CN220927170U

CN220927170U - Tufted articles

Info

Publication number: CN220927170U
Application number: CN202321136239.2U
Authority: CN
Inventors: G·D·福勒; M·马西斯
Original assignee: Shaw Industries Group Inc
Current assignee: Shaw Industries Group Inc
Priority date: 2022-05-11
Filing date: 2023-05-11
Publication date: 2024-05-10
Anticipated expiration: 2033-05-11

Abstract

Disclosed herein are tufted articles comprising a backing having a vertical axis. The backing includes an open structure material having a first surface and an opposing second surface. The open structure material includes a plurality of fibers. The plurality of fibers defines void spaces through the open structure material from the first surface to the second surface based in part on the variability of the fibers along the vertical axis. The void space is configured to allow liquid or vapor to pass from the first surface to the second surface of the open structure material. The scrim layer is coupled to an opposite second surface of the open structure material. The scrim layer has an open network structure. A plurality of second fibers are tufted through the backing and extend upwardly from the first surface of the open structure material.

Description

Tufted articles

Cross Reference to Related Applications

The present application claims priority and filing date benefits from U.S. provisional patent application Ser. Nos. 63/340,545 and 63/347,069 filed on 5/31 of 2022, 5/11, each of which is incorporated herein by reference in its entirety for all purposes.

Technical Field

The present disclosure relates generally to tufted articles, and in particular, to tufted articles (e.g., tufted artificial turf articles or tufted carpet articles) having a permeable backing layer.

Background

Air and water permeability can be important for tufted articles such as carpets and artificial turf. Conventionally, in order to achieve air and water permeability, the backing has perforations formed therethrough. For example, a hot needle (e.g., a heated conical spike), a drill, or a punch may pierce the backing to form perforations to provide the desired air and water permeability. However, the formation of the perforations increases manufacturing costs and time and leads to complications such as machine maintenance and manufacturing downtime. Thus, there is a need for a backing that is sufficiently breathable or water permeable without the need for additional processes to form perforations through the backing.

Disclosure of utility model

In one aspect, tufted articles comprising a backing are described herein. The backing includes a plurality of woven fibers defining a woven backing structure having a first surface and an opposing second surface. Void spaces are defined between respective ones of the plurality of woven fibers of the woven backing structure. The void space is configured to allow liquid or vapor to pass from the first surface to the second surface of the woven backing structure. A scrim layer (SCRIM LAYER) is coupled to an opposite second surface of the woven backing structure. The scrim layer has an open network structure. The second surface of the woven backing structure and the scrim layer cooperate to define a lower surface of the backing. Alternatively, a polymeric coating may be applied to the lower surface of the backing. At least a portion of the scrim prevents the polymer coating from entering at least one of the void spaces defined between respective ones of the plurality of woven fibers of the woven backing structure.

In one aspect, disclosed herein are tufted articles comprising a backing having a vertical axis. The backing includes an open structure material having a first surface and an opposing second surface. The open structure material includes a plurality of fibers. The plurality of fibers defines void spaces through the open structure material from the first surface to the second surface based in part on the variability of the fibers along the vertical axis. The void space is configured to allow liquid or vapor to pass from the first surface to the second surface of the open structure material. The scrim layer is coupled to an opposite second surface of the open structure material. The scrim layer has an open network structure. A plurality of second fibers are tufted through the backing and extend upwardly from the first surface of the open structure material.

In one aspect, a method of forming a tufted article is described herein. The method includes braiding a plurality of fibers together to form a braided backing structure having a first surface and an opposing second surface, the braided backing structure defining void spaces between respective braided fibers of the plurality of braided fibers of the braided backing structure, wherein the void spaces are configured to allow liquid to pass from the first surface to the second surface of the braided backing structure. The plurality of second fibers may be tufted through the backing such that the plurality of fibers extend upwardly from the first surface of the woven backing structure. The method does not include forming an opening through the backing.

In one aspect, described herein is a method comprising installing a tufted article as disclosed herein on a subfloor. The liquid is received through void spaces defined between respective ones of the plurality of woven fibers of the woven backing structure.

Additional advantages of the utility model will be set forth in part in the description which follows, and in part will be obvious from the description, or may be learned by practice of the utility model. The advantages of the utility model may be realized and obtained by means of the elements and combinations particularly pointed out in the appended claims. It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the utility model, as claimed.

Drawings

The described and other features of the preferred embodiments of the present utility model will become more apparent in the detailed description with reference to the accompanying drawings, in which:

fig. 1 is a schematic side view of an exemplary tufted article according to embodiments disclosed herein.

Fig. 2 is a schematic top view of an exemplary woven backing structure of the tufted article of fig. 1.

Fig. 3 is a schematic top view of an exemplary woven backing structure as disclosed herein.

Fig. 4 is a perspective view of a portion of the woven backing structure of fig. 3 in a dashed box.

Fig. 5 is a schematic diagram showing an acute angle between an axis along which void space may extend and a first surface of a woven backing structure.

Detailed Description

The disclosed systems and methods may be understood more readily by reference to the following detailed description of specific embodiments and the examples included therein and the drawings and their descriptions.

It is to be understood that the terminology used herein is for the purpose of describing particular embodiments only, and is not intended to limit the scope of the present utility model which will be limited only by the appended claims.

It must be noted that, as used herein and in the appended claims, the singular forms "a," "an," and "the" include plural referents unless the context clearly dictates otherwise. Thus, for example, reference to "a layer" includes one or more of the layers, and so forth.

"Optional" or "optionally" means that the subsequently described event, circumstance or material may or may not occur or be present, and that the description includes instances where the event, circumstance or material occurs or is present and instances where it does not.

Ranges may be expressed herein as from "about" one particular value, and/or to "about" another particular value. When such a range is expressed, unless the context clearly dictates otherwise, it is specifically contemplated and considered that a range from one particular value and/or to another particular value is disclosed. 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, which should be considered disclosed unless the context clearly dictates otherwise. It will be further understood that the end points of each range are significant relative to the other end points, as well as independent of the other end points, unless the context clearly indicates otherwise. Finally, it is to be understood that all individual values and subranges of values included within the explicitly disclosed range are specifically contemplated and should be considered disclosed unless the context clearly indicates otherwise. The foregoing applies regardless of whether some or all of these embodiments are explicitly disclosed in particular instances.

