Permeable backing and tufted article comprising same

Abstract

Disclosed herein is a tufted article comprising a backing having a vertical axis. The backing includes an open structural material having a first surface and an opposing second surface. The open structural material includes a plurality of fibers. The plurality of fibers define a void space through the open structural material from the first surface to the second surface based in part on variability of the fibers along the vertical axis. The void space is configured to allow liquid or vapor to pass from the first surface to the second surface of the open structural material. A scrim layer is coupled to the opposite second surface of the open structural material. The scrim layer is provided with an open net-shaped structure. A second plurality of fibers tufted through the backing and extending upwardly from the first surface of the open structural material.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims the benefit of priority and filing dates to U.S. Provisional Patent Application No. 63 / 340,545, filed on May 11, 2022, and U.S. Provisional Patent Application No. 63 / 347,069, filed on May 31, 2022, the entire contents of each of which are hereby incorporated by reference into this document for all purposes. Technical Field

[0003] The present disclosure relates generally to tufted articles, and in particular to tufted articles having a permeable backing layer (eg, a tufted artificial turf article or a tufted carpet article). Background Art

[0004] Air permeability and water permeability may be important for tufted products such as carpets and artificial turf. Conventionally, in order to achieve air permeability and water permeability, the backing has perforations formed therethrough. For example, a hot needle (e.g., a heated conical nail), a drill bit, or a punch can pierce the backing to form perforations to provide the desired air permeability and water permeability. However, the formation of such perforations increases manufacturing costs and time, as well as causes complications, such as machine maintenance and manufacturing downtime. Therefore, there is a need for a backing that is sufficiently air permeable or water permeable without requiring additional processes to form perforations through the backing. Summary of the invention

[0005] In one aspect, a tufted article including a backing is described herein. The backing includes a plurality of woven fibers that define a woven backing structure having a first surface and an opposite second surface. Void spaces are defined between corresponding woven fibers in the plurality of woven fibers of the woven backing structure. The void spaces are configured to allow liquid or vapor to pass from the first surface of the woven backing structure to the second surface. A scrim layer is coupled to the opposite second surface of the woven backing structure. The scrim layer has an open mesh structure. The second surface of the woven backing structure and the scrim layer cooperate to define the lower surface of the backing. Optionally, a polymer coating can be applied to the lower surface of the backing. At least a portion of the scrim prevents the polymer coating from entering at least one void space in the void space defined between corresponding woven fibers in the plurality of woven fibers of the woven backing structure.

[0006] In one aspect, a tufted article comprising a backing having a vertical axis is disclosed herein. The backing comprises an open structural material having a first surface and an opposite second surface. The open structural material comprises a plurality of fibers. The plurality of fibers define void spaces through the open structural material from the first surface to the second surface based in part on the variability of the fibers along the vertical axis. The void spaces are configured to allow liquid or vapor to pass from the first surface of the open structural material to the second surface. A scrim layer is coupled to the opposite second surface of the open structural material. The scrim layer has an open mesh structure. A second plurality of fibers passes through the backing tufts and extends upward from the first surface of the open structural material.

[0007] In one aspect, a method for forming a tufted article is described herein. The method includes weaving a plurality of fibers together to form a woven backing structure having a first surface and an opposite second surface, the woven backing structure defining a void space between corresponding woven fibers in the plurality of woven fibers of the woven backing structure, wherein the void space is configured to allow liquid to pass from the first surface of the woven backing structure to the second surface. The second plurality of fibers may be passed through the backing tufts so that the plurality of fibers extend upward from the first surface of the woven backing structure. The method does not include forming an opening through the backing.

[0008] In one aspect, a method is described herein, the method comprising installing a tufted article as disclosed herein on a subfloor.Liquid is received through interstitial spaces defined between corresponding ones of a plurality of woven fibers of a woven backing structure.

[0009] Additional advantages of the present invention will be set forth in part in the description that follows, and in part will be apparent from the description, or may be learned through practice of the present invention. The advantages of the present invention may be realized and obtained by means of the elements and combinations particularly pointed out in the appended claims. It should be understood that the foregoing general description and the following detailed description are merely exemplary and explanatory and do not limit the present invention as claimed. BRIEF DESCRIPTION OF THE DRAWINGS

[0010] These and other features of the preferred embodiments of the present invention will become more apparent in the following detailed description taken in conjunction with the accompanying drawings, in which:

[0011] Figure 1 is a schematic side view of an exemplary tufted article according to embodiments disclosed herein.

[0012] Figure 2 yes Figure 1 Schematic top view of an exemplary woven backing structure of a tufted article.

[0013] Figure 3is a perspective view of an exemplary woven backing structure for use in a tufted article as disclosed herein.

[0014] Figure 4 is a perspective view of an exemplary woven backing structure for a tufted article as disclosed herein, wherein the weft fibers include a plurality of filaments or ribbons.

[0015] Figure 5 Shown is a perspective view of an exemplary woven backing structure held at an angle to illustrate light passing therethrough.

[0016] Figure 6 Shown is a perspective view of an exemplary woven backing structure held at an angle to illustrate light passing therethrough.

[0017] Figure 7 Shows a ratio Figures 3 to 6 A view of a backing with finer fibers having a less wavy profile.

[0018] Figure 8 A scrim layer as disclosed herein is shown.

[0019] Fig. 9 The reverse stitch side of a tufted article as disclosed herein is shown.

[0020] Fig.10 is a schematic top view of an exemplary woven backing structure as disclosed herein.

[0021] Fig.11 yes Fig.10 A perspective view of the portion of the woven backing structure in the dashed box.

[0022] Fig.12 is a schematic diagram illustrating the acute angle between an axis along which a void space may extend and the first surface of a woven backing structure. DETAILED DESCRIPTION

[0023] The disclosed systems and methods may be understood more readily by reference to the following detailed description of specific embodiments and the examples and drawings included therein and the preceding and subsequent descriptions thereof.

[0024] 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.

[0025] It must be noted that as used herein and in the appended claims, the singular forms "a", "an", and "the" include plural referents unless the context clearly dictates otherwise. Thus, for example, reference to "a layer" includes one or more of such layers, and so forth.

[0026] "Optional" or "optionally" means that the subsequently described event, circumstance or material may or may not occur or exist, and that the description includes instances where the event, circumstance or material occurs or exists and instances where it does not.

[0027] In this article, range can be expressed as from "about" a specific value and / or to "about" another specific value. When expressing such a range, unless the context specifically indicates otherwise, it is also specifically expected and considered to disclose a range from a specific value and / or to another specific value. Similarly, when a value is expressed as an approximation by using the antecedent "about", it should be understood that unless the context specifically indicates otherwise, the specific value forms another embodiment that should be considered as disclosed and carefully considered. It should be further understood that unless the context specifically indicates otherwise, the endpoints of each range are significant relative to the other endpoint and independently of the other endpoint. Finally, it should be understood that unless the context specifically indicates otherwise, it is also specifically expected that all individual values ​​and sub-ranges of values ​​contained in the clear disclosure range and it should be considered to be disclosed. Regardless of clearly disclosing some or all of these embodiments in a particular case, the foregoing applies.

