Printed fabric substrate and method of manufacture

Abstract

The present invention relates to a printed fabric substrate, such as a flooring article, and a method for manufacturing a printed fabric substrate. Methods and steps are provided for printing color patterns that precisely register physical patterns such as varying yarn pile height, yarn glossiness, yarn color, and the like. The method provides many unique aesthetics on the fabric substrate that cannot be created in another way.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims priority to U.S. Provisional Patent Application No. 63 / 438,636, filed on January 12, 2023, entitled “Printed Textile Substrate and Process For Making,” and is incorporated herein by reference in its entirety. Technical Field

[0003] The present invention relates to printed textile substrates, such as floor coverings, and methods for making printed textile substrates. The present invention provides methods and procedures for printing color patterns that are precisely aligned with physical patterns, such as varying yarn pile height, yarn gloss, yarn color, etc. The methods provide a variety of unique aesthetics on the textile substrate that cannot be produced by other means. Background Art

[0004] Printed fabric substrates, such as floor coverings, have been dyed and / or printed by several printing processes in the past, to produce unique patterns and / or designs on their surfaces. In some cases, an impregnation machine is used to print the fabric substrate, wherein the substrate, such as a carpet tile, is immersed in a dye vat to produce solid color tones on the substrate surface. The dyed substrate can then be made to reenter the production line so as to overprint a design on its surface using printing ink. Alternatively, the fabric substrate can be printed using a digital printing machine using printing ink so as to form patterns and / or designs on the surface of the substrate. In another case, a spinning dyed yarn is used to make the fabric substrate, which can then use printing ink to print a pattern on its surface.

[0005] Despite all these options for printing textile substrates and producing a variety of patterns and / or designs thereon, consumer demand for hitherto unseen patterns and / or designs continues to grow. Consequently, manufacturers and designers alike are faced with the challenge of providing new technologies capable of achieving these effects in a cost-effective, environmentally friendly, and sustainable manner.

[0006] Therefore, there is a need for further improvements in the printing of fabric substrates, such as floor coverings, in order to provide new and interesting designs that have not been previously achieved due to technological limitations. The technology for accurately registering patterns with detectable and identifiable physical features of a substrate (such as a tufted fabric substrate) has not been successfully achieved due to bowing (such as stretching displacement), shrinkage and other processing issues that occur in the substrate during the manufacturing process. In addition, due to the cutting process of making carpet tiles from large rolls of carpet, the alignment and / or registration accuracy of the desired pattern may be lost or reduced during visual inspection. Therefore, technological innovations in digital printing equipment are needed to successfully address these problems and achieve new patterns and / or designs on fabric substrates.

[0007] The present invention addresses these issues and provides a solution for achieving precise registration of designs and patterns on the surface of a textile substrate, as described herein. Several new process steps and technological advancements are utilized to address the previously unattainable problem of precise registration of printed patterns on textile substrates. It also provides a digitally printed textile substrate that can be precisely registered, incorporating previously unattainable patterns and / or designs onto the substrate. Summary of the Invention

[0008] In one aspect, the present invention relates to a fabric base comprising tufted yarns, wherein the tufted yarns form at least two areas A1 and A2 within the fabric base, wherein the areas A1 and A2 each comprise a tufted design, wherein the area A1 comprises a first tufted design TD1, and the area A2 comprises a second tufted design TD2, wherein TD1 is different from TD2, and wherein the at least two areas A1 and A2 are further characterized by having one of the following:

[0009] (a) a print composition on at least a portion of the area A1,

[0010] (b) a print composition on at least a portion of area A2, or

[0011] (c) a print composition on at least a portion of both area A1 and area A2,

[0012] The fabric substrate is designed to be secured to a building surface.

[0013] In another aspect, the present invention relates to a method for providing a pattern on a textile substrate, the method comprising the steps of:

[0014] (a) providing a fabric base comprising tufted yarns, wherein the tufted yarns form at least two areas A1 and A2 within the fabric base, wherein the areas A1 and A2 each comprise a tufted design, the area A1 comprising a first tufted design TD1, and the area A2 comprising a second tufted design TD2, wherein TD1 is different from TD2;

[0015] (b) providing a digital printing device; and

[0016] (c) printing predetermined positions of the fabric substrate using the digital printing device, thereby forming a pattern on the fabric substrate by applying a printing composition to the surface of the fabric substrate, wherein the printing composition is applied only to one of the following predetermined positions on the fabric substrate:

[0017] (i) over at least a portion of area A1,

[0018] (ii) over at least a portion of area A2, or

[0019] (iii) over at least a portion of both area A1 and area A2,

[0020] The printing is characterized by being precisely aligned with a predetermined position selected from (i) to (iii) on the fabric substrate.

[0021] In another aspect, the present invention relates to a method of producing a design on a fabric substrate comprising the steps of:

[0022] (a) selecting a fabric substrate, wherein the fabric substrate comprises tufted yarns having a first height, tufted yarns having a second height, and regions without tufted yarns, wherein the first height is greater than the second height;

[0023] (b) selecting a printed design to be applied to a predetermined location on a surface of the fabric substrate, wherein the printed design is applied to the fabric substrate by a digital printing device, and wherein the printed design is applied to only one of the following predetermined locations on the fabric substrate:

[0024] (i) on at least a portion of the tufted yarns having a first height,

[0025] (ii) on at least a portion of the tufted yarns having a second height,

[0026] (iii) over at least a portion of the area free of tufted yarns, or

[0027] (iv) on at least a portion of the tufted yarns having a first height and the tufted yarns having a second height; and

[0028] (c) directing the digital printing device to apply the preselected print design to the fabric substrate.