Alternatively, in some aspects, when values are approximated by use of the antecedent "about," "substantially," or "generally," the expected value is within a range of up to 15%, up to 10%, up to 5%, or up to 1% (above or below) of the specifically stated value or the characteristic may be included within the range of these aspects.

Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which the disclosed devices, systems and methods belong. Although any devices, systems, and methods similar or equivalent to those described herein can be used in the practice or testing of the devices, systems, and methods of the present utility model, the particularly useful methods, devices, systems, and materials are as described.

Throughout the description and claims of this specification, the words "comprise" and variations of the words, such as "comprising" and "comprises", mean "including but not limited to", and are not intended to exclude, for example, other additives, components, integers or steps. In particular, in a method that is expressed as comprising one or more steps or operations, it is specifically contemplated that each step includes what is listed (unless the step includes a limiting term, such as "consisting of …"), which means that each step is not intended to exclude, for example, other additives, components, integers or steps not listed in the step.

As used herein, the terms "fiber" and "yarn" refer to a continuous strand or bundle of filaments. The filaments may include, for example, ribbons (e.g., flat filaments (SLIT FILMS)). Thus, the fibers and yarns may include, for example, but are not limited to, ribbon yarns, monofilament yarns, cut yarns, looped yarns, fibrillated yarns, multifilament yarns, twisted yarns (e.g., twisted staple yarns), wrapped yarns, staple yarns, and the like. Alternatively, consistent with the use of the terms "fiber" and "yarn," a continuous strand or bundle of fibers may be cut to form cut fibers or cut yarns. Alternatively, the fibers/yarns may be textured using conventional methods. The "fibers" and "yarns" as disclosed herein can be independently delivered to the backing structure (e.g., via tufting). The yarn or fiber may be single-ended fiber (single-strand yarn) or multi-ended fiber (e.g., ply yarn), which includes a plurality of single-ended fibers entangled or otherwise mixed with one another (e.g., by air entangling, twisting, winding, etc.) such that the single-ended yarns are no longer individually or independently movable. For example, a plurality of single-ended yarns may be twisted together to form a ply yarn (e.g., a doubled yarn may include two single-ended yarns twisted together). Each single end yarn/fiber may be formed from at least one filament (optionally, a plurality of filaments). Thus, within a multi-end yarn, each single-end yarn comprising the multi-end yarn may include a corresponding filament or filaments.

As used herein, the term "denier" refers to the gram weight of 9,000 meters of yarn. "denier per filament" refers to the denier per filament (in grams) of a yarn. When the yarn consists of single end yarns, the "total denier" of the yarn may refer to the combined denier (i.e., the sum of the individual deniers). When the yarn includes multiple yarn ends (multiple single end yarns) intertwined or otherwise intermixed with one another such that the yarn ends are no longer individually or independently movable, then the "total denier" of the yarn may refer to the combined denier (i.e., the sum of the respective deniers) of the multiple yarn ends (multiple single end yarns defining a multi-end yarn).

The total denier, single fiber denier (dpf) and strand information can be used to determine the number of filaments within a given yarn. As a first example, a single yarn may be identified as 6000 total denier, 4dpf yarn. This indicates that the total denier of the single yarn is 6000 and the denier per filament (per filament) of the single yarn is 4. The total number of filaments can be determined by dividing the total denier (6000) by dpf (4) to give a result of 1500 filaments in the yarn. Instead of identifying the yarn as a 6000 total denier, 4dpf yarn, it is contemplated that the yarn may be identified as a 6000/1500 filament yarn (where dpf (4) is determined by dividing the total denier (6000) by the number of filaments (1500)).

As another example, consider a doubled yarn having the same total denier (6000) but formed by twisting or otherwise blending two identical single end yarns. The yarn may be identified as 3000 x 2 yarn, which indicates that the yarn is a doubled yarn, with each strand corresponding to a single end yarn having a total denier of 3000. If the dpf of each single end yarn is 15, the number of filaments per single end yarn can be calculated by dividing the total denier (3000) by dpf (15), resulting in 200 filaments per single end yarn. Thus, the total number of filaments in the doubled yarn can be determined to be 600 (the sum of the number of filaments in the two single-ended yarns making up the doubled yarn).

In yet another example, consider a yarn formed by twisting or otherwise mixing two different single-ended yarns to form a yarn bundle. The yarn bundle may include a first single end yarn of 3000 total denier, 15dpf yarn and a second single end yarn of 3000 total denier, 4dpf yarn. This indicates a total denier of 3000 for the first single end yarn, with a denier per filament (per filament) of 15 for the yarn. The second single end yarn had a total denier of 3000 with a denier per filament (per filament) of 4. Thus, the first single end yarn has 200 filaments (15 denier per filament to provide 3000 total denier) and the second single end yarn has 750 filaments (4 denier per filament to provide 3000 total denier).

Permeable backing and tufted article having a permeable backing

Referring to fig. 1-2, an exemplary tufted article 10 may have a backing 20. The backing 20 may include a plurality of woven fibers 22 defining a woven backing structure 24 having a first surface 26 and a second surface 28. The plurality of weave fibers 22 may include warp fibers 22a and weft fibers 22b. Alternatively, the plurality of woven fibers 22 of the woven backing structure 24 may be arranged in a plain weave. In other aspects, the woven backing structure may have other arrangements. For example, the woven backing structure may be twill, plain, satin, sateen, basket, leno, corrugated, combinations thereof, and the like. It is contemplated that the woven backing structure may be formed by cam driven looms, dobby looms, or jacquard looms as known in the art.

Void spaces 30 may be defined between respective ones of the plurality of woven fibers 22 of the woven backing structure 24. Void space 30 may be configured to allow liquid or vapor to pass from first surface 26 to second surface 28 of braided backing structure 24.

In some aspects, the woven backing structure 24 may include flat filaments (tape yarn) arranged in a flat woven configuration. For example, in some aspects, both warp fibers 22a and weft fibers 22b may be flat filaments.

In an exemplary aspect, void space 30 may be provided by weft fibers 22b having a relief profile between warp fibers 22 a. More specifically, increasing the weight of the fibers (e.g., the thickness of the fibers) was found to increase the relief amplitude of the relief structure, thereby forming large void spaces 30. For example, in some embodiments a woven backing structure with thin fibers having low relief amplitude. The amplitude of the undulations is understood to be the distance the fibers extend along the vertical axis 11.

