Cut pile carpet with color accents and methods of manufacture thereof

Abstract

A multicolored and accented carpet includes a plurality of tufts of color accented fiber including two or more differently colored extruded solution dyed yarns and a base yarn twisted together whereby a plurality of color transitions are provided along the length of the single accented fiber. A cut pile carpet is produced, having the appearance of a space dyed carpet, with the fade and bleach resistance of a solution dyed carpet.

What is claimed is: 
     
         1 . A multicolored carpet comprising:
 a primary backing material; and   a plurality of piles tufted with the primary backing material to form a carpet,   wherein at least a portion of the piles of the carpet comprise color accented 2-ply yarns, the color accented 2-ply yarns comprising a single ply tri-colored solution dyed fiber twisted together with a single ply of solid colored fiber.   
     
     
         2 . The multicolored carpet of  claim 1 , further comprising one or more piles tufted with the primary backing material in the form of solid color 2-ply yarns. 
     
     
         3 . The multicolored carpet of  claim 1 , further comprising one or more piles tufted with the primary backing material in the form of a barber pole yarn. 
     
     
         4 . The multicolored carpet of  claim 3 , wherein the barber pole yarn comprises a 2-ply yarn comprising two differing colors of pre-colored, solution dyed fibers. 
     
     
         5 . The multicolored carpet of  claim 1 , wherein between about 10-70% of the piles tufted with the primary backing comprise color accented 2-ply yarns. 
     
     
         6 . The multicolored carpet of  claim 5 , wherein about 33% of the piles tufted with the primary backing comprise color accented 2-ply yarns. 
     
     
         7 . The multicolored carpet of  claim 3 , wherein the color accented 2-ply yarn in combination with the barber pole yarn provides a plurality of color transitions along a length of the carpet. 
     
     
         8 . The multicolored carpet of  claim 1 , wherein the carpet comprises cut piles. 
     
     
         9 . The multicolored carpet of  claim 8 , wherein the carpet comprises a combination of cut piles and loop piles. 
     
     
         10 . A method of manufacturing multicolored and color accented carpet, the method comprising:
 providing a color accented 2-ply yarn, the color accented 2-ply yarn comprising at least two differently colored extruded solution dyed yarns twisted together, wherein twisting of the at least two colored extruded solution dyed yarns results in a plurality of color transitions along a length of the color accented 2-ply yarn;   providing a primary backing; and   tufting the color accented 2-ply yarn into the primary backing to form the carpet.   
     
     
         11 . The method of  claim 10 , wherein prior to tufting the color accented 2-ply yarn into the primary backing, the color accented 2-ply yarn is twisted together with a main fiber, and wherein twisting of the color accented 2-ply yarn about the main fiber provides for a plurality of color transitions along the length thereof. 
     
     
         12 . The method of  claim 11 , further comprising tufting barber pole yarn into at least a portion of the primary backing. 
     
     
         13 . The method of  claim 12 , wherein the barber pole yarn comprises a 2-ply yarn comprising two differing colors of pre-colored, solution dyed fibers. 
     
     
         14 . The method of  claim 11 , further comprising tufting solid color 2-ply yarns into the primary backing. 
     
     
         15 . A multicolored and color accented carpet formed by the method of  claim 10 . 
     
     
         16 . The method of  claim 10 , further comprising cutting at least a portion of the piles of the carpet. 
     
     
         17 . A multicolored and color accented cut pile carpet comprising:
 at least one pile in the form of a color accented 2-ply yarn;   at least one pile in the form of a barber pole yarn; and   at least one pile in the form of a solid color 2-ply yarn.   
     
     
         18 . The multicolored and color accented cut pile of  claim 17 , wherein the at least one color accented 2-ply yarn comprises a single ply tri-colored solution dyed fiber twisted together with a single ply of solid colored fiber. 
     
     
         19 . The multicolored and color accented cut pile of  claim 17 , wherein the barber pole yarn comprises a 2-ply yarn comprising two differing colors of pre-colored, solution dyed fibers. 
     
     
         20 . The multicolored and color accented cut pile of  claim 17 , wherein about 33% of the piles comprise the color accented 2-ply yarn.