[0028] Optionally, in some aspects, when values ​​are approximated by use of the antecedents "about," "substantially," or "approximately," values ​​within up to 15%, up to 10%, up to 5%, or up to 1% (above or below) of the specifically stated value or characteristic may be included within the range of these aspects, with due consideration.

[0029] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which the disclosed apparatus, systems and methods belong. Although any apparatus, systems and methods similar or equivalent to those described herein can be used in the practice or testing of the apparatus, systems and methods of the present invention, particularly useful methods, devices, systems and materials are as described.

[0030] 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 a method stated as comprising one or more steps or operations, it is specifically contemplated that each step includes what is listed (unless the step includes a limiting term, such as "consisting of"), which means that each step is not intended to exclude, for example, other additives, components, integers or steps not listed in the step.

[0031] The terms "fiber" and "yarn" as used herein refer to continuous filament strands or bundles of filaments. Filaments can include, for example, ribbons (e.g., slit films). Therefore, such fibers and yarns can include, for example, but not limited to, flat ribbons, monofilament yarns, chopped yarns, looped yarns, fibrillated yarns, multifilament yarns, twisted yarns (e.g., twisted staple yarns), wrapped yarns, staple yarns, etc. Optionally, consistent with the use of the terms "fiber" and "yarn", continuous fiber strands or fiber bundles can be cut to form cut fibers or cut yarns. Optionally, conventional methods can be used to texture fibers / yarns. "Fibers" and "yarns" as disclosed herein can be independently delivered to a backing structure (e.g., via tufting). The yarn or fiber can be a single-ended fiber (single-strand yarn) or a multi-ended fiber (e.g., a plied yarn) that includes multiple single-ended fibers that are entangled or otherwise mixed with each other (e.g., by air entanglement, twisting, winding, etc.) so that the single-ended yarn is no longer individually or independently movable. For example, multiple single-ended yarns can be twisted together to form a plied yarn (e.g., two strands of yarn can include two single-ended yarns twisted together). Each single-ended yarn / fiber can be formed by at least one filament (optionally, multiple filaments). Therefore, within a multi-ended yarn, each single-ended yarn that constitutes the multi-ended yarn can include a corresponding filament or multiple filaments.

[0032] As used herein, the term "denier" refers to the weight in grams of 9,000 meters of yarn. "Denier per filament" refers to the denier of a single filament of the yarn (9,000 meters of weight in grams). When the yarn consists of a single-end yarn, the "total denier" of the yarn may refer to the combined denier of all filaments of the single-end yarn (i.e., the sum of the corresponding deniers). When the yarn includes multiple yarn ends (multiple single-end yarns) that are entangled or otherwise mixed with each other so that the yarn ends are no longer individually or independently movable, then the "total denier" of the yarn may refer to the combined denier of the multiple yarn ends (multiple single-end yarns defining the multi-end yarn) (i.e., the sum of the corresponding deniers).

[0033] Total denier, denier per fiber (dpf) and strand information can be used to determine the number of filaments in a given yarn. As a first example, a single-strand yarn can be identified as a 6000 total denier, 4dpf yarn. This indicates that the single-strand yarn has a total denier of 6000, and each filament of the single-strand yarn has a denier of 4 (per filament). The total number of filaments can be determined by dividing the total denier (6000) by the dpf (4), resulting in a result of 1500 filaments in the yarn. In addition to identifying the yarn as a 6000 total denier, 4dpf yarn, it is also contemplated that the yarn can be alternatively identified as a 6000 / 1500 filament yarn (wherein dpf (4) is determined by dividing the total denier (6000) by the number of filaments (1500)).

[0034] As another example, consider two ply yarns having the same total denier (6000) but formed by twisting or otherwise mixing two identical single-ended yarns. Such yarns can be identified as 3000x2 yarns, indicating that the yarn is a two-ply yarn, each of which corresponds to a single-ended yarn with a total denier of 3000. If the dpf of each single-ended yarn is 15, then the number of filaments in each single-ended yarn can be calculated by dividing the total denier (3000) by the dpf (15), resulting in 200 filaments in each single-ended yarn. Therefore, the total number of filaments in the two ply yarns can be determined to be 600 (the sum of the number of filaments in the two single-ended yarns that make up the two ply yarns).

[0035] In another example, consider the yarn formed by twisting or otherwise mixing two different single-end yarns to form a yarn bundle. The yarn bundle can include a first single-end yarn of 3000 total denier, 15dpf yarn and a second single-end yarn of 3000 total denier, 4dpf yarn. This shows that the first single-end yarn has a total denier of 3000, wherein each filament of the yarn has a denier (per filament) of 15. The second single-end yarn has a total denier of 3000, wherein each filament of the yarn has a denier (per filament) of 4. Therefore, the first single-end yarn has 200 filaments (wherein each filament has a denier of 15, to provide a total denier of 3000), and the second single-end yarn has 750 filaments (wherein each filament has a denier of 4, to provide a total denier of 3000).

[0036] Permeable backing and tufted product with permeable backing

[0037] refer to Figures 1 to 3, the exemplary tufted article 10 can have a backing 20. The backing 20 can include a plurality of woven fibers 22, which define a woven backing structure 24 having a first surface 26 and a second surface 28. The plurality of woven fibers 22 can include warp fibers 22a and weft fibers 22b. Optionally, the plurality of woven fibers 22 of the woven backing structure 24 can be arranged in a plain weave. In other aspects, the woven backing structure can have other arrangements. For example, the woven backing structure can be a twill, a plain weave, a satin, a satin weft, a mat weave, a gauze, a corrugated cloth, a combination thereof, etc. It is expected that the woven backing structure can be formed by a cam-driven loom, a dobby loom, or a jacquard loom as known in the art.

[0038] Void spaces 30 may be defined between respective ones of the plurality of woven fibers 22 of the woven backing structure 24. The void spaces 30 may be configured to allow liquid or vapor to pass from the first surface 26 to the second surface 28 of the woven backing structure 24.

[0039] In some aspects, the woven backing structure 24 can include flat filaments arranged in a plain weave configuration. For example, in some aspects, both the warp fibers 22a and the fill fibers 22b can be flat filaments.