[0029] In another aspect, the present invention relates to a method of producing a design on a fabric substrate comprising the steps of:

[0030] (a) selecting a fabric substrate, wherein the fabric substrate comprises tufted yarns having a first height, tufted yarns having a second height, and regions without tufted yarns, wherein the first height is greater than the second height;

[0031] (b) selecting a first printed design to be applied to a predetermined location on a surface of the fabric substrate, wherein the first printed design is applied to the fabric substrate by a digital printing device, and wherein the first printed design is applied to only one of the following predetermined locations on the fabric substrate:

[0032] (i) on at least a portion of the tufted yarns having a first height,

[0033] (ii) on at least a portion of the tufted yarns having a second height,

[0034] (iii) over at least a portion of the area free of tufted yarns, or

[0035] (iv) on at least a portion of the tufted yarns having a first height and the tufted yarns having a second height;

[0036] (c) directing the digital printing device to apply the preselected first print design to the fabric substrate;

[0037] (d) selecting a second printed design to be applied to the surface of the fabric substrate, wherein the second printed design is applied to the fabric substrate by a digital printing device, and wherein the second printed design is applied to the fabric substrate only at one of the following predetermined locations:

[0038] (i) on at least a portion of the tufted yarns having a first height,

[0039] (ii) on at least a portion of the tufted yarns having a second height,

[0040] (iii) over at least a portion of the area free of tufted yarns, or

[0041] (iv) on at least a portion of the tufted yarns having a first height and the tufted yarns having a second height; and

[0042] (e) directing the digital printing device to apply the preselected second print design onto the fabric substrate.

[0043] In another aspect, the present invention relates to a method of producing a design on a fabric substrate comprising the steps of:

[0044] (a) selecting a fabric substrate, wherein the fabric substrate comprises tufted yarns having a first height, tufted yarns having a second height, and regions without tufted yarns, wherein the first height is greater than the second height;

[0045] (b) selecting a first printed design to be applied to a predetermined location on a surface of the fabric substrate, wherein the first printed design is applied to the fabric substrate by a digital printing device, and wherein the first printed design is applied to only one of the following predetermined locations on the fabric substrate:

[0046] (i) on at least a portion of the tufted yarns having a first height,

[0047] (ii) on at least a portion of the tufted yarns having a second height,

[0048] (iii) over at least a portion of the area free of tufted yarns, or

[0049] (iv) on at least a portion of the tufted yarns having a first height and the tufted yarns having a second height;

[0050] (c) directing the digital printing device to apply the preselected first print design to the fabric substrate;

[0051] (d) selecting a second printed design to be applied to the surface of the fabric substrate, wherein the second printed design is applied to the fabric substrate by a digital printing device, and wherein the second printed design is applied to the fabric substrate only at one of the following predetermined locations:

[0052] (i) on at least a portion of the tufted yarns having a first height,

[0053] (ii) on at least a portion of the tufted yarns having a second height,

[0054] (iii) over at least a portion of the area free of tufted yarns, or

[0055] (iv) on at least a portion of the tufted yarns having a first height and the tufted yarns having a second height;

[0056] (e) directing the digital printing device to apply the preselected second print design to the fabric substrate,

[0057] (f) selecting a third print design to be applied to the surface of the fabric substrate, wherein the third print design is applied to the fabric substrate by a digital printing device, and wherein the third print design is applied to the fabric substrate only at one of the following predetermined locations:

[0058] (i) on at least a portion of the tufted yarns having a first height,

[0059] (ii) on at least a portion of the tufted yarns having a second height,

[0060] (iii) over at least a portion of the area free of tufted yarns, or

[0061] (iv) on at least a portion of the tufted yarns having a first height and the tufted yarns having a second height; and

[0062] (g) directing the digital printing device to apply the preselected third print design onto the fabric substrate.

[0063] In yet another aspect, the present invention is directed to a fabric substrate comprising a pattern, the pattern being characterized by having at least one region comprising a physical indicia and at least one region lacking a physical indicia, the physical indicia being selected from the group consisting of a print composition, a tuft density, a yarn construction, a yarn composition, and combinations thereof, the pattern being further characterized by having only one of the following:

[0064] (a) a printed ink on at least a portion of the area containing the physical marking,

[0065] (b) printed ink on at least a portion of the area that does not contain a physical marking, or

[0066] (c) printing ink on at least a portion of both the area containing the physical marking and the area not containing the physical marking,

[0067] The fabric base is designed for use on a horizontal surface.

[0068] In yet another aspect, the present invention is directed to a fabric substrate comprising a pattern, the pattern being characterized by having at least one region comprising a first physical marker and at least one region comprising a second physical marker, the physical marker being selected from the group consisting of print composition, tuft density, yarn construction, yarn composition, and combinations thereof, the pattern being further characterized by having only one of the following:

[0069] (a) printing ink A, B or C on at least a portion of the area containing the first physical marking,

[0070] (b) printed ink A, B or C on at least a portion of the area containing the second physical marking, or

[0071] (c) printed ink A, B or C on at least a portion of the area containing both the first physical mark and the second physical mark,

[0072] The fabric base is designed for use on a horizontal surface.

[0073] In yet another aspect, the present invention is directed to a fabric substrate comprising a pattern characterized by having at least one topographical region comprising tufted yarns of a first height and tufted yarns of a second height, wherein the first height is greater than the second height, the pattern further characterized by having only one of the following:

[0074] (a) printing ink A, B or C on at least a portion of the tufted yarns having a first height,

[0075] (b) printing ink A, B or C on at least a portion of the tufted yarns having a second height, or

[0076] (c) printing ink A, B or C on at least a portion of both the tufted yarns having the first height and the tufted yarns having the second height,

[0077] The fabric base is designed for use on a horizontal surface. BRIEF DESCRIPTION OF THE DRAWINGS

[0078] Figure 1 is a flow chart showing the general steps of the method of the present invention.

[0079] Figure 2A is a schematic diagram illustrating one embodiment of the physical structure of a fabric substrate comprising Tufted Region 1 , Tufted Region 2 , and Tufted Region 3 .

[0080] Figure 2B is a schematic diagram illustrating one embodiment of a color pattern structure of a print, showing pattern element 1 combined with tufted area 1, pattern element 2 combined with tufted area 2, design element 3 combined with tufted area 3, and design element 4 combined with tufted area 4.

[0081] Figure 2C is shown applied to a fabric substrate such as broadloom carpet. Figure 2B An implementation scheme and a schematic diagram of the challenges of weft bow and weft skew in achieving accurate registration of printed designs.