Thus, referring to fig. 3, in some aspects, the projection of the woven backing structure 24 into a plane parallel to the first surface along the vertical axis 11 has no open area, as verified by the absence of visible light through the woven backing structure. Thus, the woven backing structure 24 may provide a continuous structure configured to fixedly retain the face fibers, as further described herein. Which can be contrasted with the woven backing structure shown in fig. 2, fig. 2 shows a discontinuous structure, the projection of which in the plane shows the open area. Referring to fig. 4 and 5, in some aspects, void space 30 may extend along an axis 39 that forms an acute angle 41 with respect to first surface 26. That is, void space 30 may be formed by a change in the vertical position of adjacent fibers 22 of woven backing structure 24 such that moisture may flow through the void space along an axis 39 that forms an acute angle 41 with respect to the first surface. In some aspects, when the woven backing structure 24 is viewed at an acute angle (e.g., 45 degrees) relative to the first surface 26, light passing therethrough can be seen corresponding to void spaces 30 that allow liquid and vapor to pass from the first surface 26 to the second surface 28. In some optional aspects, void space 30 is not visible when the woven backing structure 24 is viewed along a vertical axis 11 perpendicular to the first surface 26, because the continuous structure does not show void space 30 along the vertical axis. In other aspects, void space 30 is substantially invisible or minimally visible when woven backing structure 24 is viewed along vertical axis 11, but becomes fully visible when viewed at an acute angle relative to first surface 26.

In some aspects, the woven backing structure 24 may have about 4 picks per inch (picks) to about 30 picks per inch (e.g., about 10 to about 28 picks per inch, or about 5 picks per inch to about 20 picks per inch). For example, the woven backing structure 24 may have 12 picks per inch to 18 picks per inch. Thus, in some exemplary aspects, it is contemplated that the woven backing structure 24 may have about 12 picks per inch, about 13 picks per inch, about 14 picks per inch, about 15 picks per inch, about 16 picks per inch, about 17 picks per inch, or about 18 picks per inch.

The plurality of woven fibers 22 of the woven backing structure 24 may weigh from about 2.6 to about 13 ounces per square yard, or from 1.5 to about 8 ounces per square yard, or from about 4.5 to about 8 ounces per square yard (e.g., alternatively, from 6 to about 7 ounces per square yard). In other aspects, the plurality of woven fibers 22 may weigh about 8, about 9, about 10, about 11, about 12, or about 13 ounces per square yard.

The heavy denier (e.g., thicker ribbons) of the plurality of woven fibers 22 of the woven backing structure 24 was found to provide unexpectedly high permeability. For example, a woven backing structure 24 having a weight of about 6 ounces per square yard is found to be three times as breathable as a woven backing structure having the same number of picks per inch and a weight of about 3 ounces per square yard.

In some aspects, warp fiber 22a may have a center-to-center distance 32 of 0.025 inches to 0.1 inches or about 0.035 inches to about 0.075 inches. In some aspects, the weft fibers 22b can have a center-to-center distance 34 of 0.025 inches to 0.1 inches or about 0.04 inches to about 0.09 inches.

In an exemplary aspect, warp fibers 22a may be about 0.025 inch to 0.1 inch (e.g., about 0.05 inch) wide. In exemplary aspects, warp fibers 22a may be about 0.0025 inches to about 0.005 inches, or about 0.003 inches to about 0.005 inches (e.g., about 0.035 inches) thick. In some aspects, the weft fibers 22b can be 0.025 inch to 0.2 inch (e.g., about 0.01 inch) wide. In exemplary aspects, warp fibers 22a may be about 0.0025 inches to about 0.005 inches, or about 0.003 inches to about 0.005 inches thick.

Still referring to fig. 1-2, the backing 20 can have a warp axis 36 and a weft axis 38. In some aspects, the weave fibers 22 may have a width w along a respective warp axis 36 or weft axis 38. It is contemplated that center-to-center distance 34 of warp fibers 22b may be equal to or substantially equal to or less than the width of the warp fibers along weft axis 38. In this manner, and with further reference to fig. 3, the woven backing structure 24 may define a continuous structure configured to fixedly retain the face fibers (as opposed to the schematic of fig. 2, which shows spaces between fibers, and thus shows a discontinuous structure). For example, the projection of the continuous structure along the vertical axis 11 on a plane perpendicular to the vertical axis may be continuous, without an opening in the projection. In other aspects, the projection of the continuous structure along the vertical axis 11 on a plane perpendicular to the vertical axis may have less than 5% open area, or less than 4% open area, or less than 3% open area, or less than 2% open area, or less than 1% open area, or substantially no open area. In these respects, it is expected that the minimum amount of open area within the continuous structure has no significant impact on the ability of the continuous structure to fixedly retain the face fibers. In some alternative aspects, the plurality of weave fibers 22 may have a generally rectangular cross-section.

In some alternative aspects, the backing 20 does not include shaped perforations. That is, the only openings present in the backing are created by the woven structure of the backing (and the resulting spaces between the woven fibers).

Referring to fig. 1, in some alternative aspects, the backing 20 may further include a scrim layer 60 coupled to the second surface 28 of the woven backing structure 24. The scrim layer 60 may have an open mesh structure. Thus, the projection of the scrim layer along a vertical axis into a plane parallel to the first surface of the woven backing structure 24 may define an open area. For example, the scrim layer 60 may optionally have a leno or plain weave construction. Thus, the warp fibers of the woven structure may be spaced apart from one another, and the weft fibers of the woven structure may be spaced apart from one another to provide openings through the scrim layer. The leno weave structure may include single or multiple yarns extending in the warp and weft directions. In other aspects, the scrim layer 60 may be knitted (knitted). In further aspects, the scrim layer 60 may comprise a nonwoven material (e.g., an open melt blown material, a needle punched material, a spunbond material, a water jet formed material, or an air layer material). Alternatively, the scrim may have about 5 picks per inch. The woven backing structure 24 and the scrim layer 60 may cooperate to define a lower surface 62 of the backing 20. In an exemplary aspect, the scrim layer may have a weight of about 1 to about 3 ounces per square yard. In some alternative aspects, the scrim layer may have 4 to 30 warp yarns and 2 to 18 weft yarns per inch. Alternatively, the scrim layer may include warp yarns comprising flat belts having a denier of 100 to 500. Alternatively, the scrim layer may comprise stuffer yarns of about 400 denier to about 2400 denier. In exemplary aspects, it is contemplated that the weft yarns may comprise air textured filaments, spun filaments, loose continuous filaments, flat belts, or fibrillated yarns.