[0040] In an exemplary aspect, the void spaces 30 can be provided by the weft fibers 22b having a wavy profile between the warp fibers 22a. More specifically, it has been found that increasing the weight of the fibers (e.g., the thickness of the fibers) increases the amplitude of the wavy structure, thereby forming large void spaces 30. For example, Figure 7 A woven backing structure 24' having fine fibers is shown, Figures 3 to 6 Compared with the thin fibers, the thin fibers have a low fluctuation amplitude. The fluctuation amplitude can be understood as the distance that the fiber extends along the vertical axis 11.

[0041] Therefore, reference Figure 3 and Fig.10 In some aspects, the projection of the woven backing structure 24 along the vertical axis 11 into a plane parallel to the first surface has no open area, as demonstrated by the absence of light visible through the woven backing structure. Thus, the woven backing structure 24 can provide a continuous structure that is configured to securely hold the face fibers, as further described herein. This can be different from a woven backing structure that shows a discontinuous structure. Figure 2 In contrast to the woven backing structure shown in FIG, a projection of the discontinuous structure into a plane does show open areas. Fig.11 and Fig.12In some aspects, the void space 30 can extend along an axis 39 that forms an acute angle 41 relative to the first surface 26. That is, the void space 30 can be formed by the change in the vertical position of adjacent fibers 22 of the woven backing structure 24, so that moisture can flow through the void space along the axis 39 that forms an acute angle 41 relative to the first surface. Figures 5 and 6 , when the woven backing structure 24 is viewed at an acute angle (e.g., 45 degrees) relative to the first surface 26, light can be seen through it, corresponding to the void spaces 30 that allow liquid and vapor to pass from the first surface 26 to the second surface 28. In some optional aspects, when the woven backing structure 24 is viewed along a vertical axis 11 that is perpendicular to the first surface 26, the void spaces 30 are not visible because the continuous structure does not show the void spaces 30 along the vertical axis. In other aspects, when the woven backing structure 24 is viewed along the vertical axis 11, the void spaces 30 are substantially not visible or minimally visible, but when viewed at an acute angle relative to the first surface 26, the void spaces become fully visible.

[0042] In some aspects, the woven backing structure 24 can have about 4 wefts per inch to about 30 wefts per inch (e.g., about 10 wefts per inch to about 28 wefts per inch, or about 5 wefts per inch to about 20 wefts per inch). For example, the woven backing structure 24 can have 12 wefts per inch to 18 wefts per inch. Thus, in some exemplary aspects, it is contemplated that the woven backing structure 24 can have about 12 wefts per inch, about 13 wefts per inch, about 14 wefts per inch, about 15 wefts per inch, about 16 wefts per inch, about 17 wefts per inch, or about 18 wefts per inch.

[0043] The plurality of woven fibers 22 of the woven backing structure 24 can have a weight of about 2.6 ounces per square yard to about 13 ounces per square yard, or about 1.5 ounces per square yard to about 8 ounces per square yard, or about 4.5 ounces per square yard to about 8 ounces per square yard (e.g., optionally, about 6 ounces per square yard to about 7 ounces per square yard). In other aspects, the plurality of woven fibers 22 can have a weight of about 8, about 9, about 10, about 11, about 12, or about 13 ounces per square yard.

[0044] It was found that a coarse denier (e.g., thicker ribbons) of the plurality of woven fibers 22 of the woven backing structure 24 provided surprisingly high air permeability. For example, a woven backing structure 24 having a weight of about 6 ounces per square yard was found to have three times the air permeability of a woven backing structure having the same pick per inch and a weight of about 3 ounces per square yard.

[0045] In some aspects, the warp fibers 22a can have a center-to-center spacing 32 of 0.025 inches to 0.1 inches or about 0.035 inches to about 0.075 inches. In some aspects, the weft fibers 22b can have a center-to-center spacing 34 of 0.025 inches to 0.1 inches or about 0.04 inches to about 0.09 inches.

[0046] In exemplary aspects, the width of the warp fibers 22a can be from about 0.025 inches to 0.1 inches (e.g., about 0.05 inches). In exemplary aspects, the thickness of the warp fibers 22a can be from about 0.0025 inches to about 0.005 inches, or from about 0.003 inches to about 0.005 inches (e.g., about 0.035 inches). In some aspects, the width of the weft fibers 22b can be from 0.025 inches to 0.2 inches (e.g., about 0.01 inches). In exemplary aspects, the thickness of the warp fibers 22a can be from about 0.0025 inches to about 0.005 inches, or from about 0.003 inches to about 0.005 inches.

[0047] Still refer to Figure 1 to Figure 2 , the backing 20 can have a warp axis 36 and a weft axis 38. In some aspects, the woven fibers 22 can have a width w along the corresponding warp axis 36 or weft axis 38. It is contemplated that the center-to-center spacing 34 of the warp fibers 22b can be equal to, or substantially equal to, or less than the width of the warp fibers along the weft axis 38. In this manner, and with further reference to Fig.10 , the woven backing structure 24 can define a continuous structure configured to securely hold the face fibers (as opposed to a structure showing spaces between the fibers and thus a discontinuous structure). Figure 2 ). For example, the projection of the continuous structure along the vertical axis 11 on a plane perpendicular to the vertical axis can be continuous, with no openings within the projection. In yet another aspect, the projection of the continuous structure along the vertical axis 11 on a plane perpendicular to the vertical axis can have an open area of ​​less than 5%, or an open area of ​​less than 4%, or an open area of ​​less than 3%, or an open area of ​​less than 2%, or an open area of ​​less than 1%, or essentially no open area. In these aspects, it is expected that the minimum amount of open area within the continuous structure has no meaningful effect on the ability of the continuous structure to securely hold the face fibers. In some optional aspects, the plurality of woven fibers 22 can have a generally rectangular cross-section.

[0048] In some optional aspects, the backing 20 does not include formed perforations. That is, the only openings present in the backing are created by the woven structure of the backing (and the spaces created between the woven fibers).

[0049] refer to Figure 1 and Figure 8 In some optional aspects, the backing 20 can further include a scrim layer 60 coupled to the second surface 28 of the woven backing structure 24. The scrim layer 60 can have an open mesh structure. Thus, a projection of the scrim layer along a vertical axis into a plane parallel to the first surface of the woven backing structure 24 can define an open area. For example, the scrim layer 60 can optionally have a leno weave structure or a plain weave structure. Thus, the warp fibers of the woven structure can be spaced apart from each other, and the weft fibers of the woven structure can be spaced apart from each other to provide openings through the scrim layer, such as Figure 8 . The leno woven structure may include a single yarn or multiple yarns extending in the warp direction and the weft direction. In other aspects, the scrim layer 60 may be knitted. In yet other aspects, the scrim layer 60 may include a nonwoven material (e.g., an open meltblown material, a needle-punched material, a spunbond material, a material formed by a water jet, or an air-laid material). Optionally, the scrim may have about 5 wefts per inch. The woven backing structure 24 and the scrim layer 60 may cooperate to define the lower surface 62 of the backing 20. In exemplary aspects, the scrim layer may have a weight ranging from about 1 to about 3 ounces per square yard. In some optional aspects, the scrim layer may have 4 to 30 warp ends per inch and 2 to 18 wefts per inch. Optionally, the scrim layer may include warp yarns, which include flat belts with 100 to 500 deniers. Optionally, the scrim layer can include weft yarns of about 400 denier to about 2400 denier. In exemplary aspects, it is contemplated that the weft yarns can include air-textured filament yarns, spun yarns, bulked continuous filament yarns, continuous filament yarns, flat tape yarns, or fibrillated yarns.

