US20210372021A1

US20210372021A1 - Artificial Turf Assembly And Process Of Manufacture Thereof

Info

Publication number: US20210372021A1
Application number: US17/335,580
Authority: US
Inventors: Philipe Aldahir; Neil Vaughan; Kyle Andrew Aylor
Original assignee: Columbia Insurance Co
Current assignee: Columbia Insurance Co; Shaw Industries Group Inc
Priority date: 2020-05-29
Filing date: 2021-06-01
Publication date: 2021-12-02

Abstract

A tufted article can have a length along a first axis and width along a second axis that is perpendicular to the first axis. The tufted article can comprise a backing and a plurality of tufts extending through the backing. The plurality of tufts can be distributed among a plurality of tuft sequences. Each tuft sequence can comprise at least one tuft of the plurality of tufts. The tufts of each tuft sequence can be formed sequentially by a single needle of a tufting machine. Each tuft sequence of the plurality of tuft sequences can be spaced from other tuft sequences of the plurality of tuft sequences along at least one of the first axis or the second axis. In some aspects, no tuft sequence of the plurality of tuft sequences extends across the entire length or the entire width of the backing.

Description

CROSS-REFERENCE TO RELATED APPLICATION

This application claims priority to and the benefit of the filing date of U.S. Provisional Patent Application No. 63/032,065, filed May 29, 2020, which is incorporated herein by reference in its entirety.

FIELD

This application relates to tufted articles and, in particular, to artificial turf.

BACKGROUND

Playing surfaces such as artificial turf have surface properties and structural features that impact player-surface interactions and ball-surface interactions. These properties, features, and interactions can define the playability of the playing surface for a particular sport. An artificial turf that improves playability is therefore desirable.

SUMMARY

Disclosed herein, in one aspect, is a tufted article having a length along a first axis and width along a second axis that is perpendicular to the first axis, the first and second axes being perpendicular to a vertical axis. The tufted article can comprise a backing and a plurality of tufts extending through the backing. The plurality of tufts can be distributed among a plurality of tuft sequences. Each tuft sequence can comprise at least one tuft of the plurality of tufts. The tufts of each tuft sequence can be formed sequentially by a single needle of a tufting machine. Each tuft sequence of the plurality of tuft sequences can be spaced from other tuft sequences of the plurality of tuft sequences along at least one of the first axis or the second axis. In some aspects, no tuft sequence of the plurality of tuft sequences extends across the entire length or the entire width of the backing.
A method of manufacturing a tufted article can comprise tufting a plurality of tuft sequences through a backing having length extending along a first axis and a width extending along a second axis that is perpendicular to the first axis. Each tuft sequence can comprise at least one tuft of the plurality of tufts. The tufts of each tuft sequence can be formed sequentially by a single needle of a tufting machine. Each tuft sequence of the plurality of tuft sequences can be spaced from other tuft sequences of the plurality of tuft sequences along at least one of the first axis or the second axis. In some aspects, no tuft sequence of the plurality of tuft sequences extends across the entire length or the entire width of the backing.
A system comprising at least one tufting machine. Each tufting machine can define a respective tufting zone and can comprise a plurality of needles that are configured to deliver yarn into a backing to form a plurality of tufts that extend through the backing. The backing can have a length along a first axis and a width along a second axis that is perpendicular to the first axis. A backing feed roll can be configured to feed the backing through at least a first tufting machine of the at least one tufting machine. The system can further comprise at least one controller, wherein each controller is communicatively coupled with at least one tufting machine of the at least one tufting machine. The at least one controller can be configured to cause the at least one tufting machine to selectively control delivery of yarn into the backing to produce a plurality of tuft sequences. Each tuft sequence can comprise at least one tuft of the plurality of tufts. The tufts of each tuft sequence can be formed sequentially by a single needle of a tufting machine. Each tuft sequence of the plurality of tuft sequences can be spaced from other tuft sequences of the plurality of tuft sequences along at least one of the first axis or the second axis. In some aspects, no tuft sequence of the plurality of tuft sequences extends across the entire length or the entire width of the backing.
Additional advantages of the invention will be set forth in part in the description that follows, and in part will be obvious from the description, or may be learned by practice of the invention. The advantages of the invention will be realized and attained by means of the elements and combinations particularly pointed out in the appended claims. It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the invention, as claimed.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of an underside of a conventional tufted article.

FIG. 2 is a perspective view of an underside of an article in accordance with embodiments of the present disclosure.

FIG. 3 is a schematic side view of a portion of an exemplary tufted article as disclosed herein.

FIG. 4 is a schematic bottom view of a portion of an exemplary tufted article as disclosed herein.

FIG. 5 is a schematic bottom view illustrating features of an exemplary tufted article as disclosed herein.

FIG. 6 is a schematic bottom view illustrating features of an exemplary tufted article as disclosed herein.

FIG. 7 is a schematic top view illustrating features of an exemplary tufted article as disclosed herein.

FIG. 8 is a schematic top view illustrating features of an exemplary tufted article as disclosed herein.

FIG. 9 is a block diagram of a system for producing a tufted article as disclosed herein.

FIG. 10 is a computing device for controlling production of an article as disclosed herein.

It should be understood that the drawings provided herein are not necessarily to scale. Rather, the drawings are formatted to help aid the understanding of certain features disclosed herein. For example, the relative sizes of the depicted tufts and backing materials shown in the figures are not necessarily indicative of what would be seen in the tufted articles disclosed herein.