The tufted article 10 may further comprise a plurality of secondary fibers 50 tufted through the backing and extending upwardly from the first surface 26 of the woven backing structure 24. The tufted fibers may optionally be looped or cut. The plurality of second fibers 50 may be face fibers of a tufted article having backstops 54 looped behind both the scrim layer 60 and the backing 20.

Alternatively, the polymeric coating 40 may be applied to the lower surface 62 of the backing 20 and scrim layer 60. That is, the polymeric coating 40 may be applied to the second surface 28 of the woven backing structure 24 and through the scrim layer 60. The polymer coating 40 can couple the plurality of second fibers 50 to the backing to inhibit movement of the plurality of second fibers relative to the backing (e.g., prevent the plurality of second fibers from falling out of the backing). In some aspects, the polymer coating 40 may include polyurethane.

At least a portion of the scrim 60 may prevent the polymer coating 40 from entering (e.g., blocking) at least one of the void spaces defined between respective ones of the plurality of woven fibers of the woven backing structure. That is, the scrim layer 60 may inhibit the polymer coating 40 from filling some or all of the void space 30 through the woven backing structure 20. The scrim layer 60 may also provide dimensional stability to the tufted article.

In some aspects, the underside of the tufted article 10 has a plurality of backstops 54 of secondary fibers 50, a backing 20, and a scrim layer 60. The polymer coating 40 may be applied to the backstops 54, backing 20, and scrim layer 60 of the plurality of second fibers 50. In an exemplary aspect, after tufting the plurality of secondary fibers 50 as disclosed herein, the polymeric coating 40 may be applied using a coater as known in the art.

In some aspects, the tufted article 10 may include only a single woven backing structure 24 (in addition to the scrim layer 60). That is, the tufted article 10 may include a single woven backing structure 24 and a scrim layer 60, and no additional woven layers. It is contemplated that having only a single backing layer may provide advantageous permeability. This can be contrasted with articles having a plurality of lower weight woven backing structure layers applied together.

Alternatively, the tufted article 10 may comprise a filler 70 (e.g., sand). The filler may optionally be provided in a weight range of about 1lb per square yard to about 9lb per square yard. In these aspects, it is contemplated that the filler may comprise a single component or any combination of components. When the filler comprises a plurality of components, it is contemplated that the filler material may optionally comprise a plurality of layers, wherein each layer corresponds to a different filler component or combination of components. Or it is contemplated that the multiple components may be provided as a mixture, which may be homogeneous or heterogeneous. In exemplary aspects, it is contemplated that the filler may comprise clay, TPE, EPDM, coconut shell, walnut shell, crushed brick, sand, or a combination thereof. More generally, it is contemplated that the filler can comprise any material capable of imparting desired characteristics to a surface covering (e.g., a floor or floor covering). In a further aspect, the tufted article 10 does not include a filler (and is not filled during use).

Alternatively, the plurality of second fibers 50 may comprise yarns.

The tufted article 10 may optionally be an artificial turf. In these aspects, the artificial turf may allow high flow drainage therethrough. In an exemplary aspect, the plurality of tufted articles 10 may form at least a portion of a playing surface, such as, but not limited to, a playing field, golf course, or park. In further exemplary aspects, it is contemplated that one or more tufted articles 10 may form at least a portion of an airport runway, landfill covering, or the like.

In a further aspect, the tufted article 10 may be a carpet (e.g., a commercial or residential carpet). The breathability of the disclosed backing 20 may advantageously allow moisture to escape from the subfloor below the tufted article. In an exemplary aspect, it is contemplated that the plurality of tufted articles 10 may form at least a portion of a surface (e.g., floor) covering.

In some aspects, the method may include coupling the tufted article 10 as disclosed herein to a substructure and receiving a liquid (e.g., water) or water vapor through void spaces defined between respective woven fibers of a plurality of woven fibers of a woven backing structure. In an exemplary aspect, the substructure may be a subfloor. In various other aspects, the tufted article 10 may be mounted on other substructures such as, but not limited to, underlayments (e.g., gravel) or gasketing platforms (e.g., underlayments). In a further aspect, the tufted article 10 may receive and allow particles to pass through the void space.

The tufted article 10 may be formed according to the methods disclosed herein. A plurality of second fibers 50 may be tufted through the backing 20 such that the plurality of fibers extend upwardly from the first surface of the woven backing structure. In some aspects, the method does not include forming an opening through the backing. In some aspects, the plurality of fibers 22 may be woven together to form a woven backing structure 24 having a first surface 26 and an opposing second surface 28, wherein the woven backing structure defines void spaces 30 between respective woven fibers of the plurality of woven fibers of the woven backing structure. Void space 30 may be configured to allow liquid to pass from first surface 26 to second surface 28 of braided backing structure 24.

The scrim layer 60 may be positioned against the second surface of the woven backing structure to provide the backing 20 prior to tufting the plurality of second fibers through the woven backing structure 24, the scrim layer having an open network structure. The polymer coating 40 may be applied to the lower surface 62 of the backing 20. For example, in some aspects, the polymer coating may roll against the lower surface 62 of the back liner 20. In alternative aspects, the polymer coating may be poured as a fluid onto the lower surface 62 of the backing 20, and the fluid may be scraped off the lower surface of the backing 20 to distribute the fluid on the lower surface. This may be referred to as stirring with a knife (puddle underknife) or spreading with a spatula (scrape bar application).

In an exemplary aspect, the plurality of woven fibers 22 and/or the plurality of second fibers 50 may comprise a polymer (e.g., nylon, polypropylene (PP), polyethylene (PE), or polyethylene terephthalate (PET)). In some aspects, the woven backing structure 24 may comprise PP. In various aspects, the plurality of woven fibers 22 and/or the plurality of second fibers 50 may include virgin material and/or recycled material. In a further aspect, the plurality of woven fibers 22 and/or the plurality of second fibers 50 may comprise natural materials, such as soybean, sugarcane, jute, hemp, and the like.