[0050] The tufted article 10 may further include a second plurality of fibers 50 extending upwardly through the backing tufts from the first surface 26 of the woven backing structure 24. The tufted fibers may optionally be looped or cut. The second plurality of fibers 50 may be the face fibers of the tufted article having a reverse stitch 54 looped behind the scrim layer 60 and the backing 20.

[0051] Optionally, the polymer coating 40 can be applied to the lower surface 62 of the backing 20 and the scrim layer 60. That is, the polymer coating 40 can be applied to the second surface 28 of the woven backing structure 24 and throughout the scrim layer 60. The polymer coating 40 can couple the second plurality of fibers 50 to the backing to inhibit movement of the second plurality of fibers relative to the backing (e.g., to prevent the second plurality of fibers from falling off the backing). In some aspects, the polymer coating 40 can include polyurethane.

[0052] At least a portion of the scrim 60 can prevent the polymer coating 40 from entering (e.g., blocking) at least one of the void spaces defined between corresponding ones of the plurality of woven fibers of the woven backing structure. That is, the scrim layer 60 can inhibit the polymer coating 40 from filling some or all of the void spaces 30 passing through the woven backing structure 20. The scrim layer 60 can further provide dimensional stability to the tufted article.

[0053] Fig. 9 The underside of the tufted article 10 is illustrated, showing the reverse stitch 54 of the second plurality of fibers 50, the backing 20, and the scrim layer 60. As illustrated, the polymer coating 40 can be applied to the reverse stitch 54 of the second plurality of fibers 50, the backing 20, and the scrim layer 60. In an exemplary aspect, after the second plurality of fibers 50 are tufted as disclosed herein, a coating machine as known in the art can be used to apply the polymer coating 40.

[0054] In some aspects, the tufted article 10 can include only a single layer of woven backing structure 24 (in addition to the scrim layer 60). That is, the tufted article 10 can include a single woven backing structure 24 and a scrim layer 60, and no additional woven layers. It is expected that having only a single backing layer can provide advantageous permeability. This can be contrasted with an article having multiple lighter weight woven backing structure layers applied together.

[0055] Optionally, the tufted product 10 may include a filler 70 (e.g., sand). The filler may optionally be provided at a weight of about 1 lb / sq. yard to about 9 lb / sq. yard. In these aspects, it is contemplated that the filler may include any combination of a single component or multiple components. When the filler includes multiple components, it is contemplated that the filler material may optionally include multiple layers, wherein each layer corresponds to a different filler component or a combination of components. Alternatively, it is contemplated that multiple components may be provided as a mixture, which may be homogeneous or inhomogeneous. In exemplary aspects, it is contemplated that the filler may include clay, TPE, EPDM, coconut shells, walnut shells, broken bricks, sand, or a combination thereof. More generally, it is contemplated that the filler may include any material capable of imparting desired properties to a surface covering (e.g., floor or ground covering) as disclosed herein. In further aspects, the tufted product 10 does not include a filler (and is not filled during use).

[0056] Optionally, the second plurality of fibers 50 may include yarns.

[0057] The tufted article 10 may optionally be an artificial turf. In these aspects, the artificial turf may allow a high flow of water to drain therethrough. In exemplary aspects, a plurality of tufted articles 10 may form at least a portion of a sports surface such as, for example, but not limited to, a sports field, a golf course, or a park. In further exemplary aspects, it is contemplated that one or more tufted articles 10 may form at least a portion of an airport runway, a landfill cover, and the like.

[0058] In further aspects, the tufted article 10 can be a carpet (e.g., commercial carpet or residential carpet). The air permeability of the disclosed backing 20 can advantageously allow moisture to escape from the subfloor beneath the tufted article. In an exemplary aspect, it is contemplated that a plurality of tufted articles 10 can form at least a portion of a surface (e.g., floor) covering.

[0059] In some aspects, the method may include coupling a tufted article 10 as disclosed herein to a substructure and receiving liquid (e.g., water) or water vapor through a void space defined between corresponding woven fibers in a plurality of woven fibers of a woven backing structure. In an exemplary aspect, the substructure may be a subfloor. In various other aspects, the tufted article 10 may be mounted on other substructures, such as, for example but not limited to, a subbase (e.g., gravel) or a pad platform (e.g., padding). In other aspects, the tufted article 10 may receive particles and allow the particles to pass into the void space.

[0060] The tufted article 10 can be formed according to the method disclosed herein. The second plurality of fibers 50 can be tufted through the backing 20 so that the plurality of fibers extend upward from the first surface of the woven backing structure. In some aspects, the method does not include forming an opening through the backing. In some aspects, the plurality of fibers 22 can be woven together to form a woven backing structure 24 having a first surface 26 and an opposite second surface 28, wherein the woven backing structure defines a void space 30 between corresponding woven fibers of the plurality of woven fibers of the woven backing structure. The void space 30 can be configured to allow liquid to pass from the first surface 26 of the woven backing structure 24 to the second surface 28.

[0061] Prior to tufting the second plurality of fibers through the woven backing structure 24, a scrim layer 60 can be positioned against the second surface of the woven backing structure to provide the backing 20, the scrim layer having an open mesh structure. The polymer coating 40 can be applied to the lower surface 62 of the backing 20. For example, in some aspects, the polymer coating can be rolled against the lower surface 62 of the backing 20. In alternative aspects, the polymer coating can be poured onto the lower surface 62 of the backing 20 as a fluid, and the fluid can be scraped across the lower surface of the backing 20 to distribute the fluid across the lower surface. This can be referred to as a puddle bed knife or scraper bar application.

[0062] In exemplary aspects, the plurality of woven fibers 22 and / or the second plurality of fibers 50 may include a polymer (e.g., nylon, polypropylene (PP), polyethylene (PE), or polyethylene terephthalate (PET)). In some aspects, the woven backing structure 24 may include PP. In various aspects, the plurality of woven fibers 22 and / or the second plurality of fibers 50 may include virgin materials and / or recycled materials. In additional aspects, the plurality of woven fibers 22 and / or the second plurality of fibers 50 may include natural materials, such as, for example, soy, sugar cane, jute, hemp, etc.