DETAILED DESCRIPTION

The disclosed system and method may be understood more readily by reference to the following detailed description of particular embodiments and the examples included therein and to the Figures and their previous and following description.
It is to be understood that the terminology used herein is for the purpose of describing particular embodiments only and is not intended to limit the scope of the present invention which will be limited only by the appended claims.
It must be noted that as used herein and in the appended claims, the singular forms “a,” “an,” and “the” include plural references unless the context clearly dictates otherwise. Thus, for example, reference to “a tuft” includes one or more of such tufts, and so forth.
“Optional” or “optionally” means that the subsequently described event, circumstance, or material may or may not occur or be present, and that the description includes instances where the event, circumstance, or material occurs or is present and instances where it does not occur or is not present.
Ranges may be expressed herein as from “about” one particular value, and/or to “about” another particular value. When such a range is expressed, also specifically contemplated and considered disclosed is the range from the one particular value and/or to the other particular value unless the context specifically indicates otherwise. Similarly, when values are expressed as approximations, by use of the antecedent “about,” it will be understood that the particular value forms another, specifically contemplated embodiment that should be considered disclosed unless the context specifically indicates otherwise. It will be further understood that the endpoints of each of the ranges are significant both in relation to the other endpoint, and independently of the other endpoint unless the context specifically indicates otherwise. Finally, it should be understood that all of the individual values and sub-ranges of values contained within an explicitly disclosed range are also specifically contemplated and should be considered disclosed unless the context specifically indicates otherwise. The foregoing applies regardless of whether in particular cases some or all of these embodiments are explicitly disclosed.
Optionally, in some aspects, when values are approximated by use of the antecedents “about,” “substantially,” or “generally,” it is contemplated that values within up to 15%, up to 10%, up to 5%, or up to 1% (above or below) of the particularly stated value or characteristic can be included within the scope of those aspects.
As used herein, the definition of the term “color” is referenced in terms of the CIELAB color scale, which was created by the International Commission on Illumination (CIE). The CIELAB color scale provides a uniform scale for measuring and comparing the color values of different samples. Three different color measurements are used to determine the CIELAB color value of a given sample: 1) a white-black color measurement; 2) a red-green color measurement; and 3) a yellow-blue color measurement. The white-black color measurement represents the amount of white present in the sample relative to the amount of black present in the sample. The red-green color measurement represents the amount of red present in the sample relative to the amount of green present in the sample. The yellow-blue color measurement represents the amount of yellow present in the sample relative to the amount of blue present in the sample. CIE LAB color scale values can be obtained using color measurement instruments known in the art, including, for example, HunterLab color measurement instruments. When two “colors” are referred to as being the same or “substantially” the same or matching or “substantially” matching, it should be understood that each of the three color measurements (in the CIELAB scale) for the colors being compared are equal or substantially equal.
The term “backing” as used herein includes both primary backing materials and secondary backing materials. The term “backing” refers to any conventional backing material that can be applied to a tufted product, such as a woven, a non-woven, a knitted, a needle punched fabric, as well as a stitch bonded primary backing material. As one skilled in the art will appreciate, materials such as polypropylene, polyesters, hemp, composites, blend, nylons, or cottons can be used to form the backing material.
The term “fiber” as used herein includes fibers of extreme or indefinite length (i.e. filaments) and fibers of short length (i.e., staple fibers).
The term “yarn” as used herein refers to a continuous strand or bundle of fibers. Such yarns can include, for example and without limitation, monofilament yarns, cut yarns, looped yarns, fibrillated yarns, multifilament yarns, twisted yarns, wrapped yarns, and the like. Optionally, yarns can be textured using conventional methods.
Unless defined otherwise, all technical and scientific terms used herein have the same meanings as commonly understood by one of skill in the art to which the disclosed apparatus, system, and method belong. Although any apparatus, systems, and methods and materials similar or equivalent to those described herein can be used in the practice or testing of the present apparatus, system, and method, the particularly useful methods, devices, systems, and materials are as described.
Throughout the description and claims of this specification, the word “comprise” and variations of the word, such as “comprising” and “comprises,” means “including but not limited to,” and is not intended to exclude, for example, other additives, components, integers or steps. In particular, in methods stated as comprising one or more steps or operations it is specifically contemplated that each step comprises what is listed (unless that step includes a limiting term such as “consisting of”), meaning that each step is not intended to exclude, for example, other additives, components, integers or steps that are not listed in the step.
It is to be understood that unless otherwise expressly stated, it is in no way intended that any method set forth herein be construed as requiring that its steps be performed in a specific order. Accordingly, where a method claim does not actually recite an order to be followed by its steps or it is not otherwise specifically stated in the claims or descriptions that the steps are to be limited to a specific order, it is in no way intended that an order be inferred, in any respect. This holds for any possible non-express basis for interpretation, including: matters of logic with respect to arrangement of steps or operational flow; plain meaning derived from grammatical organization or punctuation; and the number or type of aspects described in the specification. Thus, words denoting order, such as “first” or “next,” should be interpreted as optional aspects unless plain meaning or logic dictates otherwise.
Referring to FIG. 1, a conventional tufted article 10 (depicted as an artificial turf product) typically comprises a backing 12 and a plurality tufts 14 that extend through at least a portion of the backing 12. The backing 12 can have a longitudinal dimension 18 and a transverse dimension 20. The tufts 14 are arranged in tuft sequences 16 (i.e., rows of tufts) that extend along the entire length of the article 10. The tufts 14 are spaced by a stitch length, l, that is consistent between adjacent tufts along the length of the tuft sequences across all of the tuft sequences 16. The tuft sequences 16 are typically provided in rows extending in the longitudinal dimension 18 and are uniformly spaced relative to adjacent tuft sequences by select distance (sometimes referred to as gauge), g, in the transverse dimension 20.
In the context of artificial turf products, it is contemplated that the conventional limitations of tufted articles related to uniformity, continuity, and linearity of stitching can contribute to decreased playability. Current artificial turf assemblies are tufted linearly and continuously, creating a directional or preferential path to infill displacement inside the fabric upon footstrike, particularly for users wearing studded shoes or cleats. Such unilateral strength has been hypothesized through biomechanical studies to interfere with the peak force of the foot strike on the turf field, and the foot release time curve (the ability of the foot the rotate free inside the turf assembly via displacement of infill). However, comparisons between articles having uniform stitching gauge (spacing between stitch sequences relative to the transverse dimension of the backing), uniform frequency (stitch length), and uniform types of yarn have shown no improvement in playability, regardless of the selected gauge, selected frequency, and different yarn types used. As used herein, the “playability” or quality of a surface can be assessed using the systems and methods described in U.S. patent application Ser. No. 17/020,609, which is incorporated herein by reference in its entirety.
Referring to FIG. 2, disclosed herein is a tufted article 100, which can optionally be an artificial turf product. The article can comprise a backing 102 having a length along a first axis 104 and a width along a second axis 106 that is perpendicular to the first axis 104. It is contemplated that the first axis 104 can optionally correspond to the axis along which the backing is drawn through a tufting machine during manufacture. Each of the first axis 104 and the second axis 106 can be perpendicular to a vertical axis 107.
A plurality of tufts 108 can extend through at least a portion of the backing. Optionally, the backing can include a primary backing or at least one backing layer through which the tufts are delivered and at least one secondary backing or at least one additional backing layer that supports the primary backing or first backing layer. For purposes of the following description, it is contemplated that the description of the backing during the tufting process refers to the portion of the backing through which tufts are delivered. However, it is understood that after the tufting process is completed, other backing materials or layers can be combined with the portions of the backing through which the tufts are delivered to produce a final product. In some optional aspects, it is contemplated that the backing can consist of a single layer.
The plurality of tufts 108 can be distributed among a plurality of tuft sequences 110. Each tuft sequence can comprise a plurality of tufts 108 (i.e., at least two sequential tufts) to ensure that each tuft sequence has sufficient tuft bind. It is contemplated that each tuft can correspond to (and be formed during) a respective needle penetration through the backing. Thus, a yarn that penetrates the backing twice can form two adjacent tufts of a tuft sequence. The tufts 108 of each tuft sequence 110 can be sequentially formed by a single needle of a tufting machine. Each tuft sequence 110 can be spaced from other tuft sequences 110 along at least one of the first axis 104 or the second axis 106.
In some aspects, at least one tuft sequence 110 of the plurality of tuft sequences does not extend across the entire length or the entire width of the tufted article 100. In further aspects, at least half of the tuft sequences of the plurality of tuft sequences do not extend the entire length or the entire width of the tufted article 100. In still further aspects, no tuft sequence 110 of the plurality of tuft sequences extends across the entire length or the entire width of the tufted article 100.
