tufting machine are not instructed to deliver yam through the backing.
  • the needles 206 can be operatively associated with a conventional needle bar as is known in the art.
  • the needles of a respective tufting machine can be divided among a plurality of needle modules as further disclosed herein.
  • 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.
  • system 200 can further comprise loopers and/or cutting assemblies as are conventionally used to pull and/or cut tufts.
  • the needle bar assemblies and, optionally, the looper assemblies
  • the servo motors 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 instmctions 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.
  • 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.
  • 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.
  • 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 yam type.
  • the first tufting machine can be rotationally offset from the second tufting machine.
  • each tufting machine can have a longitudinal axis 230 along which each needle is spaced, ft 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.
  • ft 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, ft 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.
  • the first tufting machine can be configured to form stitch sequences having stitches of a first stitch length
  • 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
  • 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.
  • 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.
  • 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.
  • a coating e.g., optionally, polyurethane
  • at least one nozzle 242 can be configured to spray a coating on at least a portion of the backstitches of the tufted article.
  • the system 200 can further comprise one or more creel assemblies 270 that support yam packages can be positioned to the sides of or above the plurality of tufting machines, ft is contemplated that different sections of the creel assemblies 270 can have different yam types and/or different color yams, 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 yam within a particular tufting zone to achieve a selected tufting pattern.
  • the system 200 can comprise a yam delivery assembly 260 that is configured to deliver yam from the creel assemblies 270 to respective needles of the tufting machines.
  • the yam delivery assembly 260 can optionally comprise conventional yam delivery tubes as are known in the art. It is contemplated that the needles of each tufting machine can be configured to receive different yams 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 yam having a first color and a second plurality of needles that receive yam having a second color that is different than the first color. It is contemplated that the selection of yam color and other yam color characteristics can vary from needle-to-needle, both within a single tufting machine and among the plurality of tufting machines.
  • 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.
  • 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. Patent No. 8,695,519, which is incorporated herein by reference in its entirety.
  • the tensioning apparatus 250 can drive movement of the backing in a serpentine pattern comprising peak sections 209a where the backing passes through the gantry of a respective tufting machine and valley sections 209b where the backing is in between (before or after) sequential tufting machines.
  • peak sections 209a can be located where the backing is delivered to the tensioning apparatus from the feed roll and where the backing is delivered to the coating machine 240 (after tufting).
  • the system can further comprise a catwalk assembly 280, such as shown in FIG. 6.
  • 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.
  • the return section of the tensioning apparatus can receive the tufted article after a coating has been applied to the backstitches and then reverse the direction of travel of the tufted article so that the tufted article can be returned toward the tufting machines and the backing feed roll.
  • the return section of the tensioning apparatus can transition the tufted article from the upper section of the tensioning apparatus to the lower section of the tensioning apparatus.
  • the upper level 252 of the tensioning apparatus 250 can define a serpentine pattern of the backing as discussed above.
  • the lower level 254 can have a planar profile.
  • the at least one tensioning apparatus 250 can comprise a plurality of tensioning apparatuses that are each associated with a respective tufting machine.
  • 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).
  • the selected tolerance can be less than or equal to 1/3 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.
  • a first tufting machine can be programmed to deliver a series of tufts having a first profile (color, pile height, yam type, and the like) within a given row
  • 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.
  • 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 yam 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 yam to the tufting machines.
  • a method of manufacturing a tufted article as disclosed herein can comprise tufting the plurality of tufts through the backing.
  • 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.
  • each tuft of the plurality of tufts can have a backstitch.
  • the method can further comprise applying a coating over the backstitches of the plurality of tufts.
  • 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.
  • 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.
  • 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.
  • 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 yam to the backing.
  • 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 yam to the backing during tufting.
  • 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.
  • 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.
  • the plurality of sequentially positioned tufting machines can form a first tufting pattern using a set of tufting parameters
  • 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.
  • said at least one tufting parameter can comprise at least one of pile height, yam density, or yarn color.
  • the controller can modify said at least one tufting parameter without mechanically changing the configuration of the plurality of tufting machines.
  • 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.
  • 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.
  • 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.
  • 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.
  • a color pattern can be applied to the fabric 10.
  • the surface covering 20 can comprise a face structure 20 defined by the at least one yam 30 associated with the primary backing 12 and a color pattern applied to the face structure.
  • a system 1000 can comprise a fabric formation subsystem 1100 (e.g., a tufting machine (optionally, the system 200 of FIGS. 8-9), a knitting machine, a weaving machine, and the like), a pigment application subsystem 1200 (e.g., a dyeing apparatus or a printer as disclosed herein), and a coating and/or secondary backing application subsystem 1300 as is known in the art.