[0063] Although various exemplary yarn deniers are described herein, it is contemplated that exemplary yarns of the tufted article 10 may optionally have any total denier in the range of 500 to 23,000. In further aspects, it is contemplated that the yarns may optionally have a denier per filament in the range of 4 to 2700 dpf.

[0064] Additional Exemplary Embodiments

[0065] Although the embodiments disclosed herein describe the use of a woven backing structure to retain the face fibers while allowing water to penetrate therethrough, it is contemplated that other open structural materials having openings for water, vapor and / or particle permeability may be used. Optimally, it is contemplated that such open structural materials may derive their permeability in part from the texture of the material (e.g., the variability of the fibers along the vertical axis 11) rather than simply from the spacing between the fibers on the horizontal axes (e.g., the warp axis 36 and the weft axis 38). Therefore, in additional embodiments, a knitted structure or nonwoven material may be used in place of the woven backing structure 24.

[0066] In some optional aspects, the polymer coating 40 can be omitted from the tufted article 10. In other aspects, the polymer coating 40 can be disposed on the opposite side of the open structural material (eg, on the first surface 26 of the woven backing structure 24).

[0067] In some optional aspects, the open structural material (e.g., woven backing structure 24) and the scrim layer 60 may be positioned with respect to Figure 1 That is, for example, the scrim layer 60 can be positioned on the first surface 26 of the woven backing structure 24 (or other open structural material).

[0068] In yet another aspect, the backing 20 may include a woven backing structure 24 (or other open structural material), a woven material, and a non-woven material. For example, the backing 20 may include a woven backing structure 24, a non-woven material disposed on a first surface 26 of the woven backing structure, and a woven material disposed on a second surface 28 of the woven backing structure.

[0069] Exemplary Aspects of the Second Multiple Fibers

[0070] In some exemplary aspects, the second plurality of fibers 50 can be formed into a plurality of yarn tufts 52 extending through the backing 20. In these aspects, it is contemplated that conventional methods can be used to form the plurality of yarn tufts. For example, in these aspects, it is contemplated that one or more tufting machines can have a plurality of needles (optionally on needle bars) that deliver yarn into the backing 20 to form the plurality of yarn tufts 52. Optionally, it is contemplated that the backing 20 can be disposed on a supply roll that feeds the backing through the tufting machine.

[0071] Although depicted in the figures as including cut tufts, it is contemplated that the tufts of the tufted article 10 may include cut tufts, loop tufts, or a combination thereof. Each tuft 40 of the plurality of tufts may include at least one outwardly extending tuft portion (positioned above the backing) and a backstitch connected to the at least one outwardly extending tuft portion. In an exemplary aspect, when the plurality of tufts include cut tufts, each of the plurality of yarn tufts may have at least one pair of outwardly extending tuft portions (positioned above the backing and formed by corresponding cuts) joined by a backstitch (located below or inside the backing). When the tufts include a single yarn, it is contemplated that the tufts may include a single pair of tuft portions joined by a backstitch. However, when the tufting includes multiple yarns (for example, two or three yarn ends are simultaneously delivered through the backing by a single needle, and each of the two or three yarn ends passes through the needle), the tufting can include multiple pairs of tufted portions (one pair for each yarn), wherein each pair of tufted portions is joined by corresponding backstitch portions.

[0072] Although exemplary structures (eg, tufting) for associating the second plurality of fibers 50 with the backing are disclosed herein, it is contemplated that any conventional mechanical or structural association between the second plurality of fibers 50 and the backing may be employed.

[0073] In exemplary aspects, the second plurality of fibers 50 may include a plurality of yarn filaments. In some optional aspects, each yarn filament in the plurality of yarn filaments may have a denier (dpf) of each filament in the range of 61 to 3600 deniers, such as typically found in artificial turf yarns. Optionally, in these aspects, it is expected that each yarn filament may have a denier in the range of 61 to 1000 dpf or 61 to 750 dpf or 400 to 600 dpf. However, it is expected that other dpf values ​​may be used according to specific applications and desired performance characteristics.

[0074] In other aspects, it is expected that the second plurality of fibers 50 may include a plurality of yarn filaments. In these aspects, each yarn filament in the plurality of yarn filaments of the second plurality of fibers 50 may optionally have a denier (dpf) per filament in the range of 2 to 60 dpf, such as typically found in carpet yarns. Optionally, in these aspects, each yarn filament in the plurality of yarn filaments may have a denier (dpf) per filament in the range of 6 to 60 dpf or 10 to 40 dpf. Therefore, in some aspects, it is expected that at least one yarn of the tufted article 10 may include turf yarn, and at least one other yarn of the tufted article may include carpet yarn. Therefore, in these aspects, the tufted article 10 may be used as a mixed turf-carpet article, providing a combination of properties provided by turf and carpet products (alone). For example, it is expected that turf yarn may impart desired performance / durability properties, and carpet yarn may impart desired softness and texture properties. As further disclosed herein, it is further contemplated that the turf or carpet properties can be selectively emphasized or weakened by controlling various properties of the yarn. It is contemplated that the second plurality of fibers 50 can include any desired number of filaments, such as, for example, 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 36, 48, 96 or up to 4000 individual filaments per yarn.

[0075] Optionally, in some exemplary aspects, it is contemplated that the yarn filaments of the second plurality of fibers 50 can have a dpf in the range of 2 to 32. In these aspects, it is contemplated that the second plurality of fibers 50 can be conventional residential carpet yarn as known in the art.

[0076] Optionally, in some exemplary aspects, it is contemplated that the yarn filaments of the second plurality of fibers 50 can have a dpf in the range of 22 to 60. In these aspects, it is contemplated that the second plurality of fibers 50 can be conventional commercial carpet yarns as known in the art.

[0077] As described above, in some exemplary aspects, the second plurality of fibers 50 may be disposed in each corresponding tuft or pile extending through the backing. In an exemplary process, the fibers are suspended on a creel, and then the fiber ends are fed through corresponding tubes until they reach a guide structure immediately before the needle bar of the tufting machine. At the guide structure, the fibers are fed together through a guide hole, and the two fibers can be delivered to each needle of the tufting machine at the same rate. One or more ends of each needle can be tufted by adjusting the tension so that the fibers are picked up on the hook for cutting. Optionally, one of the fibers may be set straight, and one of the fibers may be textured, so it may be necessary to adjust the tension to ensure successful tufting. Alternatively, in other exemplary processes, the fibers may pass through the same tube until they reach the needles for tufting. The size of the expected needle and the hole or eye of the needle may be selected based on the specifications and density required for the final product.