In some aspects, each tuft sequence of the plurality of tuft sequences can comprise from 1 to 10 tufts. In further aspects, each tuft sequence of the plurality of tuft sequences can comprise from 1 to 7 tufts. In some aspects, the tuft sequences can comprise 1 tuft, 2 tufts, 3 tufts, 4 tufts, 5 tufts, 6 tufts, 7 tufts, 8 tufts, 9 tufts, or 10 tufts. In further aspects, the plurality of tuft sequences can comprise a first plurality of tuft sequences having from 2 to 3 tufts and a second plurality of tuft sequences having from 4 to 7 tufts. In some aspects, the length of some, most, or all of the tuft sequences can be selected to be less than the width across the shoe sole of a user walking or running on the tufted article. For example, in some aspects, the length of at least a portion of the tuft sequences (optionally, the length of all of the tuft sequences) can be less than 4 inches or less than 3 inches.
In some aspects, it is contemplated that the tuft sequences can have different stitch lengths. As used herein, the term “stitch length” refers to the axial spacing between sequential tufts within a tuft sequence, with the axial spacing corresponding to the distance between the sequential penetrations of the backing through which the sequential tufts were formed. For example, in some aspects, and as shown in FIG. 2, a first tuft sequence 110 a can have a first stitch length 112 a, and a second tuft sequence 110 b can have a second stitch length 112 b that is different from (i.e., greater than or less than) the length of 112 a.
Referring to FIG. 3, in some aspects, the tufts of each tuft sequence can have a respective pile height, which corresponds to the distance by which a respective tuft extends above the upper surface of the backing 102. In some aspects, the pile heights of the tufts can vary from tuft sequence to tuft sequence. For example, in some aspects the pile height 122 a of the tufts of a first tuft sequence 122 a can be different from (e.g., greater than or less than) a pile height 122 b of the tufts of a second tuft sequence 120 b. Further, in some aspects, the article can comprise a third tuft sequence 120 c, wherein the tufts of the third tuft sequence can have a pile height 122 c that is different from the pile height of the tufts of the first tuft sequence and the tufts of the second tuft sequence. In some aspects, the pile height of the tufts of the third tuft sequence can be greater than the pile height of the tufts of the first tuft sequence. In other aspects, the pile height of the tufts of the third tuft sequence can be less than the pile height of the tufts of the first tuft sequence. In such aspects, it is contemplated that pile height of the tufts of the third tuft sequence can be greater or less than the pile height of the tufts of the second tuft sequence.
In some aspects, the article can comprise a plurality of different yarns. For example, in some aspects, the yarn of a first tuft sequence can be different from the yarn of a second tuft sequence in at least one of material, color, texture, denier and cross-section. In some aspects, the first tuft sequence and second tuft sequence can be formed by respective needles of a single tufting machine. In further aspects, the first tuft sequence can be formed by a first needle of a first tufting machine, and the second tuft sequence can be formed by a second needle of a second machine. In exemplary aspects, the plurality of tufts of each tuft sequence can comprise fibers, yarns, or combinations thereof. In one aspect, at least a portion of the tufts (optionally, each tuft) within at least one tuft sequence (optionally, each tuft sequence) can comprise cut yarns. Additionally, or alternatively, at least a portion of the tufts (optionally, each tuft) within at least one tuft sequence (optionally, each tuft sequence) can comprise loop yarns. Additionally, or alternatively, at least a portion of the tufts (optionally, each tuft) within at least one tuft sequence (optionally, each tuft sequence) can comprise monofilament fibers. Additionally, or alternatively, at least a portion of the tufts (optionally, each tuft) within at least one tuft sequence (optionally, each tuft sequence) can comprise slit films. Additionally, or alternatively, at least a portion of the tufts (optionally, each tuft) within at least one tuft sequence (optionally, each tuft sequence) can comprise one or more twisted variations of any of the above-identified yarn types. More generally, it is contemplated that the tufts within each tuft sequence can comprise any type of yarn or fiber or any combination of multiple types of yarns or fibers. Optionally, each tuft sequence can comprise synthetic fibers or yarns, such as, for example a material comprising one or more of a conventional nylon, polyester, polypropylene (PP), polyethylene (PE), polyurethane (PU), thermoplastic polyurethane (TPU), polyvinyl chloride (PVC), polyethylene terephthalate (PET), polypropylene terephthalate (PPT), polybutylene terephthalate (PBT), polytrimethylene terephthalate (PTT), ethylene vinyl acetate (EVA), latex, styrene butadiene rubber, or any combination thereof. It is contemplated that the conventional nylon of the face fibers or yarns can be, for example and without limitation, nylon 6/6, nylon 6, nylon 10, nylon 10/10, nylon 10/11, nylon 11, and the like. Additionally, the face fibers or yarns can comprise natural fibers, such as cotton, wool, or jute. In exemplary aspects, the face fibers or yarns can comprise one or more biodegradable materials, including, for example and without limitation, polylactic acid (PLA).
Referring to FIG. 4, it is contemplated that the tuft sequences can extend along respective longitudinal axes. For example, a first tuft sequence 126 can extend along a first longitudinal axis 130. In some aspects, a second tuft sequence 128 can extend along a second longitudinal axis 132 that is angled at an oblique angle 134 (i.e., an acute or obtuse angle) with respect to the first longitudinal axis 130. For example, in some aspects, the angle between the first longitudinal axis 130 and the second longitudinal axis 132 can be less than or equal to 45 degrees. In other aspects, the first longitudinal axis 130 can be perpendicular to the second longitudinal axis 132. In further aspects, the angle between the first longitudinal axis 130 and the second longitudinal axis 132 can be greater than 45 degrees. In some aspects, it is contemplated that a first needle of a first tufting machine that defines a first tufting zone can form the first tuft sequence 126. A second needle of a second tufting machine that defines a second tufting zone can form the second tuft sequence 128. It is contemplated that the rotational orientation of the backing relative to the first tufting machine can be different from the rotational orientation of the backing relative to the second tufting machine. For example, it is contemplated that the tufting machines can be rotated using a gantry structure that allows the orientation of the backing to remain fixed while the tufting machines are rotated.
In still further aspects, the first longitudinal axis can be parallel to the second longitudinal axis. In these aspects, it is contemplated that the first and second tuft sequences can be formed by respective needles of a single tufting machine. In optional alternative aspects, it is contemplated that the first tuft sequence can be formed by a first needle of a first tufting machine that defines a first tufting zone, and the second tuft sequence can be formed by a second needle of a second tufting machine that defines a second tufting zone.
In some aspects, a third tuft sequence 136 can have a third longitudinal axis 138 that is oblique (at an acute or obtuse angle) to both the first longitudinal axis 130 and the second longitudinal axis 132. It is contemplated that the tuft sequences can optionally cross each other.
Referring to FIG. 5, in some aspects, the tuft sequences can have various lengths. For example, in certain aspects, the first tuft sequence 140 can have a length 142 along a first longitudinal axis 143. Similarly, the second tuft sequence can have a length along a second longitudinal axis 147. In some aspects, the length 142 of the first tuft sequence can be greater than the length of the second tuft sequence. In further aspects, the length 142 of the first tuft sequence 140 can be less than a length 146′ of a second tuft sequence 144′ relative to a second longitudinal axis 147′. Although the first and second longitudinal axes 143 are shown as parallel, it should be understood that, optionally, in further aspects, the first and second longitudinal axes can be oblique or perpendicular.
Referring to FIG. 6, in some aspects, tuft sequences that are adjacent to each other (or sequentially positioned) relative to the second axis 106 can be spaced by different lengths. For example, first, second, and third tuft sequences 150, 152, 154 can be spaced apart relative to the second axis 106, wherein the second tuft sequence 152 can be positioned between the first tuft sequence 150 and the third tuft sequence 154 relative to the second axis 106. In some aspects, the first tuft sequence can be spaced from the second tuft sequence by the first distance 156, and the second tuft sequence can be spaced from the third tuft sequence by a second distance 158. In some aspects, the first distance can be greater than the second distance. In further aspects, the first distance can be less than the second distance.
Referring to FIG. 7, the article 100 can comprise a plurality of patches 160. At least a portion of the tuft sequences can be distributed among the plurality of patches. It is contemplated that the patches can each have the same length and width. It is contemplated that a first patch 160 a of the plurality of patches can have a pattern that is different from the pattern of a second patch 106 b of the plurality of patches. For example, the patterns can differ in number of tufts, position of tufts, spacing between tufts, types of yarn, etc.
It is contemplated that the tuft sequences can be arranged to provide the tufted article with a varying strength along the first axis 104. Further, the article can have a varying strength along the second axis 106. That is, the strength reaction of the surface of the tufted article that is transferred to the user's leg upon footstrike can be non-unilateral (e.g., non-uniform) along at least one of the first and second axes (optionally, along both the first and second axes).
Referring to FIG. 8, in some aspects, the tufted article 100 can have different numbers of tufts 108 in cross sections in different planes that intersect the article and extend parallel to the first axis. In further aspects, the tufted article can have different numbers of tufts 108 in cross sections in different planes that intersect the article and extend parallel to the second axis 106. For example, a first plane 170 and a second plane 172 can intersect the article, wherein the first plane extends parallel to the first axis, and the second plane 172 is parallel to the first plane and offset from the first plane relative to the second axis. In some aspects, the first plane can intersect a first number of tufts, and the second plane can intersect a second number of tufts. In some aspects, the first number of tufts can be different from (i.e., greater than or less than) the second number of tufts.