Although various exemplary yarn deniers are described herein, it is contemplated that exemplary yarns of tufted article 10 may alternatively have any total denier in the range of 500 to 23,000. In a further aspect, it is contemplated that the yarn may optionally have a denier per filament in the range of 4 to 2700 dpf.

Additional exemplary embodiments

While the embodiments disclosed herein describe the use of a woven backing structure to retain the face fibers while allowing water to permeate therethrough, it is contemplated that other open structure materials having openings that are permeable to water, steam, and/or particles may be used. Most preferably, it is contemplated that the open structure material may obtain its permeability (e.g., variability of the fibers along the vertical axis 11) in part from the texture of the material rather than merely from the spacing between the fibers on the horizontal axis (e.g., warp and weft axes 36, 38). Thus, in other embodiments, a knitted structure or a non-woven material may be used in place of the knitted backing structure 24.

In some alternative aspects, the polymeric coating 40 may be omitted from the tufted article 10. In other aspects, the polymeric coating 40 may be disposed on opposite sides of the open structure material (e.g., on the first surface 26 of the woven backing structure 24).

In some alternative aspects, the open structure material (e.g., woven backing structure 24) and scrim layer 60 may be reversed from that shown in fig. 1. That is, for example, the scrim layer 60 may be positioned on the first surface 26 of the woven backing structure 24 (or other open structure material).

In yet a further aspect, the backing 20 may include a woven backing structure 24 (or other open structure material), a woven material, and a non-woven material. For example, the backing 20 may include a woven backing structure 24, a non-woven material disposed on a first surface 26 of the woven backing structure, and a woven material disposed on a second surface 28 of the woven backing structure.

Exemplary aspects of the second plurality of fibers

In some exemplary aspects, the plurality of secondary fibers 50 may be formed as a plurality of yarn tufts 52 extending through the backing 20. In these aspects, it is contemplated that the plurality of yarn tufts can be formed using conventional methods. For example, in these aspects, it is contemplated that one or more tufting machines may have multiple needles (optionally on a needle bar) that deliver yarn into the backing 20 to form multiple yarn tufts 52. Alternatively, it is contemplated that the backing 20 may be provided on a feed roll that feeds the backing through a tufting machine.

Although depicted in the figures as including cut tufts, it is contemplated that tufting of the tufted article 10 may include cut tufts, looped tufts, or a combination thereof. Each of the plurality of tufts 40 can include at least one outwardly extending tuft portion (located above the backing) and a backstop connected to the at least one outwardly extending tuft portion. In an exemplary aspect, when the plurality of tufts include cut tufts, each yarn tuft of the plurality of yarn tufts can have at least one pair of outwardly extending tufted portions (located above the backing and formed by a respective cut) joined by a backstitch (positioned below or within the backing). When the tufts comprise a single yarn, it is contemplated that the tufts may comprise a single pair of tufted portions joined by a single backstitch. However, when the tufts comprise a plurality of yarns (e.g., two or three yarn ends simultaneously delivered through the backing by a single needle, each of which penetrates the single needle), then the tufts may comprise a plurality of pairs of tuft portions (one pair per yarn), with each pair of tuft portions being joined by a respective backstitch portion.

Although an exemplary structure (e.g., tufting) for bonding the plurality of secondary fibers 50 to the backing is disclosed herein, it is contemplated that any conventional mechanical or structural coupling between the plurality of secondary fibers 50 and the backing may be employed.

In an exemplary aspect, the plurality of second fibers 50 may include a plurality of yarn filaments. In some alternative aspects, each of the plurality of yarn filaments may have a denier in the range of 61 to 3600 denier per filament (dpf), such as is typically present in artificial turf yarns. Alternatively, in these aspects, it is contemplated that each yarn filament may have a denier in the range of 61 to 1000dpf or 61 to 750dpf or 400 to 600 dpf. However, it is contemplated that other dpf values may be used depending on the particular application and desired performance characteristics.

In a further aspect, it is contemplated that the plurality of second fibers 50 may comprise a plurality of yarn filaments. In these aspects, each of the plurality of yarn filaments of the second plurality of fibers 50 may optionally have a denier per filament (dpf) in the range of 2 to 60dpf, such as is typically present in carpet yarns. Alternatively, in these aspects, each of the plurality of yarn filaments may have a denier per filament (dpf) in the range of 6 to 60dpf or 10 to 40 dpf. Thus, in some aspects, it is contemplated that at least one yarn of the tufted article 10 may comprise a turf yarn, while at least one other yarn of the tufted article may comprise a carpet yarn. Thus, in these aspects, the tufted article 10 may be used as a hybrid turf-carpet article, providing a combination of properties provided by the turf and carpet products (respectively). For example, it is contemplated that turf yarns may impart desired performance/durability properties, while carpet yarns may impart desired softness and texture properties. As further disclosed herein, it is further contemplated that the turf or carpet properties may be selectively reinforced or weakened by controlling various properties of the yarn. It is contemplated that the plurality of second fibers 50 may include any desired number of filaments, such as 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 36, 48, 96, or up to 4000 individual filaments per yarn.

Alternatively, in some exemplary aspects, it is contemplated that the yarn filaments of the plurality of second fibers 50 may have a dpf in the range of 2 to 32. In these aspects, it is contemplated that the plurality of second fibers 50 may be conventional residential carpet yarns known in the art.

Alternatively, in some exemplary aspects, it is contemplated that the yarn filaments of the plurality of second fibers 50 may have a dpf in the range of 22 to 60. In these aspects, it is contemplated that the plurality of second fibers 50 may be conventional commercial carpet yarns known in the art.

As described above, in some exemplary aspects, a plurality of second fibers 50 may be provided within each respective tuft or pile (pile) extending through the backing. In one exemplary method, the fibers are suspended from a creel and the fiber ends are then fed through the respective tubes until reaching a guide structure immediately before the needle bar of the tufting machine. At the guiding structure, the fibers are fed together through one guiding hole, and both fibers can be delivered to each needle of the tufting machine at the same rate. One or more ends of each needle may be tufted by adjusting the tension so that the fibers are hooked on hooks for cutting. Alternatively, one of the fibers may be straight-set (straight-set) and one of the fibers may be deformed, so that adjustment of the tension may be necessary to ensure successful tufting. Or in a further exemplary method, the fibers may be delivered all the way through the same tube to the needle for tufting. It is contemplated that the needle size and needle hole or eye of the needle may be selected based on the desired gauge and density of the final article.