[0082] Figure 2D is shown applied to a fabric substrate such as a carpet tile. Figure 2B implementation scheme, and the challenges of bow and weft skew in achieving accurate registration of the printed design, as well as the challenges of cutting the blocks and losing some of the design / pattern details when cutting into smaller blocks.

[0083] Figure 3 is a schematic diagram of an exemplary jet dyeing apparatus for applying dye to a fabric substrate in accordance with the present invention.

[0084] Figure 4 is a schematic diagram of the relationship of a jet dye applicator lance rod assembly to a carpet tile of an exemplary jet dyeing apparatus.

[0085] Figure 5A is a schematic diagram of one embodiment of a fabric substrate having high and low pile loops as exemplary physical markers according to the present invention.

[0086] Figure 5B is based on the physical markings of high and low pile loops shown in Figure 5A Schematic diagram of a printed pattern formed on a fabric base.

[0087] Figure 5Cis a schematic diagram of an exemplary general method of the present invention showing the combination of features that are precisely registered with physical markings on a fabric substrate to form a unique pattern thereon.

[0088] Figure 6 is a grayscale photograph of one embodiment of a printed floor covering according to the present invention, wherein a PCX file (Representation A) is layered with a print file (Representation B) to demonstrate solid color layout based on tuft position.

[0089] Figure 7 is a grayscale photograph illustrating another embodiment of a printed floor covering according to the present invention, in which a PCX file (Representation A) is layered with a print file (Representation B) to show texture and color layout based on tuft location.

[0090] Figure 8 is an exploded schematic diagram of an exemplary multi-layer carpet structure. DETAILED DESCRIPTION

[0091] As used herein, a "digital printing machine" refers to a computer-controlled device that emits printing ink onto the surface of a textile substrate, and may also be referred to herein as a "jet dyeing device" and / or a "digital printing device."

[0092] As used herein, the term "floor covering" is intended to describe a textile substrate that includes facing fibers and is used to cover surfaces that people walk on. Thus, carpets (broadlooms, carpet tiles, etc.) and rugs (outdoor rugs, indoor rugs, etc.) are specific types of floor coverings.

[0093] As used herein, the term "printing" refers to the process of changing the color of a fiber or yarn in whole or in part (eg, the final color of the fiber or yarn is different from the initial color) by printing ink jetted from a jet dyeing device or a digital printer.

[0094] The present invention allows for the creation of unique aesthetics on the surface of a fabric substrate, including graphic effects that are precisely aligned with the texture, antique effects, shadows, and three-dimensional effects, as shown in Table 1.

[0095] Table 1: Various exemplary precise alignment aesthetic effects

[0096]

[0097] These aesthetic features can be applied to any textile substrate containing a detectable physical mark, such as floor coverings (including broadloom and carpet tiles), decorative fabrics, wall coverings, and the like. In one aspect, the present invention allows at least a portion of the design to be precisely aligned with the carpet tile, simulating broadloom (without seams) or carpet tiles (with seams), while other design elements are also precisely aligned with the tufting pattern. When used as a floor covering, unique floor plans and multi-tile pattern designs can be created. Superimposing the features of the present invention on multiple carpet tiles can even produce large designs on a scale not previously possible.

[0098] The present invention also allows for control of different dye amounts according to different yarn types and pile heights, which allows for more effective control of color, shading, and / or bleeding in print designs. Control is typically based on identification of physical characteristics of the yarn as detected by the digital printer.

[0099] The general steps for creating the printed fabric substrate of the present invention involve selecting a design that includes a fabric pattern (e.g., a tufting pattern) and at least one additional feature (e.g., different tuft heights, yarn sheen, yarn color, etc.). These general steps are typically performed by a person skilled in the art of print design. After making these selections, the designer uses software to instruct a digital printer to create the desired print pattern on the fabric substrate.

[0100] In one aspect of the invention, the following process steps are performed:

[0101] (a) The design software reads the physical pattern file,

[0102] (b) The design software converts the resolution of the tufting design file into the physical resolution of the tufting machine,

[0103] (c) the design software assigns dimensions to the tufting pattern file,

[0104] (d) The design software assigns the physical pattern files to different design layers (e.g., cluster head heights),

[0105] (e) The designer can combine or split the physical layers as needed.

[0106] (f) The designer adds additional decal layers independent of the physical layer,

[0107] (g) the designer assigns a color palette to each layer (this can be color composition and / or color amount),

[0108] (h) The design software converts the design to the printer's resolution,

[0109] (i) designing software output layers, wherein one layer corresponds to the color and one layer corresponds to the tufting pattern,

[0110] (j) machine reading of the tufting pattern of each physical substrate (either via a detection system or cutting / marking of the substrate),

[0111] (k) machine determination of the physical pattern of the carpet tile relative to the tufted fabric base (this may include corrections for offset, bow, skew, etc. of the actual fabric base compared to the tufted pattern),

[0112] (l) a machine mathematically combines the color layers and tufting layers into a file format corresponding to the actual physical fabric base (this may include combining and / or stretching / rotating the color layers into a tufting pattern), and

[0113] (m) The machine uses the color profile to print a fabric substrate with the provided design information.

[0114] Figures 2A to 2D Variations of the illustrated embodiment include one or more of the following:

[0115] Design element 1 can be a solid color;

[0116] Design element 1 can be a solid color with reduced ink content;

[0117] Design element 1 may be a design and / or pattern created according to U.S. Patent Nos. 8,145,345, 8,655,473, and 9,060,623 to McCay et al.

[0118] Design element 1 may be a design and / or pattern created in accordance with U.S. Patent Nos. 8,155,776, 8,644,976, and 9,066,614 to Bittner et al. and precisely aligned with the carpet tile / roll;

[0119] Design element 1 may be a combination of different design elements (e.g., layers);

[0120] Design element 4 can be precisely aligned with the tufting pattern;

[0121] Design element 4 can be precisely aligned with the carpet tile at the edge, even if tufted area 3 is not precisely aligned with the carpet tile;

[0122] Any design element can be a metapixel blend as described in U.S. Pat. No. 6,911,245 to Beistline et al. and / or U.S. Pat. No. 6,793,309 to McCay et al.

[0123] Any design element can be a superpixel as taught in U.S. Pat. No. 6,911,245 to Beistline et al. and / or U.S. Pat. No. 6,793,309 to McCay et al.