  • applying the color pattern can comprise applying dye to the face structure.
  • applying the color pattern can comprise printing ink onto the face structure.
  • applying the color pattern can comprise a pre-steam process that removes or flashes off yam finishes (that are present in the yam of the face stmcture of the previously formed fabrics). Then, the printer or dye applicator apparatus 1200 can be activated to apply ink or dye to the face stmcture. Steam and/or heat can then be applied to set the color pattern. Jet printers (indirect or direct), air jet printers, bubble jet printers, inkjet 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 yams that define a face structure of a fabric as disclosed herein.
  • acid based or pre-metalized dyes can be preferred for use with nylon yams, while disperse dyes can be preferred for use with PP and PET yams.
  • UV activated dyes can be used (e.g., fluorescent dyes along with glow in the dark dyes).
  • 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 instmction or series of instructions to apply a color pattern to the face structure as disclosed herein.
  • 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.
  • 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 stmcture, thereby producing the desired color pattern.
  • the color pattern 50 can comprise any desired combination of colors and design elements.
  • the color pattern 50 can comprise a single color that is applied across at least a portion of the face stmcture of the fabric.
  • variations in dye absorption among the various yams and within individual yams can produce desired patterning within the face stmcture.
  • the color pattern 50 can comprise a plurality of colors 52.
  • the disclosed methods for applying the color pattern can permit precise application of the plurality of colors 52 to achieve high-resolution visual patterns by application of pigment (ink or dye, for example) after the fabric is formed, without the need for relying on tufting multiple pre-dyed yams or cutting and securing together separately formed fabric stmctures.
  • the color pattern 50 can comprise one or more of a boundary, a marking, a field portion, text, or a graphic design.
  • the color pattern 50 can form at least a portion of a logo, a picture, a cartoon, or an image. For example, FIG.
  • FIG. 5A is a top view of a logo that is printed onto a sample surface covering 100.
  • FIG. 5B is a top view of a sample surface covering 100 formed by applying a color pattern 50 to the face stmcture 20 of a fabric 10.
  • the depicted graphical pattern is formed using a plurality of colors, including first and second colors 52a, 52b as labeled within the drawing.
  • any desired visual element or combination of visual elements can be applied to the face structure (optionally, during a single print cycle).
  • 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).
  • the disclosed surface coverings can be installed with improved consistency, integrity, and efficiency in comparison to conventional methods.
  • 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 yam density (controlled by the number of stitches), and modifications of these parameters can be driven by changes in yam 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.
  • At least two colors 52a, 52b of the plurality of colors of the color pattern are applied to a first yam 30 of the at least one yam. More particularly, due to the resolution achievable using the disclosed dyeing and printing methods, some yam portions of a given yam may receive different colors as part of the color pattern.
  • a first yam of the at least one yam can have a base color 39 (optionally, a natural color), and the first yam can comprise: a first portion 36 in which the color pattern 50 imparts color; and a second portion 38 in which the color pattern does not impart color.
  • the second portion 38 can retain the base color after application of the color pattern.
  • the base color 39 can either be an unpigmented natural color or a color associated with pre-dyeing of the yam (prior to application of the color pattern to the fabric). For example, as shown in FIG.
  • the color pattern can be applied to the outer portions of a yam 30 (corresponding to the first portion 36), and the second portion 38 of the yam can be positioned proximate the primary backing 12 such that the ink or dye from the color pattern does not reach the second portion 38 but still produces the color pattern in the face of the patterned article.
  • the rate or amount of dye or ink uptake within a given yam can vary, thereby producing color properties (e.g., a color tone) within the first portion 36 that are different than those of the second portion 36 (optionally, such that the look of the second portion 36 does not match the look of the intended color pattern at that location within the face stmcture).
  • the first portion 36 of a yam can have a dark tone of a color, while the second portion 38 of the yam can have a lighter tone of the same color.
  • at least a portion of the yam can retain the base color 39.
  • a first yam 30 of the at least one yam can comprise a plurality of yam filaments 32, with each yam filament having a respective outer circumferential surface 33. Portions 37 of the outer circumferential surfaces 33 of the plurality of yam filaments 32 can cooperate to define a periphery 31 of the first yam.
  • the color pattern 50 can impart color to the periphery 31 of the first yam, while the color pattern does not impart color to at least a portion 34 of the outer circumferential surfaces 33 of the filaments 32 that face away (inwardly) from the periphery 31 of the first yam.
  • portions 34 of the outer circumferential surfaces 33 can retain a base color 39 even after color is applied to the periphery 31 of the yam.