Further, a third plane 174 and a fourth plane 176 can intersect the article 100, wherein the third plane extends parallel to the second axis and the fourth plane 176 is parallel to the third plane 174 and offset from the third plane relative to the first axis 104. In some aspects, the third plane can intersect a third number of tufts 108, and the fourth plane can intersect a fourth number of tufts 108. In some aspects, the third number of tufts can be different from (i.e., greater than or less than) the fourth number of tufts.
It is contemplated that the tuft sequences can be organized in a random pattern. For example, a randomizing algorithm can be employed for generating the pattern of the tuft sequences. Optionally, such a randomizing algorithm can be executed by a processor as further disclosed herein.
In some aspects, the article 100 can be artificial turf. In such aspects, the article 100 can optionally comprise an infill. In these aspects, it is contemplated that the infill can comprise a single component or any combination of a plurality of components. When the infill comprises a plurality of components, it is contemplated that the infill material can optionally comprise a plurality of layers, with each layer corresponding to a different infill component or combination of components. Alternatively, it is contemplated that the plurality of components can be provided as a mixture, which can be either homogenous or non-homogenous. In exemplary aspects, it is contemplated that the infill can comprise clay, TPE, EPDM, coconut husks, walnut shells, crushed brick, sand, or combinations thereof. More generally, it is contemplated that the infill can comprise any material that is capable of imparting desired characteristics to a tufted article (i.e., artificial turf product) as disclosed herein.
According to various aspects, the article 100 can be formed without a consistent gauge (e.g., having no uniform tuft spacing relative to the first axis or the second axis). For example, in some aspects, it is contemplated that a first portion/group of the tuft sequences of a tufted article 100 can be tufted at a nominal gauge (e.g., half-inch), while a second portion/group of the tuft sequences of the tufted article can be formed at a gauge (e.g., quarter-inch) that is less than the nominal gauge. In further aspects, the article can optionally be non-linear (e.g., having non-uniformly spaced tufts). In exemplary aspects, it is contemplated that the tufted article 100 can be formed without organized rows of tufts. More particularly, the plurality of tuft sequences can be staggered relative to one of the first axis or the second axis or both the first axis and the second axis such that the tufted article 100 does not comprise unobstructed, continuous channels that extend completely across the tufted article along the first axis or the second axis. Advantageously, it is contemplated that gauge-less configurations of the tufted article can provide improved retention of infill by eliminating the continuous, straight channels through which infill can be readily washed away (as in tufted articles having a consistent gauge), thereby maintaining desired playability properties. It is further contemplated that the use of multiple gauges (in particular, smaller gauges) within the tufted article can provide increased friction between the playing surface and the ball and/or player, thereby reducing slipping and improving playability.
In exemplary aspects, it is contemplated that the tufted articles 100 can form at least a portion of a playing surface, such as, for example and without limitation, a sports field, a golf course, a park, an airport runway, a landfill cover, and the like. Exemplary sports fields that can comprise the disclosed tufted articles 100 include football fields, soccer fields, lacrosse fields, cricket fields, baseball fields, softball fields, and the like. In various aspects, it is contemplated that the pile height of tufts within or among respective tuft sequences can be selectively varied to produce desired variations in playing surface properties that mimic or approximate the surface properties of natural surfaces. For example, in some aspects, it is contemplated that one or more tufted articles 100 can form a portion of a golf course by providing tuft sequences in a pattern that produces a decreasing pile from a “rough” of a hole of the golf course to a “fairway,” to an “approach,” to a “collar,” or to a “green” of the hole. In other aspects, it is contemplated that one or more tufted articles 100 can form a portion of a baseball field by providing tufts that simulate grass portions of the field at a higher pile height than tufts that simulate “skin” portions of the field, such as the base paths and the warning track. In these aspects, it is contemplated that the tufts of the tufted articles 100 can help secure and reinforce infill in the manner disclosed in U.S. Pat. No. 10,794,013, which is incorporated herein by reference in its entirety.
Referring to FIGS. 9-10, a system 200 for manufacturing the article 100 can comprise one or more tuning machines 202. Each tufting machine 202 can define a respective tuning zone 204. Each tufting machine can comprise a plurality of needles 206 that are configured to deliver yarn into the backing 102 to form a plurality of tufts 108 (FIG. 2) that extend through the backing. 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).
One or more controllers 220 can be communicatively coupled to the tuning machine(s) 202. It is contemplated that the controller 220 as illustrated can be embodied as a plurality of controllers, each having a memory in communication with a processor, wherein the plurality of controllers cooperatively control the system 200 to form the tufted articles as disclosed herein. For example, in some aspects, each tufting machine 202 can be in communication with a respective controller 220. Alternatively, it is contemplated that a single controller (with a central memory in communication with a central processor) can be configured to control operation of each tufting machine.
The controller 220 can be configured to cause each tufting machine, which can have at least one respective needle bar supporting a plurality of needles, to selectively control tufting of yarn into the backing to produce the plurality of tuft sequences. Thus, it is contemplated that each needle of the tufting machine can be configured to selectively form a tuft (or a tuft sequence). For example, each needle of the tufting machine can be independently and selectively actuated to penetrate the backing to form a tuft or tuft sequence. While some needles are actuated to deliver yarn through a backing to form respective tuft sequences, other needles of the tufting machine are not instructed to deliver yarn through the backing. Examples of tufting machines having such independently controllable needles are well known and have not been discussed in detail herein.
The controller 220 can comprise at least one processor and memory with instructions thereon. The at least one processor can be configured to execute instructions that cause the tufting machine(s) to selectively form tufts. For example, the controller can cause each needle of the tufting machine to selectively form tuft sequences or not form tuft sequences as the backing is moved along the first axis 210. In this way, the controller can be configured to cause the tufting device to form a plurality of tuft sequences, with the tufts of each tuft sequence being formed sequentially by a single needle. The controller can be configured to cause the tufting machine(s) 202 to form tuft sequences that are spaced from other along at least one of the first axis 210 and the second axis 212. Optionally, the controller can execute instructions that form a tufted article wherein no sequence of the plurality of tuft sequences extends across the entire length or the entire width of the backing.
In some aspects, the memory of the controller can comprise instructions that when executed by the at least one processor, cause the processor to generate a tufting pattern comprising at least one randomized parameter. The randomized parameter(s) can comprise a spacing between adjacent tuft sequences relative to the second axis, a tuft sequence length, a number of tufts per tuft sequence, a tuft pile height, and a yarn type for a selected position in the backing. For example, in one optional aspect, the randomized parameter is a tuft sequence length. The randomized tuft sequence length can be, for example, selected as a random length between select upper and lower bounds (e.g., 0-3 inches) or a random number of tufts between
In some aspects, the first tufting machine can be rotationally offset from the second tufting machine. For example, each tufting machine can have a longitudinal axis 230 along which each needle is spaced. It is contemplated that the longitudinal dimension of a first tufting machine 202 a can optionally be oblique (at an acute or obtuse angle) with respect to the longitudinal axis 230 of a second tuning machine 202 b.
It is further contemplated that the plurality of needles 206 of each tufting machine can optionally be spaced relative to each other adjacent needle by a select gauge relative to the longitudinal axis of the tufting machine. It is contemplated that the select gauge of the first tufting machine 202 a can optionally be greater or less than the select gauge of the second tufting machine 202 b. It is further contemplated that any number of gauges and/or tufting machines (having particular gauges) can be used to avoid a consistent gauge spacing throughout the tufted articles. As further described herein, it is contemplated that by avoiding a consistent gauge spacing (and organized rows of tufts), the disclosed methods can produce tufted articles that provide improved infill displacement properties (to prevent infill from washing away) and increased friction (to prevent slipping), thereby providing improved playability.
In some optional aspects, it is contemplated that the first tufting machine can be configured to form stitch sequences having stitches of a first stitch length, and the second tufting machine can be configured to form stitches having a second stitch length that is optionally different (i.e., greater than or less than) the first stitch length.
In some optional aspects, it is contemplated that a rotational orientation of the first tufting machine 202 a can be offset from a rotational orientation of the second tufting machine 202 b by 180 degrees. In these aspects, it is contemplated that the direction of movement of the backing relative to the first tufting machine can be opposite the direction of movement of the backing relative to the first tuning machine.
In some aspects, the system 200 can further comprise a coating machine 240 that is configured to apply a coating (e.g., optionally, polyurethane) on the tufted article. For example, a plurality of nozzles 242 can be configured to spray a coating on at least a portion of the article.