[0078] It is contemplated that any desired number of different fibers (e.g., yarns) may be provided in the tufted articles disclosed herein. For example, it is contemplated that a second yarn and a third yarn may be disposed in each of a plurality of tufts together with a first yarn. In yet another aspect, four, five, or more yarns may be disposed in each of a plurality of tufts.

[0079] Exemplary Material Properties

[0080] In exemplary aspects, it is contemplated that each yarn filament of the second plurality of fibers 50 can be a monofilament. Optionally, in these aspects, each yarn filament of the second plurality of fibers 50 can be a 100% nylon monofilament. In these aspects, it is contemplated that the nylon of the second plurality of fibers can be nylon 6, nylon 6,6, or other conventional forms of nylon. In some optional aspects, it is contemplated that the second plurality of fibers 50 of the tufted article 10 can be composed of a single yarn, wherein each filament of the yarn is a monofilament.

[0081] In other exemplary aspects, the second plurality of fibers 50 can be comprised of nylon. In further exemplary aspects, it is contemplated that each filament of the second plurality of fibers 50 can comprise a continuous filament.

[0082] As described above, in exemplary aspects, the yarn filaments of the second plurality of fibers 50 can optionally be uncolored natural filaments. In these aspects, it is contemplated that the second plurality of fibers 50 can be solution-dyed in a "natural" setting without the addition of color pigments during extrusion.

[0083] In further aspects, it is contemplated that the second plurality of fibers 50 may include a 4400 / 8 monofilament yarn having a total denier of 4400 and a dpf of 550 (wherein a total of 8 monofilaments are provided in the yarn). In another example, the second plurality of fibers 50 may include a 4400 / 16 monofilament yarn having a total denier of 4400 and a dpf of 275 (wherein a total of 16 monofilaments are provided in the yarn). In yet another example, the second plurality of fibers 50 may include a 4400 / 32 yarn having a total denier of 4400 and a dpf of 137.5 (wherein a total of 32 monofilaments are provided in the yarn). In yet another example, the second plurality of fibers 50 may include a 6600 / 8 monofilament yarn having a total denier of 6600 and a dpf of 825 (wherein a total of 8 monofilaments are provided in the yarn). In yet another example, the second plurality of fibers 50 may include a 6600 / 12 monofilament yarn having a total denier of 6600 and a dpf of 550 (wherein a total of 12 monofilaments are provided in the yarn). In yet another example, the second plurality of fibers 50 may include a 6600 / 24 ​​monofilament yarn having a total denier of 6600 and a dpf of 275 (wherein a total of 24 monofilaments are provided in the yarn). In further exemplary, optional aspects, the second plurality of fibers 50 may include 800 / 2 (total denier 1600), 800 / 3 (total denier 2400), 1000 / 2 (2000 denier), 1000 / 3 (3000 total denier), or 1000 / 4 (4000 total denier) fibers. In other exemplary, optional aspects, the second plurality of fibers 50 may include 2600 x 3 strands (7800 total denier), 2600 x 2 strands (5200 total denier), 1400 denier x 2 strands, or 1800 denier x 2 strands of fibers. In exemplary aspects, the second plurality of fibers 50 may have a denier of about 4 to about 30 per filament. More generally, it is contemplated that any desired total denier may be used for the second plurality of fibers 50, as long as the individual monofilaments of the second plurality of fibers 50 have a dpf consistent with the desired performance characteristics of the article. Optionally, in exemplary aspects, each fiber in the second plurality of fibers 50 may have a total denier in the range of about 500 to about 25,000, or about 3,000 to about 8,000, or about 4,000 to about 7,000. In exemplary aspects, it is contemplated that at least one fiber in the second plurality of fibers may include a multi-strand yarn.

[0084] It is contemplated that the cross-sectional profile of each filament of the second plurality of fibers 50 can be any shape conventionally used for turf yarn. For example, in some exemplary aspects, each filament of the second plurality of fibers 50 can have a cross-sectional profile comprising a diamond shape, a sawtooth diamond shape, a half-moon shape, or an elliptical or circular shape. However, it is contemplated that any desired cross-sectional profile can be used. It is further contemplated that the second plurality of fibers 50 can have desired durability and colorfastness properties.

[0085] As explained above, in exemplary aspects, the second plurality of fibers 50 of the tufted article may include conventional turf yarn and / or conventional carpet yarn. In exemplary tufted articles, the second plurality of fibers 50 may include nylon (e.g., nylon 6 or nylon 6,6), polyester or polypropylene. In one example, the second plurality of fibers 50 may include 1362 / 2 strands (1362x2) of continuous filament nylon yarn, wherein the total denier is 2724. As another example, the second plurality of fibers 50 may include solution-dyed nylon 1350 / 5 strands (1350x5) yarn, wherein the total denier is 6,750. In these examples, it is expected that each yarn may include any desired number of filaments, wherein dpf remains below 60. In various aspects, it is expected that each filament of the second plurality of fibers 50 may be a continuous filament or a discontinuous filament.

[0086] In some exemplary aspects, it is expected that the second plurality of fibers 50 can be a multi-end yarn formed by at least two different single-end yarns (at least two strands). In these aspects, it is expected that at least two different single-end yarns forming the multi-end yarn can have different dpf values, which allows different visual effects to be produced. For example, it is expected that the second plurality of fibers 50 can include a first yarn end having a 65dpf value and a second yarn end having a 65dpf value, wherein the first yarn end and the second yarn end are both composed of monofilaments. It is further expected that the second yarn can include a first yarn end having a 2dpf value and a second yarn end having a 30dpf value.

[0087] In exemplary aspects, it is expected that the material of the second plurality of fibers 50 of the tufted article 10 can be selected based on the intended use of the tufted article. For example, nylon, PP, PE and PET are all suitable for indoor use, but nylon and PET will not hold up like PP or PE during outdoor use. However, for printed yarn or dyed yarn as disclosed herein, it is expected that special dyes or coatings may be needed to give PP yarn and PE yarn color. In some aspects, it is expected that one of the yarns may include PP yarn and / or PE yarn, and another yarn may include nylon. In these aspects, it is expected that during the printing process or dyeing process, color can be given to nylon yarn, while color will not be given to PP yarn and / or PE yarn (due to the absence of special dyes or coatings required for giving PP yarn and / or PE yarn color), thereby producing a unique surface appearance. Therefore, in some aspects, the color pattern disclosed herein does not give color to some face yarn lines, even if coatings or dyes are applied to those face yarn lines. In various additional aspects, the plurality of fibers 50 of the tufted article 10 can comprise polylactic acid (PLA), polyurethane (PU), natural fibers (eg, optionally, soy, sugar cane, etc.), or other fibers that are biodegradable or at least semi-biodegradable.