  • the rate or amount of dye or ink uptake within a given yam can vary, thereby producing color properties (e.g., a color tone) within the portions 37 that are different than those of portions 34 (optionally, such that the look of portions 37 does not match the look of the intended color pattern at that location within the face stmcture).
  • portions 37 of a yam can have a dark tone of a color
  • portions 34 of the yam can have a lighter tone of the same color.
  • each tuft 40 of the plurality of tufts of the surface covering 100 can have at least one pair of outwardly extending tuft portions 42 that are joined by a backstitch 44, and wherein the color pattern does not impart color to the backstitch.
  • the backstitch 44 after application of color 52 to the face stmcture of the fabric, at least a portion of the backstitch 44 (optionally, the entire backstitch) can retain its base color 39, which can be an unpigmented natural color or a pre-dyed color.
  • the rate or amount of dye or ink uptake within a given yam can vary, thereby producing color properties (e.g., a color tone) within the upwardly extending tuft portion(s) 42 that are different than those of the backstitch 44.
  • the upwardly extending tuft portion(s) 42 of a yam can have a dark tone of a color, while the associated backstitch 44 of the yam can have a lighter tone of the same color.
  • at least a portion of the yam (such as a portion of the backstitch) can retain the base color 39.
  • 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.
  • a fabric comprises tufts that comprise a plurality of yam types within a tuft (such as, for example, a turf yam and a carpet yam as disclosed herein)
  • a color of the color pattern to the two different yam types within a single tuft can result in different amounts or rates of yarn uptake among the various yam types, leading to variations in appearance within the tuft and among adjacent tufts.
  • the turf yam e.g., a monofilament yam
  • a pre-dyeing process prior to applying dye or ink to the fabric to provide the color pattern, can be completed.
  • the predyeing process can comprise modifying bulk, shrinkage, and/or texture properties of the face yams 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 yam extmsion industry.
  • Exemplary equipment for texturizing the yarns includes the yam texturizing equipment manufactured by BARMAG and DEITZ & SCHELL.
  • steam can be applied to prepare the face yams for dyeing.
  • the patterned article can be heated in an oven to finalize the appearance and stmcture 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 yams.
  • the properties of the yams 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 yam: 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 yams for yams with different properties.
  • the backstitches of tufts of the fabric can be coated using conventional methods (for example, using a coating apparatus 1300 as shown in FIG. 6).
  • the coating of the backstitches of the tufts can be performed after printing on or dyeing of the face stmcture of the fabric.
  • the cross sections and/or sizes of the yams 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 yams (e.g., the pile heights of yam 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 yams are extmded, and the yams can be put together to produce a fabric 10 with desired performance features that are optimized for receiving a color pattern as disclosed herein.
  • control of the finished pile heights of the yams e.g., the pile heights of yam tufts
  • bulking or shrinkage recipes as are known in the art. Therefore, denier, bulk level, yarn shrinkage, and other properties can be determined as various yams are extmded, and the yams can be put together to produce a fabric 10 with desired performance features that are optimized for receiving
  • the pile heights and bulk and/or shrinkage properties of the lower or upper yams of each fabric can be selectively controlled and modified to provide a desired finished face fiber profile. More generally, it is contemplated that yam selection, yam color, yam 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.
  • the denier (i.e., size) of the A yam or the B yam can be increased or decreased to change the base level density of the surface covering.
  • the denier of the A yam e.g., a monofilament turf yam as disclosed herein
  • the bulk levels of the yams can be controlled, to adjust the amount of the A yam that serves as an “up blade” that extends above the finished pile height of the second yam.
  • the first yam can extend a first distance (e.g., about 3/16”) above the second yam.
  • a 10% bulk can cause the first yam to be a second distance (e.g., about 1/8”) higher than the second yam
  • a 20% bulk can cause the first yam to be a third distance (e.g., about 1/16”) above the second yam
  • a 30% bulk can cause the first yam to be a fourth distance (e.g., about 1/32”) above the second yam
  • a 40 % bulk can cause the first yam to be about even with the second yam
  • a 50% bulk can cause the first yam to be below the second yam by a fifth distance (e.g., about 1/32”)
  • a 60 % bulk can cause the first yam to be below the second yam by a sixth distance (e.g., about 1/8”).
  • the first yam can act as a resilient cushion yam built into the carpet stmcture by serving as a filler-thatch-spring layer to support the second (upper) yam (e.g., carpet yam B).
  • the first yam e.g., the turf yam
  • the first yam 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) yam.