[0124] Different design element layers can be selected from different color palettes;

[0125] A medallion can be created where a portion of the design is precisely aligned with the carpet tile, independent of the tufting pattern, and the position of the color design is correlated to the position in the tufting pattern medallion.

[0126] The present invention utilizes a digital printer or jet dyeing device to print colors, patterns, and / or designs onto the surface of a fabric substrate in precise alignment with (or related to or based on) the location of other detectable physical features present on or in the fabric substrate. The fabric substrate can be a fabric substrate including a pile base, such as a floor covering. In one aspect, the floor covering can be a carpet tile. The fabric substrate can also include at least a portion in which tufted yarns are present.

[0127] Figure 3 , an exemplary jet dyeing apparatus suitable for use with the present invention for pattern dyeing a fabric substrate, such as a floor covering having a pile surface, is depicted in FIG. A supply roller 97 is mounted on a suitable support 109 for supplying, for example, a roll of wide-loom carpet. Alternatively, if carpet tiles are being printed, they can be arranged on a conveyor belt using a vacuum device capable of moving the carpet tiles by suction. The floor covering is then passed through a dyeing apparatus 110 as follows. The floor covering is advanced onto the lower end of an inclined conveyor belt 111 in a jet coating section 112, where it is printed by programmed operation of a plurality of spray guns, generally designated 113, which spray streams of dye onto the front surface (or pile surface) of the floor covering as it passes beneath them. The pattern-dyed floor covering exiting the coating section is moved via conveyor belts 114 and 116 driven by motors 117 and 118 to a steam chamber 119, where the floor covering is subjected to a steam atmosphere to fix the dye therein. The dyed floor coverings leaving the steam chamber 119 are conveyed through a water washer 121 to remove excess unfixed dye from the articles. Thereafter, the washed floor coverings pass through a hot air dryer 122 to a take-up roll 123, which is mounted on a suitable support 124. Alternatively, for printed carpet tiles, the carpet tiles are removed from the conveyor belt after leaving the hot air dryer 122 and stacked for shipment.

[0128] Figure 4The process of passing a carpet tile under a series of color rods or spray guns is shown in greater detail. These color rods or spray guns spray printing ink onto the surface of the carpet tile, thereby providing a printed carpet tile. The printing ink or dye is contained within each color rod until a signal is received from an electronic control system, which causes a specific color rod to dispense or drip ink onto the surface of the floor covering. Further details of jet dyeing equipment are described, for example, in U.S. Patent No. 3,939,675 to Klein and U.S. Patent No. 4,740,214 to McBride et al.

[0129] The printing ink ejected from a digital printing machine or a jet dyeing device contains at least one dye. The dye can be selected from acid dyes, direct dyes, reactive dyes, cationic dyes, disperse dyes, and mixtures thereof. Acid dyes include azo, anthraquinone, triphenylmethane, and xanthine types. Direct dyes include azo, stilbene, thiazole, dioxazine, and phthalocyanine types. Reactive dyes include azo, anthraquinone, and phthalocyanine types. Cationic dyes include thiazole, methane, cyanine, quinolone, xanthene, azine, and triarylmethine. Disperse dyes include azo, anthraquinone, nitrodiphenylamine, naphthalimide, naphthoquinoneimide, and methane, triarylmethine, and quinoline types.

[0130] Concrete dye selection will depend on the type of a kind of fiber and / or multiple fibers that constitute the fabric substrate of printing.For example, usually, disperse dyes can be used for printing polyester or acetate fiber.Yet anionic dyes, direct dyes, acid dyes, reactive dyes and mixtures thereof can be used for printing the fiber that is made of wool, silk, polyamide, cotton and rayon.For the material that is made of acrylic fiber and cationic dyeable polyester fiber, can use cationic dye.

[0131] like Figure 4 As shown, the printing device comprises a number of color rods. Typically, some will contain dyes including a large amount of viscosity modifiers, while others will contain no or very small amounts of viscosity modifiers. Viscosity modifiers generally include any material that increases the viscosity of an aqueous medium when added to the aqueous medium.

[0132] Suitable viscosity modifiers that can be used include known natural water-soluble polymers, such as polysaccharides, such as starch materials derived from corn and wheat, gum arabic, locust bean gum, tragacanth gum, guar gum, guar flour, polygalactomannan gum, xanthan gum, alginates, and tamarind seeds; protein materials, such as gelatin and casein; tannin materials; and lignin materials. Examples of water-soluble polymers also include synthetic polymers, such as known polyvinyl alcohol compounds and polyethylene oxide compounds. Mixtures of the above viscosity modifiers can also be used. Viscosity is typically measured in centipoise at 25°C using a Brookfield viscometer model LVF, spindle 2, at 6 rpm.

[0133] A digital printing machine used in the present invention typically includes multiple printheads. In one aspect of the present invention, each printhead may contain a specific chemical composition. These printhead chemical compositions may be dye-containing or dye-free. The chemical composition may contain a chromophore or not. The printhead chemical composition may include at least one wetting agent, with or without a dye and / or a chromophore. In the case of a printhead that does not contain a chromophore (i.e., the printhead contains a printing ink without a chromophore), the chemical composition contained therein may be colorless. The chemical composition of each printhead may be the same as or different from that of the other printheads. In other words, printhead-specific chemicals can be used to provide additional patterns and / or designs to the fabric substrate printed thereon. For example, different dyes, dye formulas and viscosities, as well as wetting chemicals, may be present in various printheads, and these printheads can be used to precisely align features on the fabric substrate (e.g., certain tufts such as high pile loops) to produce unique designs. In one aspect of the present invention, printing technology such as that taught in U.S. Patent Application Publication No. 2014 / 0212618A1 to McBride et al. can be used for incorporation into the present invention. Additionally, drop-on-demand printing equipment may also be used to practice the present invention.