[0088] It is expected that the cross-sectional profile of each filament of the second plurality of fibers 50 can be any shape conventionally used for carpet yarn. For example, in some exemplary aspects, the filaments of the second plurality of fibers 50 can each have a cross-sectional profile of a trilobal shape as known in the art. It is expected that the cross-sectional profile of the filaments of the second plurality of fibers 50 can be selected to impart the desired gloss, hardness / softness, elasticity and other characteristics. It is expected that the yarn density of the tufted product can determine the final surface interaction between the yarn and the ball or person when the tufted product is used for the floor / sports surface device. For example, the yarn density can be changed to provide the desired amount of friction when the yarn interacts with the shoe. In other aspects, it is expected that the yarn density can change along the surface of the tufted product. For example, in these aspects, it is expected that the yarn density can change at the position where the surface structure of the tufted product changes (for example, changes in color, yarn type, bulkiness, pile height, etc.). In exemplary aspects, as further disclosed herein, it is expected that a pad (for example, a polyurethane pad) can be added to the tufted product at the position where the carpet surface characteristics change, thereby increasing human safety. In further optional aspects, a system can include the tufted article herein and an upholstery (eg, a pad).In various optional aspects, the tufted article can be attached to the upholstery or unattached to the upholstery.

[0089] It is contemplated that the second plurality of fibers 50 of the tufted article 10 can be colored in any desired manner prior to applying a color pattern as further disclosed herein. For example, the second plurality of fibers 50 can be uncolored natural yarns that are not pre-dyed, or the second plurality of fibers can be pre-dyed, as further explained herein. In another example, the second plurality of fibers 50 can all be pre-dyed or solution-dyed.

[0090] It is further contemplated that the cross-sectional shape and / or size of the fibers / yarns may be selectively altered to vary color and texture, as further disclosed herein.

[0091] Exemplary Aspects

[0092] In view of the described products, systems and methods, and variations thereof, certain more specifically described aspects of the invention are described herein below. However, these specifically described aspects should not be construed as having any limiting effect on any different claims containing different or more general teachings described herein, or that the "specific" aspects are limited in some way other than the inherent meaning of the language literally used therein.

[0093] Aspect 1: A tufted product comprising:

[0094] A backing comprising:

[0095] a plurality of woven fibers defining a woven backing structure having a first surface and an opposing second surface, wherein void spaces are defined between respective woven fibers of the plurality of woven fibers of the woven backing structure, and wherein the void spaces are configured to allow liquid or vapor to transfer from the first surface to the second surface of the woven backing structure; and

[0096] a scrim layer coupled to the opposing second surface of the woven backing structure, wherein the scrim layer has an open mesh structure,

[0097] Wherein the second surface of the woven backing structure and the scrim layer cooperate to define a lower surface of the backing.

[0098] Aspect 2: The tufted article according to Aspect 1, further comprising a polymer coating applied to the lower surface of the backing, wherein at least a portion of the scrim prevents the polymer coating from entering at least one of the void spaces defined between corresponding woven fibers of the plurality of woven fibers of the woven backing structure.

[0099] Aspect 3: The tufted article of aspect 1 or aspect 2, wherein the scrim layer comprises a leno weave.

[0100] Aspect 4: The tufted article of any preceding aspect, wherein a projection of the backing along a vertical axis and into a plane parallel to the first surface has no open area.

[0101] Aspect 5: The tufted article of aspect 4, wherein a projection of the scrim layer along the vertical axis and into the plane defines an open area.

[0102] Aspect 6: The tufted article of any of the preceding aspects, wherein the plurality of woven fibers of the woven backing structure of the backing comprises 5 to 20 picks per inch, and wherein the woven backing structure has a weight of about 1.5 ounces per square yard to about 8 ounces per square yard.

[0103] Aspect 7: The tufted article of any preceding aspect, wherein the plurality of woven fibers of the woven backing structure of the backing comprises 12 to 18 picks per inch.

[0104] Aspect 8: The tufted article of any of the preceding aspects, wherein the woven backing structure has a weight of about 6 ounces per square yard to about 7 ounces per square yard.

[0105] Aspect 9: The tufted article of any preceding aspect, wherein the plurality of woven fibers of the woven backing structure are arranged in a plain weave.

[0106] Aspect 10: The tufted article of any preceding aspect, wherein the backing does not include formed perforations.

[0107] Aspect 11: The tufted article of any preceding aspect, wherein each fiber of the plurality of woven fibers of the woven backing structure has a generally rectangular cross-section.

[0108] Aspect 12: The tufted article of any of Aspects 2 to 11, wherein the polymer coating comprises polyurethane.

[0109] Aspect 13: The tufted article of any of the preceding aspects, further comprising a second plurality of fibers extending through the backing tufts and upwardly from the first surface of the woven backing structure.

[0110] Aspect 14: The tufted article according to any of the preceding aspects, further comprising a filler.

[0111] Aspect 15: The tufted article of aspect 14, wherein the filler comprises sand.

[0112] Aspect 16: The tufted article of aspect 14 or aspect 15, wherein the fill is provided at a weight in a range of about 1 lb / sq yd to about 3 lb / sq yd.

[0113] Aspect 17: The tufted article of any of Aspects 13 to 16, wherein the second plurality of fibers comprises yarn.

[0114] Aspect 18: The tufted article according to any one of aspects 13 to 16, wherein the tufted article is artificial turf.

[0115] Aspect 19: The tufted article of any one of Aspects 13 to 16, wherein the tufted article is a carpet.

[0116] Aspect 20: A method of forming a tufted article, the method comprising:

[0117] weaving a plurality of fibers together to form a woven backing structure having a first surface and an opposing second surface, the woven backing structure defining void spaces between respective ones of the plurality of woven fibers of the woven backing structure, and wherein the void spaces are configured to allow liquid or vapor to transfer from the first surface to the second surface of the woven backing structure; and

[0118] tufting a second plurality of fibers through the woven backing structure such that the plurality of fibers extend upwardly from the first surface of the woven backing structure,

[0119] Wherein after braiding the plurality of fibers together, the method does not include forming openings through the braided backing structure.

[0120] Aspect 21: The method according to Aspect 20, further comprising:

[0121] Prior to tufting the second plurality of fibers through the woven backing structure, a scrim layer is positioned against the second surface of the woven backing structure to provide a backing, wherein the scrim layer has an open mesh structure, wherein the second surface of the woven backing structure and the scrim layer cooperate to define a lower surface of the backing.

[0122] Aspect 22: The method of aspect 21, further comprising applying a polymer coating to the lower surface of the backing.

[0123] Aspect 23: The method of aspect 22, wherein applying the polymer coating to the lower surface of the backing comprises rolling the polymer coating against the lower surface of the backing.