  • the first yam (e.g., a monofilament turf yam) can be exposed to a 30% bulk process such that the first yam is at about 30% bulk, causing the pile height of the first yam to be about 1/32” above the second yam (e.g., the carpet yam), or about 1/64” above the second yam, for overdyeing a solid shade or printing a color pattern as further disclosed herein.
  • the first yam can dye at a different uptake/strike rate and have a different (e.g., slightly lighter) color than the second yam.
  • 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.
  • the pile heights of the yams can be selected to achieve various appearance and performance goals.
  • the pile heights can range from about ‘A” to about 1”.
  • any selected pile height can be used.
  • the first yam e.g., the carpet yam, which can optionally comprise a monofilament yam as disclosed herein
  • the second yam has a lower pile height, thereby producing a shag-carpet type look.
  • a golf ball can be held up (supported) in a desired fashion to provide a better-performing tee- type turf article.
  • the primary backing 12 can be provided as a component of a backing stmcture 11 that can include at least one secondary backing 18 or at least one additional backing layer that supports the primary backing or first backing layer.
  • a backing stmcture 11 can include at least one secondary backing 18 or at least one additional backing layer that supports the primary backing or first backing layer.
  • tufts or fabric pile yams can be delivered through the primary backing 12 (or first backing layer).
  • other backing materials or layers can be combined with the primary backing to produce a final surface covering as further disclosed herein.
  • the backing stmcture 11 can consist of a single primary backing layer.
  • the surface covering 100 can comprise a multi-layered backing stmcture.
  • the surface covering 100 can optionally comprise at least one yam, a primary backing, a back coating to hold the yam 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.
  • any desired material for the secondary backing can be used.
  • 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.
  • the surface covering 100 can comprise an infill.
  • the infill can comprise a single component or any combination of a plurality of components.
  • the infill material can optionally comprise a plurality of layers, with each layer corresponding to a different infill component or combination of components.
  • the plurality of components can be provided as a mixture, which can be either homogenous or non-homogenous.
  • 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.
  • the disclosed systems and methods can produce a turf carpet using 100% nylon Monofilament yam with overprinting or secondary dyeing of a solution dyed fiber for solid or multicolored visuals.
  • the disclosed systems and methods can produce a hybrid turf-carpet article using at least one yam bundle that is a conventional residential carpet yam combined with a turf yam conventional to the turf industry such as Nylon, polypropylene (PP), polyethylene terephthalate (PET), polylactic acid (PLA) or polyurethane (PU) yams. It is contemplated that at least a portion of the yarns (optionally, the entirety of the yams) can comprise virgin or recycled resin(s). Monofilament yams or multi-yam bundles of blade shapes and/or various cross sections can be used.
  • yams can accept dye or be left as their natural color state with selection of ink or dye formulations that will not dye the Turf yams along with the Residential yams.
  • Such residential yams can have small dpf values ranging from 2-32 dpf.
  • the turf yam can be provided in combination with a commercial carpet grade yam, which is typically in the range of 22-60 dpf.
  • a turf carpet (hybrid) article can comprise one or more types of yams (1, 2, 3, 4, 5, 6 or more types of yams) that are combined by multiple yam end-per tuft penetration or by using thread-ups of single or combined ends in a partem thread up, with distinct types of yams being combined with each other (e.g., turf yams being provided with or alongside carpet yams).
  • 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.
  • carpet yams and turf yams together can allow for manufacture of patterned turf carpet articles on a variety of carpet production machines. It is contemplated the combination of both yam types into a single fabric provides a hybrid fabric product with unique performance properties that neither yam 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 yam types as disclosed herein. It is contemplated that such fabrics can be produced with or without pre-dyed yams and with or without secondary steps such as printing to make graphic images or other color patterns on the fabric.
  • various embodiments disclosed herein comprise using all unpigmented yams, all pigmented yams, or a combination of pigmented and unpigmented yams to form a patterned fabric.
  • Said patterned fabric can be formed via weaving, knitting, tufting or any other suitable manufacturing method.
  • 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 yam.
  • the fabric can have multi-level, multi-bulk / shrinkage yams that are used to form a specialty surface characteristics using pre-dyed or colored yams and using a fabric forming machine to impart a desired pattern.
  • the pattern can be formed by coloring the fabric 10 itself. Exemplary Considerations and Applications
  • 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 yam (e.g., the monofilament blade yam) should be increased to provide more realistic looking turf and better footing and durability.
  • the first yam e.g., the monofilament blade yam
  • Ball roll properties can be another factor when selecting face yam properties. It is contemplated that for soccer, field hockey and golf, the higher the pile height of the first yam (e.g., the “blade” yam), the slower and less tme the ball roll will be. It is contemplated that by using a textured monofilament yam that has more resiliency and stiffness than the second (carpet) yam, the first yam 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 yams can be the same or substantially the same.