[0134] Fabric substrates suitable for use in the present invention include, but are not limited to, fabrics (such as those used for decoration and wall covering) and floor coverings. The fabric can be formed from fibers such as synthetic fibers, natural fibers, or combinations thereof. Synthetic fibers include, for example, polyesters, acrylics, polyamides, polyolefins, polyaramids, polyurethanes, regenerated cellulose (such as rayon), and blends thereof. The term "polyester" is intended to describe long chain polymers having repeating ester groups (--C(O)-O--). Examples of polyesters include aromatic polyesters such as polyethylene terephthalate (PET), polytrimethylene terephthalate, polytrimethylene terephthalate (PTT), and polybutylene terephthalate (PBT), and aliphatic polyesters such as polylactic acid. Polyamides include, for example, nylon 6, nylon 6,6, nylon 1,1, and nylon 6,10, and combinations thereof. Polyolefins include, for example, polypropylene, polyethylene, and combinations thereof. Polyaramids include, for example, poly(p-phenylene terephthalamide) (i.e., ), poly(m-phenylene isophthalamide) (i.e. ) and combinations thereof. Natural fibers include, for example, wool, silk, cotton, flax, and blends thereof.

[0135] Fabric can be formed by the fiber or yarn of any size, comprises micro denier fiber and yarn (having the fiber or yarn of every monofilament less than 1 denier).The denier value of fiber or yarn can be less than about 1 denier every monofilament to about 2000 denier every monofilament, or more preferably less than about 1 denier every monofilament to about 500 denier every monofilament, or even more preferably less than about 1 denier every monofilament to about 300 denier every monofilament.In addition, fabric can be partially or entirely made up of multicomponent or bicomponent fiber or yarn, and these fibers or yarn can be split along its length by chemical or mechanical action.Fabric can be made up of fiber such as short fiber, filament fiber, spun fiber or their combination.Fabric can be any kind, includes but not limited to woven fabric, knitted fabric, nonwoven fabric or its combination, and also comprises any fabric type, can comprise tufted fabric.

[0136] Floor coverings printed according to the present invention as described herein include, but are not limited to, woven carpets, knitted carpets, tufted carpets, patterned tufted carpets, flocked carpets, bonded pile carpets, crocheted carpets, knotted pile carpets, and the like. Floor coverings can be broadloom carpets or carpet tiles. Carpet tiles (i.e., patchwork carpets) can have any geometric shape or size required for their end-use applications. The longitudinal edges of the carpet tiles can have the same length and width, thereby forming a square shape. Alternatively, the longitudinal edges of the carpet tiles can have different sizes, such that the width and length are different (e.g., thereby forming carpet planks). Floor coverings can have any suitable construction (e.g., hard back, cushioned back, etc.). The carpet surface can be made of any suitable textile material suitable for dyeing and patterning yarn or pile form, and can have a uniform or uneven carpet surface height or pile height (e.g., a texture common in multi-level loop pile) produced by tufting, needle punching, flocking, bonding, etc., or using a non-woven substrate.

[0137] Figure 8An exemplary multi-layer carpet construction is shown in FIG. In this exemplary construction, a base structure 225 is comprised of a primary carpet fabric 212 formed from a plurality of pile yarns 214 tufted through a primary backing layer 216, such as a scrim or nonwoven fiber textile of polyester, polyamide, and / or polypropylene, as is known to those skilled in the art. A pre-coat backing layer 218 of an elastic adhesive, such as SBR latex and / or vinyl acetate-ethylene ("VAE") latex, is disposed on the bottom surface of the primary carpet fabric 212 to secure the pile yarns 214 within the primary backing layer 216. An adhesive layer 220, such as a hot melt adhesive, extends away from the pre-coat backing layer 218. A layer of stabilizing material 222, such as woven or non-woven glass, is disposed between the adhesive layer 220 and a cushioning layer 224, such as virgin or resilient polyurethane foam. A secondary backing layer 226, such as a blended nonwoven of polyester and polypropylene fibers, is disposed on the bottom surface of the cushioning layer 224.

[0138] It will be appreciated that the actual configuration of the base structure 225 may be subject to a wide range of variations. Figure 8 The multi-layer construction shown in should be understood to constitute merely exemplary constructions representing floor coverings, and the present invention is equally applicable to any other constructions of carpet and / or other textiles that may be desired. By way of example only, various carpet tile constructions are described in U.S. Patent Nos. 6,203,881 and 6,468,623.

[0139] In the case where the fabric substrate is a floor covering, the pile yarn 214 can be a staple yarn or a filament yarn formed from natural fibers such as wool, cotton, etc. The pile yarn 214 can also be formed from synthetic materials, such as polyamide polymers, including nylon 6 or nylon 6,6; polyesters, such as PET and PBT; polyolefins, such as polyethylene and polypropylene; rayon; and polyethylene polymers, such as polyacrylonitrile. Blends of natural and synthetic fibers, such as blends of cotton, wool, polyester, and nylon, can also be used in the pile yarn 214. Figure 8 In the embodiment of the present invention, the pile yarn 214 is shown with a loop pile structure. Of course, it should be understood that other pile structures known to those skilled in the art can be used equally, including cut pile structures etc.

[0140] The floor covering may have a fiber face weight of about 1 to about 75 oz / yd2, or about 5 to about 60 oz / yd2, or about 10 to about 55 oz / yd2, or about 20 to about 50 oz / yd2, or even about 12 to about 40 oz / yd2.

[0141] The material comprising the fabric substrate, such as the pile surface of a floor covering, may be a synthetic fiber, a natural fiber, a man-made fiber using natural ingredients, an inorganic fiber, a glass fiber, or a blend of any of the foregoing. By way of example only, the synthetic fiber may comprise polyester, acrylic, polyamide, polyolefin, polyaramid, polyurethane, or a blend thereof. More specifically, the polyester may comprise polyethylene terephthalate, polypropylene terephthalate, polybutylene terephthalate, polylactic acid, or a combination thereof. The polyamide may comprise nylon 6, nylon 6,6, or a combination thereof. The polyolefin may comprise polypropylene, polyethylene, or a combination thereof. The polyaramid may comprise poly(p-phenylene terephthalamide) (i.e., ), poly(m-phenylene isophthalamide) (i.e. ) or a combination thereof. Exemplary natural fibers include wool, cotton, flax, ramie, jute, linen, silk, hemp, or blends thereof. Exemplary man-made materials using natural ingredients include regenerated cellulose (i.e., rayon), lyocell, or blends thereof.