It is contemplated that any desired number of different fibers (e.g., yarns) may be provided within a tufted article as disclosed herein. For example, it is contemplated that the second yarn and the third yarn may be provided in conjunction with the first yarn within each of the plurality of tufts. In yet a further aspect, four, five, or more yarns may be provided within each of the plurality of tufts.

Exemplary Material Properties

In an exemplary aspect, it is contemplated that each yarn filament of the plurality of second fibers 50 may be a monofilament. Alternatively, in these aspects, each yarn filament of the plurality of second fibers 50 may be 100% nylon monofilament. In these aspects, it is contemplated that the nylon of the plurality of second fibers may be nylon-6, or other conventional forms of nylon. In some alternative aspects, it is contemplated that the plurality of secondary fibers 50 of the tufted article 10 may be comprised of a single yarn wherein each filament of the yarn is a monofilament.

In further exemplary aspects, the plurality of second fibers 50 may be comprised of nylon. In further exemplary aspects, it is contemplated that each filament of the plurality of second fibers 50 may comprise a continuous filament.

As noted above, in an exemplary aspect, the yarn filaments of the plurality of second fibers 50 may optionally be uncolored natural filaments. In these aspects, it is contemplated that the plurality of second fibers 50 may be solution dyed on a "natural" basis without adding color pigments during extrusion (extrusion).

In a further aspect, it is contemplated that the plurality of second fibers 50 may comprise 4400/8 monofilament yarns having a total denier of 4400 and a dpf of 550 (providing a total of 8 monofilaments within the yarn). In another example, the plurality of second fibers 50 may comprise 4400/16 monofilament yarns having a total denier of 4400 and a dpf of 275 (providing a total of 16 monofilaments within the yarn). In yet another example, the plurality of second fibers 50 may comprise 4400/32 yarns having a total denier of 4400 and a dpf of 137.5 (providing a total of 32 monofilaments within the yarn). In yet another example, the plurality of second fibers 50 may comprise 6600/8 monofilament yarns having a total denier of 6600 and a dpf of 825 (providing a total of 8 monofilaments within the yarn). In yet another example, the plurality of second fibers 50 may comprise 6600/12 monofilament yarns having a total denier of 6600 and a dpf of 550 (providing a total of 12 monofilaments within the yarn). In yet another example, the plurality of second fibers 50 may comprise 6600/24 monofilament yarns having a total denier of 6600 and a dpf of 275 (providing a total of 24 monofilaments within the yarn). In further exemplary optional aspects, the plurality of second fibers 50 may comprise 800/2 (total denier 1600), 800/3 (total denier 2400), 1000/2 (2000 denier), 1000/3 (3000 total denier), or 1000/4 (4000 total denier) fibers. In further exemplary optional aspects, the plurality of second fibers 50 may include 2600×3 strands (7800 total denier), 2600×2 strands (5200 total denier), 1400 denier×2 strands, or 1800 denier×2 strands of fibers. In an exemplary aspect, the plurality of second fibers 50 may have a denier per filament of about 4 to about 30. More generally, it is contemplated that any desired total denier may be used for the plurality of second fibers 50, provided that the individual filaments of the plurality of second fibers 50 have dpf consistent with the desired performance characteristics of the article. Alternatively, in exemplary aspects, each fiber of the plurality of second fibers 50 may have a total denier in the range of about 500 to about 25,000 or about 3,000 to about 8,000 or about 4,000 to about 7,000. In an exemplary aspect, it is contemplated that at least one fiber of the plurality of second fibers may comprise a plurality of yarns.

It is contemplated that the cross-sectional profile of each filament of the plurality of second fibers 50 may be any shape conventionally used for turf yarns. For example, in some exemplary aspects, each filament of the plurality of second fibers 50 may have a cross-sectional profile including diamond, saw tooth diamond, half moon, or oval or circular. However, it is contemplated that any desired cross-sectional profile may be used. It is also contemplated that the plurality of second fibers 50 may have desirable durability and fastness properties.

As noted above, in exemplary aspects, the plurality of secondary fibers 50 of the tufted article may include conventional turf yarns and/or conventional carpet yarns. In an exemplary tufted article, the plurality of secondary fibers 50 may comprise nylon (e.g., nylon-6 or nylon-6, 6), polyester, or polypropylene. In one example, the plurality of second fibers 50 may comprise 1362/2 strands (1362 x 2) continuous filament nylon yarn having a total denier of 2724. As another example, the plurality of second fibers 50 may comprise solution dyed nylon 1350/5 (1350 x 5) yarns having a total denier of 6,750. In these embodiments, it is contemplated that each yarn may include any desired number of filaments, with dpf remaining below 60. In various aspects, it is contemplated that each filament of the plurality of second fibers 50 may be a continuous filament or a discontinuous filament.

In some exemplary aspects, it is contemplated that the plurality of second fibers 50 may be multi-end yarns formed from at least two different single-end yarns (at least two strands). In these aspects, it is contemplated that at least two different single-ended yarns forming a multi-ended yarn may have different dpf values that allow for different visual effects to be produced. For example, it is contemplated that the plurality of second fibers 50 may include a first yarn end having a 65dpf value and a second yarn end having a 65dpf value, wherein both the first yarn end and the second yarn end are comprised of monofilaments. It is further contemplated that the second yarn may include a first yarn end having a 2dpf value and a second yarn end having a 30dpf value.