  • the pile height of the first yam can be greater than the pile height of the second yam by a selected percentage (for example, about 60% higher than the second yam).
  • the pile height of the first yam can be a selected percentage greater than the pile height of the second yam (for example, 25%, 50%, or 75% higher than the second yam).
  • the first yam can be subjected to a low bulk process of about 5 to about 15 percent bulk.
  • the pile height of the first yam can be a selected percentage higher (e.g., about 20% higher) than the pile height of the second yam.
  • 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 stmcture.
  • the pile heights of the second (carpet) yam can be near the heights of the first (turf) yam to provide optimal clarity.
  • providing the first (turf) yam 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 mg for a child's bedroom, a more open gauge of tufting machine can be used for a higher and less dense fabric design. Softer yams can also be employed.
  • 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.
  • the disclosed systems and methods can be used to produce wall murals as well as full scale or miniature scale Golf Courses.
  • 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.
  • 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.
  • the disclosed systems and methods can be used to produce a hanging vertical stmcture (such as those used in golf simulators) or a wall covering.
  • 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 yams 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.
  • 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 yams.
  • 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.
  • the turf yams can provide the high traffic performance while the addition of the conventional carpet yams can provide the surface area for absorbing and holding the dyestuffs, thereby allowing for a clear pattern design
  • the disclosed surface coverings can be in any installation, particularly installations where it is useful to incorporate graphics into the installation.
  • 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.
  • the disclosed surface coverings can be provided as modular turf stmctures that are optimized for indoor applications.
  • 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.
  • the disclosed surface coverings can be optimized for use in applications where the properties of a turf yam (e.g., a first yam as disclosed herein) are emphasized (optionally, emphasized relative to a carpet yam (e.g., a second yam as disclosed herein)).
  • a turf yam e.g., a first yam as disclosed herein
  • the disclosed surface coverings can be used to form at least a portion of an indoor or outdoor running track, with portions of the yams being colored or patterned to define running lanes, finish lines, and other boundaries.
  • running tracks can further comprise team logos and other graphical elements.
  • 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 “comer”), and the like.
  • sections of the baseball field can be removed and replaced periodically in response to wear/usage.
  • these sections of the baseball field can comprise base path markings and/or color changes representing transitions from grass to dirt areas.
  • 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.
  • the disclosed sections of the field can comprise logos that are formed by color differences among the yams or by a color pattern as disclosed herein.
  • a hybrid turf-carpet article comprising: a backing stmcture comprising a primary backing having a face surface and an opposing rear surface; and a plurality of yams 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, wherein the plurality of yarns comprises: a first yam having a plurality of yam filaments, wherein each yam filament of the plurality of yam filaments of the first yam has a denier ranging from 61 to 3,600 denier per filament (dpf); and a second yam having a plurality of yam filaments, wherein each yam filament of the plurality of yam filaments of the second yam has a denier per filament (dpf) ranging from 2 to 60 dpf.
  • Aspect 2 wherein the yam filaments of the second yam have a dpf
  • Aspect 3 The article of aspect 1 , wherein the yam filaments of the second yam have a dpf ranging from 22 to 60.
  • Aspect 4 The article of any one of aspects 1-3, wherein the plurality of yams are tufted through the primary backing to define a plurality of yam tufts, wherein each tuft of the plurality of tufts comprises the first yam and the second yarn, and wherein the first yam is not entangled with the second yam.
  • Aspect 5 The article of any one of aspects 1-3, wherein the first yam is tufted through the primary backing to define a first plurality of yam tufts, and wherein the second yam is tufted through the primary backing to define a second plurality of yam tufts, wherein each tuft of the first plurality of yarn tufts consists of the first yam, and wherein each tuft of the second plurality of yam tufts consists of the second yam.
  • Aspect 6 The article of aspect 1, wherein each yam filament of the first yam is a monofilament.
  • Aspect 7 The article of any one of aspects 1-6, further comprising a color pattern applied to the plurality of yams.
  • Aspect 8 The article of aspect 7, wherein at least one yam tuft of the plurality of yam tufts comprises: a first portion in which the color pattern imparts color to an exterior surface of the first portion; and a second portion in which the color pattern does not impart color to an exterior surface of the second portion, wherein the second portion retains the base color.
  • Aspect 9 The article of any one of aspects 1-8, wherein the plurality of yams further comprises a third yam having a plurality of yam filaments, wherein each yam filament of the plurality of yam filaments of the second yam has a denier per filament (dpf) ranging from 2 to 60 dpf.