Computing Device

FIG. 10 shows a computing system 1000 including an exemplary configuration of a computing device 1001 for controlling the system 200. For example, the controller 220 (FIG. 9) can be embodied as one or more computing devices 1001 as further disclosed herein.
The computing device 1001 may comprise one or more processors 1003, a system memory 1012, and a bus 1013 that couples various components of the computing device 1001 including the one or more processors 1003 to the system memory 1012. In the case of multiple processors 1003, the computing device 1001 may utilize parallel computing.
The bus 1013 may comprise one or more of several possible types of bus structures, such as a memory bus, memory controller, a peripheral bus, an accelerated graphics port, and a processor or local bus using any of a variety of bus architectures.
The computing device 1001 may operate on and/or comprise a variety of computer readable media (e.g., non-transitory). Computer readable media may be any available media that is accessible by the computing device 1001 and comprises, non-transitory, volatile and/or non-volatile media, removable and non-removable media. The system memory 1012 has computer readable media in the form of volatile memory, such as random access memory (RAM), and/or non-volatile memory, such as read only memory (ROM). The system memory 1012 may store data such as pattern data 1007 (i.e., data provided by a system operator or generated by software that is executed by a processor) and/or program modules such as operating system 1005 and tufting machine control software 1006 that are accessible to and/or are operated on by the one or more processors 1003.
The computing device 1001 may also comprise other removable/non-removable, volatile/non-volatile computer storage media. The mass storage device 1004 may provide non-volatile storage of computer code, computer readable instructions, data structures, program modules, and other data for the computing device 1001. The mass storage device 1004 may be a hard disk, a removable magnetic disk, a removable optical disk, magnetic cassettes or other magnetic storage devices, flash memory cards, CD-ROM, digital versatile disks (DVD) or other optical storage, random access memories (RAM), read only memories (ROM), electrically erasable programmable read-only memory (EEPROM), and the like.
Any number of program modules may be stored on the mass storage device 1004. An operating system 1005 and tufting machine control software 1006 may be stored on the mass storage device 1004. One or more of the operating system 1005 and tufting machine control software 1006 (or some combination thereof) may comprise program modules and the tufting machine control software 1006. The pattern data 1007 may also be stored on the mass storage device 1004. The pattern data 1007 may be stored in any of one or more databases known in the art. The databases may be centralized or distributed across multiple locations within the network 1015.
A user may enter commands and information into the computing device 1001 using an input device (not shown). Such input devices comprise, but are not limited to, a keyboard, pointing device (e.g., a computer mouse, remote control), a touchscreen, a microphone, a joystick, a scanner, tactile input devices such as gloves, and other body coverings, motion sensor, and the like. These and other input devices may be connected to the one or more processors 1003 using a human machine interface 1002 that is coupled to the bus 1013, but may be connected by other interface and bus structures, such as a parallel port, game port, an IEEE 1394 Port (also known as a Firewire port), a serial port, network adapter 1008, and/or a universal serial bus (USB).
A display device 1011 may also be connected to the bus 1013 using an interface, such as a display adapter 1009. It is contemplated that the computing device 1001 may have more than one display adapter 1009 and the computing device 1001 may have more than one display device 1011. A display device 1011 may be a monitor, an LCD (Liquid Crystal Display), light emitting diode (LED) display, television, smart lens, smart glass, and/or a projector. In addition to the display device 1011, other output peripheral devices may comprise components such as speakers (not shown) and a printer (not shown) which may be connected to the computing device 1001 using Input/Output Interface 1010. Any step and/or result of the methods may be output (or caused to be output) in any form to an output device. Such output may be any form of visual representation, including, but not limited to, textual, graphical, animation, audio, tactile, and the like. The display 101 l and computing device 1001 may be part of one device, or separate devices.
The computing device 1001 may operate in a networked environment using logical connections to one or more remote computing devices 1014 a,b,c. A remote computing device 1014 a,b,c may be a personal computer, computing station (e.g., workstation), portable computer (e.g., laptop, mobile phone, tablet device), smart device (e.g., smartphone, smart watch, activity tracker, smart apparel, smart accessory), security and/or monitoring device, a server, a router, a network computer, a peer device, edge device or other common network node, and so on. Logical connections between the computing device 1001 and a remote computing device 1014 a,b,c may be made using a network 1015, such as a local area network (LAN) and/or a general wide area network (WAN). Such network connections may be through a network adapter 1008. A network adapter 1008 may be implemented in both wired and wireless environments. Such networking environments are conventional and commonplace in dwellings, offices, enterprise-wide computer networks, intranets, and the Internet. It is contemplated that the remote computing devices 1014 a,b,c can optionally have some or all of the components disclosed as being part of computing device 1001.