[0142] The fabric substrate of the present invention can be formed from staple fibers, filament fibers, slit film fibers, or combinations thereof. The fibers can be exposed to one or more pile-making processes. The fibers can then be spun or otherwise combined into yarns, for example, by ring spinning, open-end spinning, air spinning, vortex spinning, or combinations thereof. Thus, the fabric substrate typically consists of interwoven fibers, interwoven yarns, pile, or combinations thereof.

[0143] The fabric substrate can be composed of fibers or yarns of any size, including microdenier fibers or yarns (fibers or yarns having less than 1 denier per filament). The fibers or yarns may have a denier value of less than about 0.1 denier per filament to about 2000 denier per filament, or more preferably less than about 1 denier per filament to about 500 denier per filament.

[0144] Furthermore, the fabric substrate may be composed in part or in whole of multicomponent or bicomponent fibers or yarns in various configurations, such as islands-in-the-sea, core-sheath, side-by-side, or segmented-segment configurations. Depending on the configuration of the bicomponent or multicomponent fibers or yarns, the fibers or yarns may be split along their length by chemical or mechanical action.

[0145] Additionally, the fibers comprising the fabric substrate may include additives coextruded therein, may be pre-coated with any amount of various materials (including those listed in more detail below), and / or may be dyed or colored with any type of colorant, such as poly(oxyalkylenated) colorants, as well as pigments, dyes, stains, etc., to provide other aesthetic characteristics to the end user. Other additives may also be present on and / or within the target fibers or yarns, including antistatic agents, brightening compounds, nucleating agents, antioxidants, UV stabilizers, fillers, durable press finishes, softeners, lubricants, cure accelerators, and the like.

[0146] The printing method of the present invention uses a jet dyeing machine or a digital printer to place printing ink at predetermined locations on the surface of a fabric substrate (e.g., carpet tile). One suitable and commercially available digital printer is the ® ... Digital printing machine. The machine uses a nozzle array with a continuous stream of dye that can be deflected by controlled air nozzles. The nozzle array or spray gun bar is usually fixed. Another suitable and commercially available digital printing machine is available from Zimmer Machinery Corporation of Spartanburg, South Carolina. Carpet Printing Machines. Another digital printing machine that can be used is an inkjet digital printer for printing high-resolution graphic designs onto carpet, which allows for the printing of complex designs and is also available from Milliken & Company of Spartanburg, South Carolina; this technology is also known as a multi-deflection inkjet system and is described, for example, in U.S. Patents Nos. 9,452,602 and 9,550,355. In one aspect, tufted carpet made according to the methods disclosed in Weiner U.S. Patents Nos. 7,678,159 and 7,846,214 can be printed using the jet dyeing apparatus described and exemplified herein.

[0147] In particular, suitable tufting machines and the various types of tufted fabric substrates produced therefrom are those available from tufting machine manufacturers such as Card-Monroe Corporation of Hixson, Tennessee, and include exemplary technologies such as ColorPoint. TM and custom ring tufting.

[0148] The present invention allows printing ink to be applied to the surface of a textile substrate in a predetermined position by a digital printing machine based on the location of specific physical markings, such as areas of tufted yarns, areas without tufted yarns, presence or absence of yarn color, gloss, twist, etc. Figure 1The following is a flowchart illustrating the general steps of the process. First, several components are provided, including a digital printer, a fabric substrate containing at least one physical marking, and a system for detecting the physical marking. Next, as the fabric substrate moves on a conveyor belt in close proximity to the detection system, the detection system (e.g., a camera system) observes and identifies the physical marking. The detection system then sends an electronic signal to the digital printer. This signal is analyzed by the digital printer, and based on predetermined instructions, the machine prints a specific color in a specific amount that is precisely aligned with the area containing the observed physical marking. This results in a printed fabric substrate comprising a unique pattern and / or design.

[0149] As used herein, a physical marker includes any physical feature contained within a fabric substrate and / or disposed on the surface of a fabric substrate that can be detected by an electronic mechanism (e.g., a camera or scanning system) and whose presence can be reported to a digital printer. For example, physical markers include, but are not limited to, changes in print composition (e.g., color changes), tuft density, yarn construction, yarn composition, and the like, and combinations thereof. Changes in yarn construction include differences in yarn height, yarn color, yarn gloss, yarn twist, yarn cut, yarn loops, yarn denier, and the like, and combinations thereof. Changes in yarn composition include differences in the materials comprising the yarn and any finish applied thereto. Changes in yarn construction can include yarns having loop pile and cut pile. Changes in yarn height include, for example, yarns having a first tuft height and a second tuft height, wherein the first tuft height is greater than the second tuft height.

[0150] By providing the ability to print in this manner, the present invention enables printed fabric substrates to have designs and / or patterns on their surfaces that have heretofore been unattainable. Physical markings are detected by a detection system, such as a camera or scanning technology, that is capable of identifying differences in the surface area of the fabric substrate. Electronic communication between the detection system and the digital printer provides information that instructs the printer to print or not print in specific areas. For example, when a camera identifies a physical marking (e.g., an area of high yarn tufting), an electronic signal is sent to the digital printer to dispense printing ink at that location.

[0151] In one aspect of the present invention, a fabric substrate comprises tufted yarns forming at least two areas A1 and A2 within the fabric substrate, said areas A1 and A2 each comprising a tufted design, said area A1 comprising a first tufted design TD1, said area A2 comprising a second tufted design TD2, said TD1 being different from TD2, said at least two areas A1 and A2 being further characterized by having one of the following: (a) a print composition on at least a portion of area A1, (b) a print composition on at least a portion of area A2, or (c) a print composition on at least a portion of both areas A1 and A2, wherein the fabric substrate is designed to be secured to a building surface. In one aspect, the fabric substrate described herein has a first tufted design TD1 and a second tufted design TD2 independently selected from and formed of variations in print composition, tuft density, yarn construction, yarn composition, and combinations thereof.