  • dpf denier per filament
  • Aspect 10 The article of aspect 9, wherein the third yam is commingled with the first and second yams.
  • Aspect 11 The article of aspect 9, wherein the third yam is commingled with the first and second yams.
  • a method comprising: forming a face stmcture of a fabric, wherein forming the face stmcture comprises securing a plurality of yams to a primary backing having a face surface and an opposing rear surface, wherein the plurality of yams extend outwardly from the face surface of the primary backing in a direction moving away from the primary backing, wherein the plurality of yams comprise: a first yam having a plurality of yam filaments, wherein each yam filament of the plurality of yam filaments of the first yam has a denier ranging from 61 to 3,600 denier per filament (dpf); and a second yam having a plurality of yam filaments, wherein each yam filament of the plurality of yam filaments of the second yam has a denier per filament (dpf) ranging from 2 to 60 dpf; and applying a color pattern to the face st
  • Aspect 13 The method of aspect 12, wherein the yam filaments of the second yam have a dpf ranging from 2 to 32.
  • Aspect 14 The method of aspect 12, wherein the yam filaments of the second yam 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 yam tufts, wherein each tuft of the plurality of tufts comprises the first yam and the second yam.
  • Aspect 16 The method of any one of aspects 12-14, further comprising: tufting the first yam through the primary backing to define a first plurality of yam tufts; and tufting the second yam through the primary backing to define a second plurality of yam tufts.
  • Aspect 17 The method of any one of aspects 12-16, wherein each yam filament of the first yam is a monofilament.
  • Aspect 18 The method of any one of aspects 12-18, wherein the first yam comprises a plurality of yam filaments, wherein each yam filament of the plurality of yam 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 stmcture.
  • Aspect 20 The method of any one of aspects 12-18, wherein applying the color pattern comprises printing ink onto the face stmcture.
  • 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 yams are tufted through the primary backing, and wherein coating is applied over backstitches formed by the plurality of yams
  • 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 yams are positioned on a rear side of the primary backing, and wherein method comprises melting said at least a portion of the plurality of yams that is positioned on a rear side of the primary backing.
  • Aspect 28 The method of aspect 27, wherein the plurality of yams 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 yams.
  • a surface covering comprising: a backing structure comprising a primary backing having a face surface and an opposing rear surface; and a face structure defined by at least one yam 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, wherein the at least one yam of the face stmcture comprises a first yam, wherein the face stmcture has a color pattern.
  • Aspect 30 The surface covering of aspect 29, wherein the color pattern is applied to the face stmcture.
  • 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 yam.
  • Aspect 32 The surface covering of any one of aspects 29-31, wherein the at least one yam comprises a first yam comprising a plurality of yam filaments, wherein each yam filament of the plurality of yam filaments of the first yam is a monofilament.
  • Aspect 33 The surface covering of aspect 32, wherein the at least one yam further comprises the second yam having a plurality of yam filaments, wherein each yam filament of the plurality of yam filaments of the second yam has a denier per filament (dpf) ranging from 2 to 60 dpf.
  • dpf denier per filament
  • Aspect 34 The surface covering of aspect 33, wherein the plurality of yams comprises further at a third yam having a plurality of yam filaments, wherein each yarn filament of the plurality of yam filaments of the second yam has a denier per filament (dpf) ranging from 2 to 60 dpf.
  • dpf denier per filament
  • Aspect 35 The surface covering of aspect 34, wherein the third yam is commingled with the first and second yams.
  • Aspect 36 The surface covering of aspect 34, wherein the third yam is commingled with the first and second yams.
  • a fabric comprising: a primary backing having a face surface and an opposing rear surface; and a first yam 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, wherein the first yam is an unpigmented natural yarn.
  • Aspect 38 The fabric of aspect 37, wherein the first yam comprises a plurality of yam filaments, and wherein each yam filament of the plurality of yam filaments is an unpigmented monofilament.
  • Aspect 39 The fabric of aspect 37 or aspect 38, wherein the first yam 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 yam 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 yam is an unpigmented natural yam.
  • Aspect 42 The fabric of aspect 40, wherein the second yam is a dyed yam with added pigment.
  • Aspect 43 The fabric of any one of aspects 40-42, wherein the first yam is formed into a first plurality of yam tufts that extend through the primary backing, and wherein the second yam 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 yams are formed into a plurality of yam tufts that extend through the primary backing, wherein each yarn tuft of the plurality of yam tufts comprises the first yam and the second yam.