Exemplary Aspects

in view of the described products, systems, and methods and variations thereof, herein below are described certain more particularly described aspects of the invention. These particularly recited aspects should not however be interpreted to have any limiting effect on any different claims containing different or more general teachings described herein, or that the “particular” aspects are somehow limited in some way other than the inherent meanings of the language literally used therein.
Aspect 1: A tufted article having a length along a first axis and width along a second axis that is perpendicular to the first axis, the first and second axes being perpendicular to a vertical axis, the tufted article comprising: a backing; and a plurality of tufts extending through the backing, the plurality of tufts distributed among a plurality of tuft sequences, wherein each tuft sequence comprises at least one tuft of the plurality of tufts, wherein the tufts of each tuft sequence are formed sequentially by a single needle of a tufting machine, wherein each tuft sequence of the plurality of tuft sequences is spaced from other tuft sequences of the plurality of tuft sequences along at least one of the first axis or the second axis, and wherein no tuft sequence of the plurality of tuft sequences extends across the entire length or the entire width of the tufted article.
Aspect 2: The tufted article of aspect 1, wherein each tuft sequence of the plurality of tuft sequences comprises from 1 to 10 tufts.
Aspect 3: The tufted article of aspect 1, wherein each tuft sequence of the plurality of tuft sequences comprises from 1 to 7 tufts.
Aspect 4: The tufted article of aspect 1, wherein the plurality of tuft sequences comprises a first plurality of tuft sequences having from 2 to 3 tufts and a second plurality of tuft sequences having from 4 to 7 tufts.
Aspect 5: The tufted article of any one of the preceding aspects, wherein at least one tuft sequence of the plurality of tuft sequences comprises two tufts.
Aspect 6: The tufted article of any one of the preceding aspects, wherein the tufts of each tuft sequence of the plurality of tuft sequences have a respective pile height, and wherein the pile height of tufts of a first tuft sequence of the plurality of tuft sequences is different than the pile height of tufts of at least a second tuft sequence of the plurality of tuft sequences.
Aspect 7: The tufted article of aspect 6, wherein the pile height of tufts of the first tuft sequence is greater than the pile height of tufts of the second tuft sequence.
Aspect 8: The tufted article of aspect 6, wherein the pile height of tufts of the first tuft sequence is less than the pile height of tufts of the second tuft sequence.
Aspect 9: The tufted article of any one of aspects 6-8, wherein the pile height of tufts of a third tuft sequence of the plurality of tuft sequences is different than the pile height of tufts of the first and second tuft sequences.
Aspect 10: The tufted article of aspect 9, wherein the pile height of tufts of the third tuft sequence is greater than the pile height of tufts of the first tuft sequence.
Aspect 11: The tufted article of aspect 9, wherein the pile height of tufts of the third tuft sequence is less than the pile height of tufts of the first tuft sequence.
Aspect 12: The tufted article of any one of aspects 9-11, wherein the pile height of tufts of the third tuft sequence is greater than the pile height of tufts of the second tuft sequence.
Aspect 13: The tufted article of any one of aspects 9-11, wherein the pile height of tufts of the third tuft sequence is less than the pile height of tufts of the second tuft sequence.
Aspect 14: The tufted article of any one of any one of the preceding aspects, wherein a first tuft sequence of the plurality of tuft sequences comprises a first yarn, and wherein a second tuft sequence of the plurality of tuft sequences comprises a second yarn that is different from the first yarn in at least one of material, color, texture, denier and cross-section.
Aspect 15: The tufted article of any one of the preceding aspects, wherein a first tuft sequence of the plurality of tuft sequences extends along a first longitudinal axis, and wherein a second tuft sequence of the plurality of tuft sequences extends along a second longitudinal axis that is oriented at an angle that is less than or equal to 45 degrees with respect to the first longitudinal axis.
Aspect 16: The tufted article of any one of aspects 1-14, wherein a first tuft sequence of the plurality of tuft sequences extends along a first longitudinal axis, and wherein a second tuft sequence of the plurality of tuft sequences extends along a second longitudinal axis that is oriented at an angle that is greater than 45 degrees with respect to the first longitudinal axis.
Aspect 17: The tufted article of any one of aspects 1-14, wherein a first tuft sequence of the plurality of tuft sequences extends along a first longitudinal axis, and wherein a second tuft sequence of the plurality of tuft sequences extends along a second longitudinal axis that is oriented perpendicular to the first longitudinal axis.
Aspect 18: The tufted article of any one of aspects 1-14, wherein a first tuft sequence of the plurality of tuft sequences extends along a first longitudinal axis, and wherein a second tuft sequence of the plurality of tuft sequences extends along a second longitudinal axis that is oriented parallel to the first longitudinal axis.
Aspect 19: The tufted article of any one of aspects 15-18, wherein the first tuft sequence has a length along the first longitudinal axis, wherein the second tuft sequence has a length along the second longitudinal axis, and wherein the length of the first tuft sequence is different than the length of the second tuft sequence.
Aspect 20: The tufted article of any one of aspects 15-18, wherein the first tuft sequence has a length along the first longitudinal axis, wherein the second tuft sequence has a length along the second longitudinal axis, and wherein the length of the first tuft sequence is greater than the length of the second tuft sequence.
Aspect 21: The tufted article of any one of aspects 15-18, wherein the first tuft sequence has a length along the first longitudinal axis, wherein the second tuft sequence has a length along the second longitudinal axis, and wherein the length of the first tuft sequence is less than the length of the second tuft sequence.
Aspect 22: The tufted article of any one of the preceding aspects, wherein first, second, and third tuft sequences of the plurality of tuft sequences are spaced apart relative to the second axis, wherein the second tuft sequence is positioned between the first and third tuft sequences relative to the second axis, wherein the first tuft sequence is spaced from the second tuft sequence by a first distance along the second axis, and wherein the second tuft sequence is spaced from the third tuft sequence by a second distance along the second axis that is different than the first distance.
Aspect 23: The tufted article of aspect 22, wherein the second distance is greater than the first distance.
Aspect 24: The tufted article of aspect 22, wherein the second distance is less than the first distance.
Aspect 25: The tufted article of any one of the preceding aspects, wherein first, second, and third tuft sequences of the plurality of tuft sequences are spaced apart relative to the second axis, wherein the second tuft sequence is positioned between the first and third tuft sequences relative to the second axis, wherein the first tuft sequence is spaced from the second tuft sequence by a first distance along the second axis, and wherein the second tuft sequence is spaced from the third tuft sequence by a second distance along the second axis that is different than the first distance.
Aspect 26: The tufted article of aspect 25, wherein the second distance is greater than the first distance.
Aspect 27: The tufted article of aspect 25, wherein the second distance is less than the first distance.
Aspect 28: The tufted article of any one of the preceding aspects, wherein at least a portion of the plurality of tuft sequences are distributed among a plurality of patches, each patch of the plurality of patches comprising at least one tuft sequence that defines a pattern of the patch, wherein the plurality of patches comprises a first patch and a second patch, and wherein the pattern of the first patch is different than the pattern of the second patch.
Aspect 29: The tufted article of any one of the preceding aspects, wherein the tufted article has a varying strength along the first axis and the second axis.
Aspect 30: The tufted article of any one of the preceding aspects, wherein a first number of tufts is intersected by a first cross-sectional plane extending parallel to the first axis, wherein a second number of tufts is intersected by a second cross-sectional plane extending parallel to the first axis, wherein a third number of tufts is intersected by a third cross-sectional plane extending parallel to the second axis, wherein a fourth number of tufts is intersected by a fourth cross-sectional plane extending parallel to the second axis, wherein the first number of tufts is different than the second number of tufts, and wherein the third number of tufts is different than the fourth number of tufts.
Aspect 31: The tufted article of any one of the preceding aspects, wherein the plurality of tuft sequences are organized in a random pattern.
Aspect 32: The tufted article of any one of the preceding aspects, wherein the tufted article is artificial turf.
Aspect 33: A method of manufacturing a tufted article, the method comprising: tufting a plurality of tuft sequences through a backing having length extending along a first axis and a width extending along a second axis that is perpendicular to the first axis, each tuft sequence comprising at least one tuft, wherein the tufts of each tuft sequence are formed sequentially by a single needle of a tufting machine, wherein each tuft sequence of the plurality of tuft sequences is spaced from other tuft sequences of the plurality of tuft sequences along at least one of the first axis or the second axis, and wherein no tuft sequence of the plurality of tuft sequences extends across the entire length or the entire width of the backing.
Aspect 34: The method of aspect 33, wherein each tuft sequence of the plurality of tuft sequences comprises from 1 to 10 tufts.
Aspect 35: The method of aspect 33, wherein each tuft sequence of the plurality of tuft sequences comprises from 1 to 7 tufts.
Aspect 36: The method of aspect 33, wherein the plurality of tuft sequences comprises a first plurality of tuft sequences having from 2 to 3 tufts and a second plurality of tuft sequences having from 4 to 7 tufts.
Aspect 37: The method of any one of aspects 33-36, wherein at least one tuft sequence of the plurality of tuft sequences comprises two tufts.
Aspect 38: The method of any one of aspects 33-37, wherein the tufts of each tuft sequence of the plurality of tuft sequences have a respective pile height, and wherein the pile height of tufts of a first tuft sequence of the plurality of tuft sequences is different than the pile height of tufts of at least a second tuft sequence of the plurality of tuft sequences.
Aspect 39: The method of aspect 38, wherein the pile height of tufts of the first tuft sequence is greater than the pile height of tufts of the second tuft sequence.
Aspect 40: The method of aspect 38, wherein the pile height of tufts of the first tuft sequence is less than the pile height of tufts of the second tuft sequence.
Aspect 41: The method of any one of aspects 38-40, wherein the pile height of tufts of a third tuft sequence of the plurality of tuft sequences is different than the pile height of tufts of the first and second tuft sequences.
Aspect 42: The method of aspect 41, wherein the pile height of tufts of the third tuft sequence is greater than the pile height of tufts of the first tuft sequence.
Aspect 43: The method of aspect 41, wherein the pile height of tufts of the third tuft sequence is less than the pile height of tufts of the first tuft sequence.