[0152] On the other hand, the variation in yarn height can include yarns having a first tuft height and a second tuft height, wherein the first tuft height is greater than the second tuft height. The fabric substrate of this arrangement can include a print composition on at least a portion of the tufted yarns having the first height, and the tufted yarns having the second height can be substantially free of the print composition. Alternatively, the fabric substrate can include a print composition on at least a portion of the tufted yarns having the second height, and the tufted yarns having the first height can be substantially free of the print composition. In another alternative, the fabric substrate can include a print composition on all tufted yarns having the first height and the second height. The difference in tuft height can be achieved by a cut pile and loop pile structure and / or a variable loop pile cut pile (VLOC) structure.

[0153] With respect to tuft height, in one aspect of the invention, the first tuft height can be at least 10% higher than the second tuft height, or the first tuft height can be about 10% to about 100% higher than the second tuft height, or the first tuft height can be about 10% to about 75% higher than the second tuft height, or the first tuft height can even be about 10% to about 50% higher than the second tuft height.

[0154] Regarding the printing composition, area A1 of the fabric substrate may contain a first printing composition PC1, while area A2 may contain a second printing composition PC2, wherein PC1 is different in composition from PC2. In this arrangement, PC1 may form a printing pattern PP1, while PC2 may form a printing pattern PP2, wherein PP1 is different from PP2. The PC1 applied to A1 may be different in quantity from the PC2 applied to A2. Alternatively, the PC1 applied to A1 may be different in composition from the PC2 applied to A2. In addition, the PC1 applied to A1 may be different in quantity and composition from the PC2 applied to A2. In another alternative, area A1 may contain the first printing composition PC1, while area A2 may contain the second printing composition PC2, wherein PC1 is the same composition as PC2. The printing composition may be precisely aligned with the tufting yarns in A1, A2, or both A1 and A2 of the fabric substrate. In another aspect of the present invention, a first base layer of printed color may be applied to the surface of the fabric substrate, followed by a second layer comprising PC1 and / or PC2. In this aspect, the present invention is capable of providing more than one (e.g., two, three, four, etc.) printing ink layer to the surface of a fabric substrate using detectable markings on the fabric substrate to determine printing instructions (e.g., where to apply ink, how much ink to apply, etc.).

[0155] Regarding tufting designs, the fabric base may further include a third tufting design TD3 that is different from TD1 and TD2. TD3 may differ from TD1 and TD2 in at least one of a print composition, a tufting density, a yarn construction, and a yarn composition. The fabric base may further include at least one additional tufting design TD4 that is different from TD1, TD2, and TD3. TD4 may differ from TD1, TD2, and TD3 in at least one of a print composition, a tufting density, a yarn construction, and a yarn composition.

[0156] As described herein, ink printing instructions are provided to a digital printer based on the presence of a detectable physical marker on the surface of a fabric substrate. In one aspect, the present invention includes the ability to utilize at least one physical marker area on the surface of a fabric substrate to electronically instruct a digital printer to apply (or not apply) printing ink to that area. The deposition of printing ink on the substrate surface is determined by the location and / or presence of those physical markers. The machine is also capable of adjusting the amount of printing ink applied to those areas. For example, areas with high tufting (physical markers) may have more ink deposited on their surface, while areas with low tufting (also physical markers) may have less ink deposited on them. Thus, by including at least one detectable marker in or on a fabric substrate during the manufacture and / or finishing of the fabric substrate and developing technology to use that marker to generate a printing response from a digital printer, new patterns and designs for fabric substrates can be generated. In one aspect, these new patterns and designs are formed on the fabric substrate in a single-pass (one-pass through the printing area) manufacturing process.

[0157] Example

[0158] The following examples further illustrate the above subject matter, but should of course not be construed as limiting the scope thereof in any way.

[0159] Figure 5A and 5B A printed precise register design on a textile substrate is shown, based on pile height differences as physical markers for instructing a digital printer to apply printing ink only to areas of low pile height ("low loops"). Figure 5A is a cross-sectional view of a fabric base having four rows of tufts and 11 rows of loops. Figure 5B yes Figure 5A A plan view of a fabric substrate is shown, showing that a first printing ink is selectively applied only to the high pile loop areas, thereby producing a printing pattern A (an area with high pile loops and printing ink), and a second printing ink is selectively applied only to the low pile loop areas, thereby producing a printing pattern B (an area with low pile loops and printing ink).

[0160] supply Figure 5C To illustrate one aspect of the general method of the present invention, a printed pattern on a fabric substrate is shown, corrected for distortion (if any) resulting from the manufacturing and / or printing process. The printed pattern on the fabric substrate is then exposed to a printing device (e.g., a digital printer) positioned adjacent to a printing zone. The printed pattern on the fabric substrate moves along the printing zone and receives additional printing ink precisely aligned with predetermined designated areas of the substrate, thereby further adding another printed pattern to the fabric substrate. Figure 5CA fabric substrate having a tufted area is also shown. The tufted fabric substrate is exposed to a computer image recognition system. If any deformation of the tufted fabric substrate is detected, the deformation is corrected before the tufted fabric substrate is exposed to the printing equipment. After the deformation is corrected (if necessary), the tufted fabric substrate is exposed to the printing equipment in the printed area. The print on the tufted fabric substrate is precisely aligned with the predetermined positions (i.e., physical identifications) of the tufts. This results in a unique, precisely registered print and tufted fabric substrate having a pattern and / or design heretofore unachievable using prior art printing techniques.

[0161] supply Figure 6 and 7 To further illustrate the present invention. Figure 6 and Figure 7 To illustrate a tufted fabric base with a printed overlay that is precisely registered to the tufting pattern. Figure 6 and Figure 7 Each contains a representation A and a representation B. Figure 6 In [1], Representation A is a Picture Exchange ("PCX") file that contains codes that represent the height of the pile on the tufting machine. The PCX file contains codes that represent the height of the pile on the tufting machine. The pile height forms a pattern when tufted. Representation B is a combination of Representation A with the added features of a print file that includes instructions for solid color positioning. The print design matches the solid color to the PCX file code (pile setting). By Digital printing machine completes the printing.

[0162] exist Figure 7 In the example, profile A is a PCX file containing the code that represents the pile height on the tufting machine, while profile B is a combination of profile A with the added features of a print file that includes instructions for both texture and color positioning. The print design matches the texture pattern and color to the PCX file code (pile setting).