  • Aspect 45 The fabric of any one of aspects 40-44, wherein the first yam comprises a plurality of yam filaments, wherein each yam filament of the plurality of yam filaments of the first yam has a denier ranging from 61 to 3600 denier per filament (dpf), and wherein the second yam comprises a plurality of yam filaments, wherein each yam filament of the plurality of yam filaments of the second yam has a denier per filament (dpf) ranging from 2 to 60 dpf.
  • dpf denier per filament
  • Aspect 46 The fabric of aspect 45, wherein each yam filament of the plurality of yam filaments of the first yam is a continuous filament, and wherein each yam filament of the plurality of yam filaments of the second yam is a continuous filament.
  • Aspect 47 The fabric of any one of aspects 40-46, further comprising a third yam 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 yam is commingled with the first and second yams.
  • Aspect 49 The fabric of aspect 48, wherein the first yam comprises a plurality of yam filaments, and wherein each yam filament of the plurality of yam filaments is an unpigmented monofilament, wherein the second yam comprises a plurality of yam filaments, wherein each yarn filament of the plurality of yam filaments of the second yam has a denier per filament (dpf) ranging from 2 to 60 dpf, and wherein the third yam comprises a plurality of yam filaments, wherein each yam filament of the plurality of yam filaments of the third yam has a denier per filament (dpf) ranging from 2 to 60 dpf.
  • dpf denier per filament
  • Aspect 50 The fabric of aspect 47, wherein the third yam is not commingled with the first and second yams.
  • a surface covering comprising: a backing stmcture comprising a primary backing having a face surface and an opposing rear surface; and a face stmcture defined by at least one yam 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, wherein the at least one yam of the face stmcture comprises a first yam; and a color partem applied to the face stmcture.
  • Aspect 52 The surface covering of aspect 51, wherein the first yam comprises a plurality of yam filaments, wherein each yam filament of the plurality of yam filaments of the first yam is a monofilament.
  • Aspect 53 The surface covering of aspect 52, wherein each yam filament of the plurality of yam filaments of the first yam is a 100% nylon monofilament.
  • Aspect 54 The surface covering of any one of aspects 51-53, wherein the first yam is formed into a plurality of yam tufts that extend through the primary backing.
  • Aspect 55 The surface covering of aspect 54, wherein each yam tuft of the plurality of yam 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 yam comprises a first yam and a second yam.
  • Aspect 58 The surface covering of aspect 58, wherein the first yam is formed into a first plurality of yam tufts that extend through the primary backing, and wherein the second yam 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 yams are formed into a plurality of yam tufts that extend through the primary backing, wherein each yam tuft of the plurality of yam tufts comprises the first yam and the second yarn.
  • Aspect 60 The surface covering of aspect 57, wherein the first and second yams are woven into the primary backing.
  • Aspect 61 The surface covering of aspect 57, wherein the first and second yams 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 yam of the at least one yam.
  • 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 yam of the at least one yam has a base color, wherein the first yam comprises: a first portion in which the color pattern imparts color to an exterior surface of the first portion; and a second portion in which the color pattern does not impart color to an exterior surface of the second portion, wherein the second portion retains the base color.
  • Aspect 67 The surface covering of any one of aspects 51-66, wherein the first yam of the at least one yam comprises a plurality of yam filaments, each yam 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 yam, wherein the second portion of the first yam is at least partially defined by portions of the outer circumferential surfaces that face away from the periphery of the first yam.
  • Aspect 68 The surface covering of any one of aspects 58-67, wherein each yarn tuft of the plurality of yam 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 yam further comprises a third yam.
  • Aspect 71 The surface covering of aspect 70, wherein the third yam is commingled with the first and second yams.
  • Aspect 72 The surface covering of aspect 70, wherein the third yam is not commingled with the first and second yams.
  • Aspect 73 The surface covering of any one of aspects 57-72, wherein the first yam is an unpigmented natural yam.
  • Aspect 74 The surface covering of any one of aspects 57-72, wherein the first and second yams are pigmented.
  • Aspect 75 The surface covering of any one of aspects 57-74, wherein the first and second yams are pigmented associated with the backing in an arrangement to form a pattern.
  • a method comprising: forming a face structure of a fabric, wherein forming the face structure comprises securing at least one yam to a primary backing having a face surface and an opposing rear surface, wherein the at least one yam extends outwardly from the face surface of the primary backing in a direction moving away from the primary backing, wherein the at least one yam comprises a first yam; and applying a color pattern to the face stmcture of the fabric.
  • Aspect 77 The method of aspect 76, wherein forming the face stmcture comprises passing the at least one yam through the backing stmcture to define a plurality of yam tufts.
  • Aspect 78 The method of aspect 76, wherein forming the face stmcture comprises weaving the at least one yam into the backing stmcture.