Aspect 44: The method of any one of aspects 41-43, wherein the pile height of tufts of the third tuft sequence is greater than the pile height of tufts of the second tuft sequence.
Aspect 45: The method of any one of aspects 41-43, wherein the pile height of tufts of the third tuft sequence is less than the pile height of tufts of the second tuft sequence.
Aspect 46: The method of any one of aspects 33-45, wherein a first tuft sequence of the plurality of tuft sequences comprises a first yarn, and wherein a second tuft sequence of the plurality of tuft sequences comprises a second yarn that is different from the first yarn in at least one of material, color, texture, denier and cross-section.
Aspect 47: The method of aspect 46, wherein the first and second tuft sequences are formed by respective needles of a single tufting machine.
Aspect 48: The method of aspect 46, wherein the first tuft sequence is formed by a first needle of a first tufting machine, and wherein the second tuft sequence is formed by a second needle of a second tufting machine.
Aspect 49: The method of any one of aspects 33-48, wherein a first tuft sequence of the plurality of tuft sequences extends along a first longitudinal axis, wherein a second tuft sequence of the plurality of tuft sequences extends along a second longitudinal axis that is oriented at an angle that is less than or equal to 45 degrees with respect to the first longitudinal axis, wherein the first tuft sequence is formed by a first needle of a first tufting machine that defines a first tufting zone, wherein the second tuft sequence is formed by a second needle of a second tufting machine that defines a second tufting zone, and wherein a rotational orientation of the backing relative to the first tufting machine is different than a rotational orientation of the backing relative to the second tufting machine.
Aspect 50: The method of any one of aspects 33-48, wherein a first tuft sequence of the plurality of tuft sequences extends along a first longitudinal axis, and wherein a second tuft sequence of the plurality of tuft sequences extends along a second longitudinal axis that is oriented at an angle that is greater than 45 degrees with respect to the first longitudinal axis, wherein the first tuft sequence is formed by a first needle of a first tufting machine that defines a first tufting zone, wherein the second tuft sequence is formed by a second needle of a second tufting machine that defines a second tufting zone, and wherein a rotational orientation of the backing relative to the first tufting machine is different than a rotational orientation of the backing relative to the second tufting machine.
Aspect 51: The method of any one of aspects 33-48, wherein a first tuft sequence of the plurality of tuft sequences extends along a first longitudinal axis, wherein a second tuft sequence of the plurality of tuft sequences extends along a second longitudinal axis that is oriented perpendicular to the first longitudinal axis, wherein the first tuft sequence is formed by a first needle of a first tufting machine that defines a first tufting zone, wherein the second tuft sequence is formed by a second needle of a second tufting machine that defines a second tufting zone, and wherein a rotational orientation of the backing with respect to the first tufting machine is different than a rotational orientation of the backing with respect to the second tufting machine.
Aspect 52: The method of any one of aspects 3348, wherein a first tuft sequence of the plurality of tuft sequences extends along a first longitudinal axis, and wherein a second tuft sequence of the plurality of tuft sequences extends along a second longitudinal axis that is oriented parallel to the first longitudinal axis.
Aspect 53: The method of aspect 52, wherein the first and second tuft sequences are formed by respective needles of a single tufting machine.
Aspect 54: The method of aspect 52, wherein the first tuft sequence is formed by a first needle of a first tufting machine that defines a first tufting zone, and wherein the second tuft sequence is formed by a second needle of a second tufting machine that defines a second tufting zone.
Aspect 55: The method of aspect 54, wherein a rotation of the first tufting machine is offset 180 degrees from a rotational orientation of the second tufting machine.
Aspect 56: The method of any one of aspects 49-55, wherein the first tuft sequence has a length along the first longitudinal axis, wherein the second tuft sequence has a length along the second longitudinal axis, and wherein the length of the first tuft sequence is different than the length of the second tuft sequence.
Aspect 57: The method of any one of aspects 49-55, wherein the first tuft sequence has a length along the first longitudinal axis, wherein the second tuft sequence has a length along the second longitudinal axis, and wherein the length of the first tuft sequence is greater than the length of the second tuft sequence.
Aspect 58: The method of any one of aspects 49-55, wherein the first tuft sequence has a length along the first longitudinal axis, wherein the second tuft sequence has a length along the second longitudinal axis, and wherein the length of the first tuft sequence is less than the length of the second tuft sequence.
Aspect 59: The method of any one of aspects 33-58, wherein first, second, and third tuft sequences of the plurality of tuft sequences are spaced apart relative to the second axis, wherein the second tuft sequence is positioned between the first and third tuft sequences relative to the second axis, wherein the first tuft sequence is spaced from the second tuft sequence by a first distance along the second axis, and wherein the second tuft sequence is spaced from the third tuft sequence by a second distance along the second axis that is different than the first distance.
Aspect 60: The method of aspect 59, wherein the second distance is greater than the first distance.
Aspect 61: The method of aspect 59, wherein the second distance is less than the first distance.
Aspect 62: The method of any one of aspects 59-61, wherein at least one of the first, second, or third tuft sequences is tufted using a first tufting machine, and wherein at least one other tuft sequence of the first, second, or third tuft sequences is tufted using a second tufting machine.
Aspect 63: The method of any one of aspects 59-62, wherein at least two of the first, second, and third tuft sequences are collinear relative to second axis.
Aspect 64: The method of any one of aspects 33-63, wherein first, second, and third tuft sequences of the plurality of tuft sequences are spaced apart relative to the second axis, wherein the second tuft sequence is positioned between the first and third tuft sequences relative to the second axis, wherein the first tuft sequence is spaced from the second tuft sequence by a first distance along the second axis, and wherein the second tuft sequence is spaced from the third tuft sequence by a second distance along the second axis that is different than the first distance.
Aspect 65: The method of aspect 64, wherein the second distance is greater than the first distance.
Aspect 66: The method of aspect 64, wherein the second distance is less than the first distance.
Aspect 67: The method of any one of aspects 64-66, wherein at least one of the first, second, or third tuft sequences is tufted using a first tufting machine having a first gauge spacing between respective needles of the first tufting machine, and wherein at least one other tuft sequence of the first, second, or third tuft sequences is tufted using a second tufting machine having a second gauge spacing between respective needles of the second tufting machine, wherein the second gauge spacing is different than the first gauge spacing.
Aspect 68: The method of any one of aspects 64-67, wherein at least two of the first, second, and third tuft sequences are collinear relative to the first axis.
Aspect 69: The method of any one of aspects 33-68, wherein at least a portion of the plurality of tuft sequences are distributed among a plurality of patches, each patch of the plurality of patches comprising at least one tuft sequence that defines a pattern.
Aspect 70: The method of aspect 69, wherein the plurality of patches comprises a first patch and a second patch, and wherein the pattern of the first patch is different than the pattern of the second patch.
Aspect 71: The method of any one of aspects 33-70, wherein the plurality of tuft sequences are organized in a random pattern.
Aspect 72: The method of any one of aspects 33-71, wherein the tufted article is artificial turf.
Aspect 73: A system comprising: at least one tufting machine, each tufting machine defining a respective tufting zone and comprising a plurality of needles that are configured to deliver yarn into a backing to form a plurality of tufts that extend through the backing, the backing having a length along a first axis and a width along a second axis that is perpendicular to the first axis; and a backing feed roll that is configured to feed the backing through at least a first tufting machine of the at least one tufting machine; and at least one controller, wherein each controller of the at least one controller is communicatively coupled with at least one tufting machine of the at least one tufting machine, wherein the at least one controller is configured to cause the at least one tufting machine to selectively control delivery of yarn into the backing to produce a plurality of tuft sequences, wherein each tuft sequence comprises at least one tuft of the plurality of tufts, wherein the tufts of each tuft sequence are formed sequentially by a single needle of a tufting machine, wherein each tuft sequence of the plurality of tuft sequences is spaced from other tuft sequences of the plurality of tuft sequences along at least one of the first axis or the second axis, and wherein no tuft sequence of the plurality of tuft sequences extends across the entire length or the entire width of the backing.
Aspect 74: The system of aspect 73, wherein the controller is configured to cause the at least one tufting machine to form a tufted article as in any one of aspects 1-32.
Aspect 75: The system of aspect 73 or aspect 74, wherein the controller comprises: at least one processor; and a memory in communication with the at least one processor, wherein the memory comprises instructions that, when executed by the at least one processor, cause the processor to cause the at least one tufting machine to selectively form the plurality of tuft sequences.
Aspect 76: The system of aspect 75, wherein the memory comprises instructions that, when executed by the at least one processor, cause the processor to generate a tufting pattern comprising at least one randomized parameter, wherein the at least one randomized parameter comprises at least one of 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, or a yarn type for a selected position in the backing.
Aspect 77: The system of any one of aspects 73-76, wherein the at least one tuning machine comprises a plurality of tuning machines, and wherein a first tufting machine of the plurality of tufting machines is rotationally offset from a second tuning machine of the plurality of tuning machines.
Although several embodiments of the invention have been disclosed in the foregoing specification and the following appendices, it is understood by those skilled in the art that many modifications and other embodiments of the invention will come to mind to which the invention pertains, having the benefit of the teaching presented in the foregoing description and associated drawings. It is thus understood that the invention is not limited to the specific embodiments disclosed herein, and that many modifications and other embodiments are intended to be included within the scope of the appended claims. Moreover, although specific terms are employed herein, as well as in the claims which follow, they are used only in a generic and descriptive sense, and not for the purposes of limiting the described invention, nor the claims which follow.