In an exemplary aspect, the material of the plurality of second fibers 50 of the contemplated tufted article 10 may be selected based on the intended use of the tufted article. For example, nylon, PP, PE and PET are all suitable for indoor use, but nylon and PET are not as durable as PP or PE when used outdoors. However, for printed or dyed yarns as disclosed herein, it is contemplated that special dyes or coatings may be required to impart color to PP and PE yarns. In some aspects, it is contemplated that one of the yarns may comprise PP and/or PE yarns, while the other of the yarns may comprise nylon. In these aspects, it is contemplated that color may be imparted to the nylon yarn during the printing or dyeing process without imparting color to the PP and/or PE yarn (due to the absence of special dyes or paints required to impart color to the PP and/or PE yarn), thereby creating a unique surface appearance. Thus, in some aspects, the color patterns disclosed herein do not impart color to some face yarns even if a coating or dye is applied to those face yarns. In various further aspects, the plurality of fibers 50 of the tufted article 10 may include polylactic acid (PLA), polyurethane (PU), natural fibers (e.g., optionally, soy, sugarcane, etc.), or other fibers that may be biodegradable or at least semi-biodegradable.

It is contemplated that the cross-sectional profile of each filament of the plurality of second fibers 50 may be any shape conventionally used for carpet yarns. For example, in some exemplary aspects, the filaments of the plurality of second fibers 50 may each have a trilobal cross-sectional profile as known in the art. It is contemplated that the cross-sectional profile of the filaments of the plurality of second fibers 50 may be selected to impart desired gloss, stiffness/softness, elasticity, and other characteristics. It is contemplated that when the tufted article is used for floor/playing surface mounting, the yarn density of the tufted article may determine the final surface interaction between the yarn and the ball or person. For example, the yarn density may be varied to provide a desired amount of friction as the yarn interacts with the shoe. In a further aspect, it is contemplated that the yarn density may vary along the surface of the tufted article. For example, in these aspects, it is contemplated that the yarn density may vary (e.g., changes in color, yarn type, bulk, pile height, etc.) at locations where the face structure of the tufted article changes. In exemplary aspects, it is contemplated that a pad (e.g., a polyurethane pad) can be added to the tufted article at a location where the carpet surface properties change, thereby increasing human safety, as further disclosed herein. In a further optional aspect, the system can include tufted articles and an underlayment (e.g., a mat) herein. In various alternative aspects, the tufted article may or may not be attached to a backing.

It is contemplated that the plurality of secondary fibers 50 of the tufted article 10 may be colored in any desired manner prior to application of the color pattern as further disclosed herein. For example, as further explained herein, the plurality of second fibers 50 may be uncolored natural yarns that are not pre-dyed, or the plurality of second fibers may be pre-dyed. In another example, the plurality of second fibers 50 may all be pre-dyed or solution dyed.

As further disclosed herein, it is further contemplated that the cross-sectional shape and/or size of the fibers/yarns may be selectively varied to change color and texture.

Exemplary aspects

In view of the described products, systems and methods, and variations thereof, certain more specifically described aspects of the utility model are described below. However, these specifically recited aspects should not be construed as having any limiting effect on any of the different claims containing different or more general teachings described herein, or as being limited in some way other than by the inherent meaning of the language used literally herein.

Aspect 1: a tufted article comprising:

A backing, comprising:

A plurality of woven fibers defining a woven backing structure having a first surface and an opposing second surface, wherein void spaces are defined between respective woven fibers of the plurality of woven fibers of the woven backing structure, and wherein the void spaces are configured to allow liquid or vapor to pass from the first surface to the second surface of the woven backing structure; and

A scrim layer coupled to an opposite second surface of the woven backing structure, wherein the scrim layer has an open mesh structure,

Wherein the second surface of the woven backing structure and the scrim layer cooperate to define a lower surface of the backing.

Aspect 2: the tufted article of aspect 1, further comprising a polymeric coating applied to the lower surface of the backing, wherein at least a portion of the scrim prevents the polymeric coating from entering at least one of the void spaces defined between respective ones of the plurality of woven fibers of the woven backing structure.

Aspect 3: the tufted article of aspect 1 or aspect 2, wherein the scrim layer comprises a leno weave.

Aspect 4: the tufted article of any of the previous aspects, wherein the backing has no open areas in projection along a vertical axis into a plane parallel to the first surface.

Aspect 5: the tufted article of aspect 4, wherein the projection of the scrim layer along a vertical axis to the plane defines an open area.

Aspect 6: the tufted article of any of the preceding aspects, wherein the plurality of woven fibers of the woven backing structure of the backing comprises 5 to 20 picks per inch, and wherein the woven backing structure has a weight of about 1.5 ounces per square yard to about 8 ounces per square yard.

Aspect 7: the tufted article of any of the preceding aspects, wherein the plurality of woven fibers of the woven backing structure of the backing comprises 12 to 18 picks per inch.

Aspect 8: the tufted article of any one of the preceding aspects, wherein the woven backing structure has a weight of about 6 ounces per square yard to about 7 ounces per square yard.

Aspect 9: the tufted article of any one of the preceding aspects, wherein the plurality of woven fibers of the woven backing structure are arranged in a plain weave.

Aspect 10: the tufted article of any of the preceding aspects wherein the backing does not include shaped perforations.

Aspect 11: the tufted article of any one of the preceding aspects, wherein each fiber of the plurality of woven fibers of the woven backing structure has a generally rectangular cross-section.

Aspect 12: the tufted article of any one of aspects 2-11 wherein the polymer coating comprises polyurethane.

Aspect 13: the tufted article of any of the preceding aspects, further comprising a plurality of second fibers tufted through the backing and extending upwardly from the first surface of the woven backing structure.

Aspect 14: the tufted article of any one of the preceding aspects further comprising a filler.

Aspect 15: the tufted article of aspect 14, wherein the filler comprises sand.

Aspect 16: the tufted article of aspect 14 or aspect 15, wherein the filler is provided at a weight of about 1lb per square yard to about 3lb per square yard.

Aspect 17: the tufted article of any one of aspects 13-16, wherein the plurality of second fibers comprise yarns.

Aspect 18: the tufted article of any one of aspects 13-16, wherein the tufted article is an artificial turf.

Aspect 19: the tufted article of any one of aspects 13-16, wherein the tufted article is a carpet.

Aspect 20: a method of forming a tufted article, the method comprising:

Braiding a plurality of fibers together to form a braided backing structure having a first surface and an opposing second surface, the braided backing structure defining void spaces between respective braided fibers of the plurality of braided fibers of the braided backing structure, and wherein the void spaces are configured to allow liquid or vapor to pass from the first surface to the second surface of the braided backing structure; and

Tufting a plurality of secondary fibers through the woven backing structure such that the plurality of fibers extend upwardly from a first surface of the woven backing structure,

Wherein after braiding the plurality of fibers together, the method does not include forming openings through the braided backing structure.