[0163] Figure 6 and Figure 7 The feature is accomplished by importing a PCX file into digital design software and scaling it to match the tufting scale. This PCX file is a 12th gauge, so a 20th gauge printed SRX file needs to be scaled to match the scale. For example, a 744 x 1200 pixel PCX tufting file with a width of 12 stitches per inch and a length of 10 stitches will result in a finished tufted pattern that is 62 inches wide and 120 inches long. The same file, when printed, will be 37.2 inches wide by 60 inches long. The printed file needs to be scaled to 1240 x 2400 pixels to match the tufted material.

[0164] Design Process A can be used when only solid colors are applied to match each code area of the tufted material. A print version file can be created. However, in order to apply a pattern / texture to the print design, the pattern or texture should be scaled to match the newly created SRX print file. Using the super impose function in the digital design software, the selected pattern / texture will be added to the original code location of the tufted pattern, which is referred to as Design Process B in this article.

[0165] Figure 6 and 7 The samples of the present invention shown in are produced by a manual process in which tufted ecru carpet tiles are matched to areas in a complete printed design. A portion is cut from the main design and then printed onto a single carpet tile. It is foreseeable that this manual process is also performed using hardware and software technology. In this regard, for example, hardware and software components located at the production / manufacturing site are capable of electronically and / or automatically detecting physical features on a fabric substrate (e.g., an ecru carpet tile). These components can then "scan" the ecru material and find corresponding areas from the SRX print file, thereby creating a precisely registered printed fabric substrate in accordance with the present invention. The precisely registered printed textile substrate thus created contains unique designs and / or patterns that have heretofore been unattainable, which are exactly what designers and consumers have come to expect in the digital printing industry for fabric substrates.

[0166] All references, including publications, patent applications, and patents, cited herein are hereby incorporated by reference to the same extent as if each reference were individually and specifically indicated to be incorporated by reference and were set forth in its entirety herein.

[0167] Unless otherwise specified herein or clearly contradictory with context, otherwise the use of terms "one" and "an" and "the" and similar references in the context of describing the subject matter of the present application (especially in the context of the appended claims) should be interpreted as covering the singular and plural. Unless otherwise specified, the terms "include", "have", "include" and "contain" should be interpreted as open terms (that is, meaning "including but not limited to") unless otherwise specified herein. Unless otherwise specified herein, the reference to value ranges herein is only intended to be used as a shorthand method for quoting each individual value falling within the range individually, and each individual value is incorporated into the specification as if it were quoted individually in this article. Unless otherwise specified herein or clearly contradictory with context, all methods described herein can be performed in any suitable order. Unless otherwise claimed, the use of any and all examples or exemplary languages (e.g., "such as") provided herein is only intended to better illustrate the subject matter of the present application, and is not intended to limit the scope of the subject matter. The language in the specification should not be interpreted as indicating any unclaimed element as being necessary for the practice of the subject matter described herein.

[0168] The preferred embodiments of the subject matter of the present application are described herein, including the best mode known to the inventor for carrying out the claimed subject matter. After reading the foregoing description, variations of those preferred embodiments may become apparent to those skilled in the art. The inventor expects that the skilled person will appropriately adopt such variations, and the inventor intends to implement the subject matter described herein in a manner different from that specifically described herein. Therefore, this disclosure includes all modifications and equivalents of the subject matter recited in the appended claims as permitted by applicable law. In addition, unless otherwise specified herein or the context clearly contradicts, this disclosure covers any combination of the above-mentioned elements in all their possible variations.

Claims

1. A fabric substrate comprising a pattern, the pattern being characterized by having at least one area containing a physical indicia and at least one area without a physical indicia, the physical indicia being selected from the group consisting of a print composition, a tuft density, a yarn construction, a yarn composition, and combinations thereof, the pattern being further characterized by having only one of the following: (a) printing ink on at least a portion of the area containing the physical marking, (b) a printed ink on at least a portion of said area devoid of physical markings, or (c) printing ink on at least a portion of the area containing the physical marking and the area without the physical marking, The fabric base is designed for use on a horizontal surface.

2. The fabric substrate of claim 1, wherein the fabric substrate comprises a tufted yarn area.

3. The fabric substrate of claim 2, wherein the fabric substrate comprises a tufted yarn region having at least one of high tufting and low tufting.

4. The fabric substrate of claim 2, wherein the tufted yarn is further characterized as loop pile, cut pile, and combinations thereof.

5. The fabric substrate of claim 1, wherein the horizontal surface is a floor surface.

6. The fabric substrate of claim 1, wherein the fabric substrate is a floor covering.

7. A fabric substrate comprising a pattern, the pattern characterized by having at least one region comprising a first physical marker and at least one region comprising a second physical marker, the physical markers being selected from the group consisting of print composition, tuft density, yarn construction, yarn composition, and combinations thereof, the pattern further characterized by having only one of the following: (a) printing ink A, B or C on at least a portion of the area containing the first physical mark, (b) printing ink A, B or C on at least a portion of the area having the second physical marking, or (c) printed ink A, B or C on at least a portion of the area containing both the first physical mark and the second physical mark, The fabric base is designed for use on a horizontal surface.

8. The fabric substrate of claim 7, wherein the first physical marker and the second physical marker are the same.

9. The fabric substrate of claim 7, wherein the first physical marker and the second physical marker are different.

10. The fabric substrate according to claim 7, wherein each of the printing inks A, B, and C comprises a different composition.

11. The fabric substrate according to claim 7, wherein at least two of the printing inks A, B, and C comprise the same composition.

12. The fabric substrate of claim 7, further comprising a third physical marker.

13. The fabric substrate of claim 12, further comprising a fourth physical marker.

14. The fabric substrate of claim 13, wherein the third and fourth physical markings are different from each other.

15. The fabric substrate of claim 7, wherein each physical marking is detectable by hardware, which transmits printing instructions to a digital printer via software to apply at least one of printing inks A, B, and C to the fabric substrate.

16. The fabric substrate of claim 7, wherein the fabric substrate comprises a printed ink in precise registration with at least one area comprising a first physical marking.

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