  • Aspect 79 The method of aspect 76, wherein forming the face stmcture comprises knitting the at least one yam into the backing stmcture.
  • Aspect 80 The method of any one of aspects 76-79, wherein the first yam comprises a plurality of yam filaments, wherein each yam filament of the plurality of yam 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 stmcture.
  • Aspect 82 The method of any one of aspects 76-80, wherein applying the color pattern comprises printing ink onto the face stmcture.
  • 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: applying a coating to the rear surface of the primary backing; and applying a secondary backing to the coating.
  • Aspect 87 The method of any one of aspects 76-86, wherein the first yam is an unpigmented natural yam.
  • Aspect 88 The method of any one of aspects 76-87, wherein the first yam is turf tape or monofilament blade yam.
  • Aspect 89 The surface covering of any one of aspects 51-74, wherein the at least one yam of the face structure comprises turf tape or monofilament blade yam.
  • Aspect 90 The hybrid turf-carpet article of any one of aspects 1-11, wherein the first yam comprises turf tape or monofilament blade yam.
  • Aspect 91 The method of any one of aspects 12-28, wherein the first yam comprises turf tape or monofilament blade yam.
  • Aspect 92 The surface covering of any one of aspects 29-36, wherein at least one of the at least one yam comprises turf tape or monofilament blade yam.
  • Aspect 93 The fabric of any one of aspects 37-51, wherein the first yam comprises turf tape or monofilament blade yam.

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  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Architecture (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Materials Engineering (AREA)
  • Yarns And Mechanical Finishing Of Yarns Or Ropes (AREA)
  • Woven Fabrics (AREA)
  • Carpets (AREA)

Abstract

L'invention concerne un article de tapis-gazon hybride comprenant : une structure de support ayant une surface avant et une surface arrière opposée; et une pluralité de fils associés au support primaire et s'étendant vers l'extérieur depuis la surface avant du support primaire dans une direction s'éloignant du support primaire, la pluralité de fils comprenant : un premier fil présentant une pluralité de filaments de fil, chaque filament de fil de la pluralité de filaments de fil du premier fil ayant un denier allant de 61 à 3600 deniers par filament (dpf); et un second fil ayant une pluralité de filaments de fil, chaque filament de fil de la pluralité de filaments de fil du second fil ayant un denier par filament (dpf) allant de 2 à 60 dpf.
PCT/US2022/046086 2021-10-08 2022-10-07 Tissus, revêtements de surface comprenant ceux-ci, et systèmes et procédés de production de ceux-ci Ceased WO2023059897A1 (fr)

Priority Applications (4)

Application Number Priority Date Filing Date Title
EP22879338.6A EP4413196A4 (fr) 2021-10-08 2022-10-07 Tissus, revêtements de surface comprenant ceux-ci, et systèmes et procédés de production de ceux-ci
CN202280072971.XA CN118234904A (zh) 2021-10-08 2022-10-07 织物、包括所述织物的表面覆盖物以及用于产生所述织物的系统和方法
MX2024004065A MX2024004065A (es) 2021-10-08 2022-10-07 Tejidos, recubrimientos que los comprenden y sistemas y métodos para producirlos.
CA3233624A CA3233624A1 (fr) 2021-10-08 2022-10-07 Tissus, revetements de surface comprenant ceux-ci, et systemes et procedes de production de ceux-ci

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US202163253697P 2021-10-08 2021-10-08
US63/253,697 2021-10-08

Publications (1)

Publication Number Publication Date
WO2023059897A1 true WO2023059897A1 (fr) 2023-04-13

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Country Status (6)

Country Link
US (2) US20230115841A1 (fr)
EP (1) EP4413196A4 (fr)
CN (1) CN118234904A (fr)
CA (1) CA3233624A1 (fr)
MX (1) MX2024004065A (fr)
WO (1) WO2023059897A1 (fr)

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WO2025024660A1 (fr) * 2023-07-25 2025-01-30 Seaton Reed J Système et procédé de conception, de fabrication et d'installation de gazon synthétique personnalisé
WO2025133835A1 (fr) * 2023-12-20 2025-06-26 Aladdin Manufacturing Corporation Gazon artificiel tissé

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Also Published As

Publication number Publication date
MX2024004065A (es) 2024-05-29
CA3233624A1 (fr) 2023-04-13
US20230115841A1 (en) 2023-04-13
EP4413196A1 (fr) 2024-08-14
CN118234904A (zh) 2024-06-21
US20250223757A1 (en) 2025-07-10
EP4413196A4 (fr) 2025-07-02

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