Aspect 21: the method of aspect 20, further comprising:

positioning a scrim layer against a second surface of the woven backing structure prior to tufting the plurality of second fibers through the woven backing structure to provide a backing, wherein the scrim layer has an open network structure, wherein the second surface of the woven backing structure and the scrim layer cooperate to define a lower surface of the backing.

Aspect 22: the method of aspect 21, further comprising applying a polymeric coating to the lower surface of the backing.

Aspect 23: the method of aspect 22, wherein applying the polymer coating to the lower surface of the backing comprises rolling the polymer coating against the lower surface of the backing.

Aspect 24: the method of aspect 22, wherein applying the polymer coating to the lower surface of the backing comprises:

Pouring the polymer coating as a fluid onto the lower surface of the backing; and

The fluid is scraped to distribute the fluid over the lower surface of the backing.

Aspect 25: a method, comprising:

Mounting the tufted article of any one of aspects 1-19 to a substructure; and

The liquid or water vapor is received through void spaces defined between respective ones of the plurality of woven fibers of the woven backing structure.

Aspect 26: a tufted article comprising:

A backing having a vertical axis, the backing comprising:

An open structure material having a first surface and an opposing second surface, wherein the open structure material comprises a plurality of fibers, wherein the plurality of fibers define void spaces through the open structure material from the first surface to the second surface based in part on variability of the fibers along a vertical axis, wherein the void spaces are configured to allow liquid or vapor to pass from the first surface to the second surface of the open structure material;

A scrim layer coupled to an opposite second surface of the open structure material, wherein the scrim layer has an open mesh structure, and

A plurality of second fibers tufted through the backing and extending upwardly from the first surface of the open structure material.

Aspect 27: the tufted article of claim 26, wherein the open structure material comprises a plurality of woven fibers defining a woven backing structure, wherein the void spaces are defined between respective woven fibers of the plurality of woven fibers of the woven backing structure, and wherein the void spaces are configured to allow liquid or vapor transfer from a first surface to a second surface of the woven backing structure.

Aspect 28: the tufted article of aspect 26, wherein the plurality of fibers of the open structure material comprise knitted fibers.

Aspect 29: the tufted article of aspect 26, wherein the plurality of fibers of the open structure material comprise a nonwoven material.

Aspect 30: the tufted article of any of claims 26-29, wherein the second surface of the open structure material and the scrim layer cooperate to define a lower surface of the backing, wherein the tufted article further comprises a polymer coating applied to the lower surface of the backing, wherein at least a portion of the scrim prevents the polymer coating from entering at least one of the void spaces defined between respective woven fibers of the plurality of woven fibers of the open structure material.

Aspect 31: the tufted article of any one of aspects 26-29, wherein the tufted article does not include a polymer coating.

Although the foregoing utility model has been described in some detail by way of illustration and example for purposes of clarity of understanding, certain changes and modifications may be practiced within the scope of the appended claims.

Claims

1. A tufted article, the tufted article comprising:

A backing, comprising:

2. The tufted article of claim 1 and further comprising a polymeric coating applied to a lower surface of the backing and wherein at least a portion of said scrim prevents said polymeric coating from entering at least one of the void spaces defined between respective ones of the plurality of woven fibers of the woven backing structure.

3. The tufted article of claim 1 wherein said scrim layer comprises a leno weave.

4. The tufted article of claim 1 wherein the projection of said backing along a vertical axis into a plane parallel to the first surface has no open areas.

5. The tufted article of claim 4 wherein the projection of said scrim layer along a vertical axis to said plane defines an open area.

6. The tufted article of claim 1 wherein the plurality of woven fibers of said woven backing structure of said backing comprises 5 to 20 picks per inch and wherein said woven backing structure has a weight of about 1.5 ounces per square yard to about 8 ounces per square yard.

7. The tufted article of claim 1 and wherein the plurality of woven fibers of said woven backing structure of said backing comprises 12 to 18 picks per inch.

8. The tufted article of claim 1 wherein said woven backing structure has a weight of about 6 ounces per square yard to about 7 ounces per square yard.

9. The tufted article of claim 1 and wherein said plurality of woven fibers of said woven backing structure are arranged in a plain weave.

10. The tufted article of claim 1 wherein said backing does not comprise shaped perforations.

11. The tufted article of claim 1 and wherein each of said plurality of woven fibers of said woven backing structure has a generally rectangular cross-section.

12. The tufted article of claim 2 and wherein said polymeric coating comprises polyurethane.

13. The tufted article of claim 1 and further comprising a plurality of second fibers tufted through the backing and extending upwardly from the first surface of the woven backing structure.

14. The tufted article of claim 1 and further comprising a filler.

15. The tufted article of claim 14 and wherein said filler comprises sand.

16. The tufted article of claim 14 and wherein said filler is provided at a weight of about 1lb per square yard to about 3lb per square yard.

17. The tufted article of claim 13 wherein said plurality of second fibers comprise yarns.

18. The tufted article of claim 13 and wherein said tufted article is an artificial turf.

19. The tufted article of claim 13 and wherein said tufted article is a carpet.

20. A tufted article, the tufted article comprising:

A backing having a vertical axis, the backing comprising:

21. The tufted article of claim 20 wherein said open structure material comprises a plurality of woven fibers defining a woven backing structure, wherein said void spaces are defined between respective woven fibers of the plurality of woven fibers of the woven backing structure, and wherein said void spaces are configured to allow liquid or vapor transfer from a first surface to a second surface of the woven backing structure.

22. The tufted article of claim 20 and wherein said plurality of fibers of said open structure material comprise knitted fibers.

23. The tufted article of claim 20 and wherein said plurality of fibers of said open structure material comprise a nonwoven material.

24. The tufted article of any one of claims 20-23 wherein said open structure material second surface and a scrim layer cooperate to define a lower surface of a backing, wherein said tufted article further comprises a polymer coating applied to the lower surface of the backing, wherein at least a portion of the scrim prevents the polymer coating from entering at least one of the void spaces defined between respective woven fibers of the plurality of woven fibers of open structure material.

25. The tufted article of any one of claims 20-23 wherein said tufted article does not comprise a polymeric coating.