[0124] Aspect 24: The method of aspect 22, wherein applying the polymer coating to the lower surface of the backing comprises:

[0125] pouring the polymer coating as a fluid onto the lower surface of the backing; and

[0126] The fluid is scraped to distribute the fluid across the lower surface of the backing.

[0127] Aspect 25: A method comprising:

[0128] installing the tufted article of any one of aspects 1 to 19 on a substructure; and

[0129] Liquid or water vapor is received through interstitial spaces defined between respective ones of the plurality of woven fibers of the woven backing structure.

[0130] Aspect 26: A tufted product comprising:

[0131] A backing having a vertical axis, the backing comprising:

[0132] an open structural material having a first surface and an opposite second surface, wherein the open structural material comprises a plurality of fibers, wherein the plurality of fibers define a void space through the open structural material from the first surface to the second surface based in part on the variability of the fibers along the vertical axis, wherein the void space is configured to allow liquid or vapor to pass from the first surface to the second surface of the open structural material;

[0133] a scrim layer coupled to the second, opposing surface of the open structural material, wherein the scrim layer has an open mesh structure; and

[0134] A second plurality of fibers extends through the backing tufts and upwardly from the first surface of the open structure material.

[0135] Aspect 27: A tufted article according to Aspect 26, wherein the open structural material includes a plurality of woven fibers defining a woven backing structure, wherein the void space is defined between corresponding woven fibers of the plurality of woven fibers of the woven backing structure, and wherein the void space is configured to allow liquid or vapor to transfer from the first surface of the woven backing structure to the second surface.

[0136] Aspect 28: The tufted article of aspect 26, wherein the plurality of fibers of the open structural material comprises knitted fibers.

[0137] Aspect 29: The tufted article of aspect 26, wherein the plurality of fibers of the open structural material comprises a nonwoven material.

[0138] Aspect 30: A tufted article according to any one of Aspects 26 to 29, wherein the second surface of the open structural material and the scrim layer cooperate to define a lower surface of the backing, wherein the tufted article further includes a polymer coating applied to the lower surface of the backing, wherein at least a portion of the scrim prevents the polymer coating from entering at least one of the void spaces defined between corresponding woven fibers of the plurality of woven fibers of the open structural material.

[0139] Aspect 31: The tufted article of any one of Aspects 26 to 29, wherein the tufted article does not comprise a polymer coating.

[0140] Although the foregoing invention has been described in some detail by way of illustration and example for purposes of clarity of understanding, certain changes and modifications may be practiced within the scope of the appended claims.

Claims

1. A tufted product, comprising: A backing comprising: a plurality of woven fibers defining a woven backing structure having a first surface and an opposing second surface, wherein void spaces are defined between respective woven fibers of the plurality of woven fibers of the woven backing structure, and wherein the void spaces are configured to allow liquid or vapor to transfer from the first surface to the second surface of the woven backing structure; and a scrim layer coupled to the opposing second surface of the woven backing structure, wherein the scrim layer has an open mesh structure, Wherein the second surface of the woven backing structure and the scrim layer cooperate to define a lower surface of the backing.

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

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

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

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

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

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

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

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

10. The tufted article of claim 1, wherein the backing does not include formed perforations.

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

12. The tufted article of claim 2, wherein the polymer coating comprises polyurethane.

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

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

15. The tufted article of claim 14, wherein the filler comprises sand.

16. The tufted article of claim 14, wherein the fill is provided at a weight in the range of about 1 lb / sq yd to about 3 lb / sqyd.

17. The tufted article of claim 13, wherein the second plurality of fibers comprises yarn.

18. The tufted article of claim 13, wherein the tufted article is artificial turf.

19. The tufted article of claim 13, wherein the tufted article is a carpet.

20. A method of forming a tufted article, the method comprising: weaving a plurality of fibers together to form a woven backing structure having a first surface and an opposing second surface, the woven backing structure defining void spaces between respective ones of the plurality of woven fibers of the woven backing structure, and wherein the void spaces are configured to allow liquid or vapor to transfer from the first surface to the second surface of the woven backing structure; as well as tufting a second plurality of fibers through the woven backing structure such that the plurality of fibers extend upwardly from the first surface of the woven backing structure, Wherein after braiding the plurality of fibers together, the method does not include forming openings through the braided backing structure.

21. The method according to claim 20, further comprising: Prior to tufting the second plurality of fibers through the woven backing structure, a scrim layer is positioned against the second surface of the woven backing structure to provide a backing, wherein the scrim layer has an open mesh structure, wherein the second surface of the woven backing structure and the scrim layer cooperate to define a lower surface of the backing.

22. The method of claim 21 further comprising applying a polymer coating to the lower surface of the backing.

23. The method of claim 22, wherein applying the polymer coating to the lower surface of the backing comprises rolling the polymer coating against the lower surface of the backing.

24. The method of claim 22, wherein applying the polymer coating to the lower surface of the backing comprises: pouring the polymer coating as a fluid onto the lower surface of the backing; as well as The fluid is scraped to distribute the fluid across the lower surface of the backing.

25. A method comprising: Mounting the tufted product according to any one of claims 1 to 19 on a lower structure; as well as Liquid or water vapor is received through interstitial spaces defined between respective ones of the plurality of woven fibers of the woven backing structure.

26. A tufted product comprising: A backing having a vertical axis, the backing comprising: an open structural material having a first surface and an opposite second surface, wherein the open structural material comprises a plurality of fibers, wherein the plurality of fibers define a void space through the open structural material from the first surface to the second surface based in part on the variability of the fibers along the vertical axis, wherein the void space is configured to allow liquid or vapor to pass from the first surface to the second surface of the open structural material; a scrim layer coupled to the opposing second surface of the open structural material, wherein the The scrim layer has an open mesh structure; and A second plurality of fibers extends through the backing tufts and upwardly from the first surface of the open structure material.

27. A tufted article according to claim 26, wherein the open structural material includes a plurality of woven fibers defining a woven backing structure, wherein the void space is defined between corresponding woven fibers among the plurality of woven fibers of the woven backing structure, and wherein the void space is configured to allow liquid or vapor to transfer from the first surface of the woven backing structure to the second surface.

28. The tufted article of claim 26, wherein the plurality of fibers of the open structural material comprises knitted fibers.

29. The tufted article of claim 26, wherein the plurality of fibers of the open structural material comprises a nonwoven material.

30. A tufted article according to any one of claims 26 to 29, wherein the second surface of the open structural material and the scrim layer cooperate to define a lower surface of the backing, wherein the tufted article further includes a polymer coating applied to the lower surface of the backing, wherein at least a portion of the scrim prevents the polymer coating from entering at least one of the void spaces defined between corresponding woven fibers of the plurality of woven fibers of the open structural material.

31. The tufted article of any one of claims 26 to 29, wherein the tufted article does not comprise a polymer coating.

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