Fabrics, Surface Coverings Comprising Same, And Systems And Methods For Producing Same

Abstract

Fabrics having conventional turf yarns provided in combination with traditional carpet yarns. Optionally, the turf yarns and/or the carpet yarns can be unpigmented natural yarns. A color pattern can be applied to the fabrics to produce surface coverings, such as floor coverings.

What is claimed is: 
     
         1 . A hybrid turf-carpet article comprising:
 a backing structure comprising a primary backing having a face surface and an opposing rear surface; and   a plurality of yarns associated with the primary backing and extending outwardly from the face surface of the primary backing in a direction moving away from the primary backing, wherein the plurality of yarns comprises:
 a first yarn having a plurality of yarn filaments, wherein each yarn filament of the plurality of yarn filaments of the first yarn has a denier ranging from 61 to 3,600 denier per filament (dpf); and 
 a second yarn having a plurality of yarn filaments, wherein each yarn filament of the plurality of yarn filaments of the second yarn has a denier per filament (dpf) ranging from 2 to 60 dpf. 
   
     
     
         2 . The article of  claim 1 , wherein the yarn filaments of the second yarn have a dpf ranging from 2 to 32. 
     
     
         3 . The article of  claim 1 , wherein the yarn filaments of the second yarn have a dpf ranging from 22 to 60. 
     
     
         4 . The article of  claim 1 , wherein the plurality of yarns are tufted through the primary backing to define a plurality of yarn tufts, wherein each tuft of the plurality of tufts comprises the first yarn and the second yarn, and wherein the first yarn is not entangled with the second yarn. 
     
     
         5 . The article of  claim 1 , wherein the first yarn is tufted through the primary backing to define a first plurality of yarn tufts, and wherein the second yarn is tufted through the primary backing to define a second plurality of yarn tufts, wherein each tuft of the first plurality of yarn tufts consists of the first yarn, and wherein each tuft of the second plurality of yarn tufts consists of the second yarn. 
     
     
         6 . The article of  claim 1 , wherein each yarn filament of the first yarn is a monofilament. 
     
     
         7 . The article of  claim 1 , further comprising a color pattern applied to the plurality of yarns. 
     
     
         8 . The article of  claim 4 , wherein at least one yarn tuft of the plurality of yarn tufts comprises:
 a first portion in which the color pattern imparts color to an exterior surface of the first portion; and   a second portion in which the color pattern does not impart color to an exterior surface of the second portion, wherein the second portion retains a base color.   
     
     
         9 . The article of any one of  claims 1 , wherein the plurality of yarns further comprises a third yarn having a plurality of yarn filaments, wherein each yarn filament of the plurality of yarn filaments of the second yarn has a denier per filament (dpf) ranging from 2 to 60 dpf. 
     
     
         10 . The article of  claim 9 , wherein the third yarn is commingled with the first and second yarns. 
     
     
         11 . The article of  claim 9 , wherein the third yarn is not commingled with the first and second yarns. 
     
     
         12 . A method comprising:
 forming a face structure of a fabric, wherein forming the face structure comprises securing a plurality of yarns to a primary backing having a face surface and an opposing rear surface, wherein the plurality of yarns extend outwardly from the face surface of the primary backing in a direction moving away from the primary backing, wherein the plurality of yarns comprise:
 a first yarn having a plurality of yarn filaments, wherein each yarn filament of the plurality of yarn filaments of the first yarn has a denier ranging from 61 to 3,600 denier per filament (dpf); and 
 a second yarn having a plurality of yarn filaments, wherein each yarn filament of the plurality of yarn filaments of the second yarn has a denier per filament (dpf) ranging from 2 to 60 dpf; and 
 applying a color pattern to the face structure of the fabric. 
   
     
     
         13 . The method of  claim 12 , further comprising:
 tufting the plurality of yarns through the primary backing to define a plurality of yarn tufts, wherein each tuft of the plurality of tufts comprises the first yarn and the second yarn.   
     
     
         14 . The method of  claim 12 , further comprising:
 tufting the first yarn through the primary backing to define a first plurality of yarn tufts; and   tufting the second yarn through the primary backing to define a second plurality of yarn tufts.   
     
     
         15 . The method of  claim 12 , wherein each yarn filament of the first yarn is a monofilament. 
     
     
         16 . The method of  claim 12 , wherein applying the color pattern comprises applying dye to the face structure. 
     
     
         17 . The method of  claim 12 , wherein applying the color pattern comprises printing ink onto the face structure. 
     
     
         18 . A surface covering comprising:
 a backing structure comprising a primary backing having a face surface and an opposing rear surface; and   a face structure defined by at least one yarn associated with the primary backing and extending outwardly from the face surface of the primary backing in a direction moving away from the primary backing, wherein the at least one yarn of the face structure comprises a first yarn, wherein the face structure has a color pattern.   
     
     
         19 . The surface covering of  claim 18 , wherein the color pattern is applied to the face structure. 
     
     
         20 . The surface covering of  claim 18 , wherein the color pattern is imparted at least in part by tufting, knitting or weaving the at least one yarn. 
     
     
         21 . The surface covering of  claim 18 , wherein the first yarn is a turf tape yarn or a monofilament blade yarn.