Covering for floors and/or walls
View Patent ↗A fabric is provided having discrete surface portions of a primary backing and tufted yarns exposed on the technical face of the fabric. To form the fabric, the yarn feed controlled by servomotors is adjusted in increments to rob back yarn sufficient to pull out the previously tufted loops in selected portions of the fabric, leaving the primary backing portion of the pulled-out loops exposed on the technical face. By the selection process, random or patterned tufted portions and exposed primary backing surface portions are provided on the technical face of the fabric.
1. A method of manufacturing a tufted pile fabric having a technical face with exposed surface portions of tufted yarn and primary backing, comprising the steps of:
(a) providing at least one needle bar carrying a plurality of needles spaced from one another in a weft direction;
(b) supplying yarns to the needles carried by the needle bar;
(c) displacing the needle bar and the primary backing relative to one another in a warp direction;
(d) tufting yarns into the primary backing to form yarn loops on the technical face upon relative displacement of the needle bar and the primary backing;
(e) controlling yarn feed to selected needles during tufting to withdraw through the primary backing yarn loops previously tufted into the primary backing by the selected needles to form discrete surface portions of the primary backing and tufted yarns exposed on the technical face of the fabric;
said method producing the tufted pile fabric having said technical face with exposed surface portions of tufted yarn and primary backing.
2. A method according to claim 1 including providing servomotors for controlling yarn feed and differentially actuating the servomotors to control yarn feed to the selected and non selected needles, respectively.
3. A method according to claim 1 including controlling the yarn feed to selected needles to form a random pattern of tufted and primary backing surface portions exposed on the technical face of the fabric.
4. A method according to claim 1 including controlling the yarn feed to selected needles to form a selected pattern of tufted and primary backing surface portions exposed on the technical face of the fabric.
5. A method according to claim 1 including cutting the loops to form exposed surface portions of cut loop pile and the primary backing.
6. A method according to claim 1 including controlling yard feed to non selected needles to form yarn loops of different heights.
7. A method of manufacturing a tufted pile fabric comprising tufting yarns through a primary backing and pulling selected tufted yarns in their entirety back through the primary backing to form discrete exposed and aesthetically distinct surface portions of the primary backing and the tufted yarns on the technical face of the fabric.
8. A method according to claim 7 including tufting yarns through the entirety of the primary backing prior to pulling selected tufted yarns through the primary backing.
9. A method according to claim 8 including controlling yarn feed to non selected tufted yarns to form yarn loops of different heights.
10. A method according to claim 7 including controlling yarn feed to non selected tufted yarns to form a random pattern of tufted and primary backing surface portions exposed on the technical face of the fabric.
11. A method according to claim 7 including controlling yarn feed to non selected tufted yarns to form a selected pattern of tufted and primary backing surface portions exposed on the technical face of the fabric.
12. A method according to claim 7 including cutting non selected tufted yarns to form cut loop pile on the technical face of the fabric.