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. The color pattern can be applied by printing or applying dye.

What is claimed is: 
     
         1 . A method comprising:
 applying ink or dye to a face structure of a hybrid turf-carpet article to form a color pattern, wherein the hybrid turf-carpet article comprises:
 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, 
 
 wherein the plurality of yarns have portions positioned above the backing structure that define the face structure of the hybrid turf-carpet article. 
   
     
     
         2 . The method of  claim 1 , wherein the yarn filaments of the second yarn have a dpf ranging from 2 to 32. 
     
     
         3 . The method of  claim 1 , wherein the yarn filaments of the second yarn have a dpf ranging from 22 to 60. 
     
     
         4 . The method 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 method 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 method of  claim 1 , wherein each yarn filament of the first yarn is a monofilament. 
     
     
         7 . The method 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.   
     
     
         8 . The method of  claim 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 third yarn has a denier per filament (dpf) ranging from 2 to 60 dpf. 
     
     
         9 . The method of  claim 8 , wherein the third yarn is commingled with the first and second yarns. 
     
     
         10 . The method of  claim 8 , wherein the third yarn is not commingled with the first and second yarns. 
     
     
         11 . The method of  claim 1 , further comprising forming the hybrid turf-carpet article, wherein forming the hybrid turf-carpet article comprises securing the plurality of yarns to the primary backing. 
     
     
         12 . The method of  claim 11 , wherein securing the plurality of yarns to the primary backing comprises tufting the plurality of yarns through the backing. 
     
     
         13 . The method of  claim 1 , wherein the first yarn is an unpigmented yarn prior to the color pattern being printed thereon. 
     
     
         14 . The method of  claim 1 , wherein the plurality of yarns are tufted through the primary backing to form a plurality of yarn tufts, wherein each tuft of the plurality of tufts has a backstitch, wherein the color pattern does not impart color to the backstitch. 
     
     
         15 . The method of  claim 1 , wherein the plurality of yarns are tufted through the primary backing to form a plurality of yarn tufts, wherein a first tuft of the plurality of tufts comprises the first yarn having a first portion upon which a first color of the color pattern is applied and a second portion upon which a second color of the color pattern is applied. 
     
     
         16 . The method of  claim 1 , wherein the color pattern forms at least a portion of one of a logo, a picture, a cartoon, or an image. 
     
     
         17 . The method of  claim 1 , wherein applying ink or dye to the face structure of the hybrid turf-carpet article comprises printing ink on the face structure. 
     
     
         18 . The method of  claim 1 , wherein applying ink or dye to the face structure of the hybrid turf-carpet article comprises applying dye to the face structure.