Claims

1. A tufted article having a length along a first axis and a width along a second axis that is perpendicular to the first axis, the first and second axes being perpendicular to a vertical axis, the tufted article comprising:

a backing; and

a plurality of tufts extending through the backing, the plurality of tufts distributed among a plurality of tuft sequences, wherein each tuft sequence comprises at least one tuft of the plurality of tufts, wherein the tufts of each tuft sequence are formed sequentially by a single needle of a tufting machine,

wherein each tuft sequence of the plurality of tuft sequences is spaced from other tuft sequences of the plurality of tuft sequences along at least one of the first axis or the second axis, and

wherein no tuft sequence of the plurality of tuft sequences extends across the entire length or the entire width of the tufted article.

2. The tufted article of claim 1, wherein each tuft sequence of the plurality of tuft sequences comprises from 1 to 10 tufts.

3. The tufted article of claim 1, wherein the plurality of tuft sequences comprises a first plurality of tuft sequences having from 2 to 3 tufts and a second plurality of tuft sequences having from 4 to 7 tufts.

4. The tufted article of claim 1, wherein the tufts of each tuft sequence of the plurality of tuft sequences have a respective pile height, and wherein the pile height of tufts of a first tuft sequence of the plurality of tuft sequences is different than the pile height of tufts of at least a second tuft sequence of the plurality of tuft sequences.

5. The tufted article of claim 4, wherein the pile height of tufts of a third tuft sequence of the plurality of tuft sequences is different than the pile height of tufts of the first and second tuft sequences.

6. The tufted article of claim 1, wherein a first tuft sequence of the plurality of tuft sequences comprises a first yarn, and wherein a second tuft sequence of the plurality of tuft sequences comprises a second yarn that is different from the first yarn in at least one of material, color, texture, denier and cross-section.

7. The tufted article of claim 1, wherein a first tuft sequence of the plurality of tuft sequences extends along a first longitudinal axis, and wherein a second tuft sequence of the plurality of tuft sequences extends along a second longitudinal axis that is oriented at an oblique angle with respect to the first longitudinal axis.

8. The tufted article of claim 7, wherein the first tuft sequence has a length along the first longitudinal axis, wherein the second tuft sequence has a length along the second longitudinal axis, and wherein the length of the first tuft sequence is different than the length of the second tuft sequence.

9. The tufted article of claim 1, wherein a first tuft sequence of the plurality of tuft sequences extends along a first longitudinal axis, and wherein a second tuft sequence of the plurality of tuft sequences extends along a second longitudinal axis that is oriented perpendicular to the first longitudinal axis.

10. The tufted article of claim 9, wherein the first tuft sequence has a length along the first longitudinal axis, wherein the second tuft sequence has a length along the second longitudinal axis, and wherein the length of the first tuft sequence is different than the length of the second tuft sequence.

11. The tufted article of claim 1, wherein a first tuft sequence of the plurality of tuft sequences extends along a first longitudinal axis, and wherein a second tuft sequence of the plurality of tuft sequences extends along a second longitudinal axis that is oriented parallel to the first longitudinal axis.

12. The tufted article of claim 11, wherein the first tuft sequence has a length along the first longitudinal axis, wherein the second tuft sequence has a length along the second longitudinal axis, and wherein the length of the first tuft sequence is different than the length of the second tuft sequence.

13. The tufted article of claim 1, wherein first, second, and third tuft sequences of the plurality of tuft sequences are spaced apart relative to the second axis, wherein the second tuft sequence is positioned between the first and third tuft sequences relative to the second axis, wherein the first tuft sequence is spaced from the second tuft sequence by a first distance along the second axis, and wherein the second tuft sequence is spaced from the third tuft sequence by a second distance along the second axis that is different than the first distance.

14. The tufted article of claim 1, wherein the tufted article has a varying strength along the first axis and the second axis.

15. The tufted article of claim 1, wherein a first number of tufts is intersected by a first cross-sectional plane extending parallel to the first axis, wherein a second number of tufts is intersected by a second cross-sectional plane extending parallel to the first axis, wherein a third number of tufts is intersected by a third cross-sectional plane extending parallel to the second axis, wherein a fourth number of tufts is intersected by a fourth cross-sectional plane extending parallel to the second axis, wherein the first number of tufts is different than the second number of tufts, and wherein the third number of tufts is different than the fourth number of tufts.

16. The tufted article of claim 1, wherein the tufted article is artificial turf.

17. A method of manufacturing a tufted article, the method comprising:

tufting a plurality of tuft sequences through a backing having length extending along a first axis and a width extending along a second axis that is perpendicular to the first axis, each tuft sequence comprising at least one tuft, wherein the tufts of each tuft sequence are formed sequentially by a single needle of a tufting machine,

wherein no tuft sequence of the plurality of tuft sequences extends across the entire length or the entire width of the backing.

18. The method of claim 17, wherein a first tuft sequence of the plurality of tuft sequences comprises a first yarn, and wherein a second tuft sequence of the plurality of tuft sequences comprises a second yarn that is different from the first yarn in at least one of material, color, texture, denier and cross-section.

19. The method of claim 17, wherein a first tuft sequence of the plurality of tuft sequences extends along a first longitudinal axis, wherein a second tuft sequence of the plurality of tuft sequences extends along a second longitudinal axis that is oriented at an oblique angle with respect to the first longitudinal axis, wherein the first tuft sequence is formed by a first needle of a first tufting machine that defines a first tufting zone, wherein the second tuft sequence is formed by a second needle of a second tufting machine that defines a second tufting zone, and wherein a rotational orientation of the backing relative to the first tufting machine is different than a rotational orientation of the backing relative to the second tufting machine.

20. The method of claim 17, wherein a first tuft sequence of the plurality of tuft sequences extends along a first longitudinal axis, wherein a second tuft sequence of the plurality of tuft sequences extends along a second longitudinal axis that is oriented perpendicular to the first longitudinal axis, wherein the first tuft sequence is formed by a first needle of a first tufting machine that defines a first tufting zone, wherein the second tuft sequence is formed by a second needle of a second tufting machine that defines a second tufting zone, and wherein a rotational orientation of the backing with respect to the first tufting machine is different than a rotational orientation of the backing with respect to the second tufting machine.

21. The method of claim 17, wherein a first tuft sequence of the plurality of tuft sequences extends along a first longitudinal axis, and wherein a second tuft sequence of the plurality of tuft sequences extends along a second longitudinal axis that is oriented parallel to the first longitudinal axis.

22. The method of claim 17, wherein first, second, and third tuft sequences of the plurality of tuft sequences are spaced apart relative to the second axis, wherein the second tuft sequence is positioned between the first and third tuft sequences relative to the second axis, wherein the first tuft sequence is spaced from the second tuft sequence by a first distance along the second axis, and wherein the second tuft sequence is spaced from the third tuft sequence by a second distance along the second axis that is different than the first distance.

23. The method of claim 22, wherein at least one of the first, second, or third tuft sequences is tufted using a first tufting machine having a first gauge spacing between respective needles of the first tufting machine, and wherein at least one other tuft sequence of the first, second, or third tuft sequences is tufted using a second tufting machine having a second gauge spacing between respective needles of the second tuning machine, wherein the second gauge spacing is different than the first gauge spacing.

24. The method of claim 22, wherein at least two of the first, second, and third tuft sequences are collinear relative to the first axis.

25. The method of claim 17, wherein the tufted article is artificial turf.

26. A system comprising:

at least one tufting machine, each tufting machine defining a respective tufting zone and comprising a plurality of needles that are configured to deliver yarn into a backing to form a plurality of tufts that extend through the backing, the backing having a length along a first axis and a width along a second axis that is perpendicular to the first axis; and

a backing feed roll that is configured to feed the backing through at least a first tufting machine of the at least one tufting machine; and

at least one controller, wherein each controller of the at least one controller is communicatively coupled with at least one tufting machine of the at least one tufting machine,

wherein the at least one controller is configured to cause the at least one tufting machine to selectively control delivery of yarn into the backing to produce a plurality of tuft sequences, wherein each tuft sequence comprises at least one tuft of the plurality of tufts, wherein the tufts of each tuft sequence are formed sequentially by a single needle of a tufting machine,

27. The system of claim 26, wherein the controller comprises:

at least one processor; and

a memory in communication with the at least one processor, wherein the memory comprises instructions that, when executed by the at least one processor, cause the processor to cause the at least one tufting machine to selectively form the plurality of tuft sequences.

28. The system of claim 27, wherein the memory comprises instructions that, when executed by the at least one processor, cause the processor to generate a tufting pattern comprising at least one randomized parameter, wherein the at least one randomized parameter comprises at least one of 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, or a yarn type for a selected position in the backing.

29. The system of claim 26, wherein the at least one tufting machine comprises a plurality of tuning machines, and wherein a first tuning machine of the plurality of tufting machines is rotationally offset from a second tufting machine of the plurality of tufting machines.