Patterned carpet and method
Color, pattern, design, and/or the like is applied by means of a jet dye process, or any other secondary or post pattern application process, including but not exclusively, silk screen printing and rotary printing, etc., to a carpet substrate, where the yarn in the carpet is all white (no dye applied) or where the yarn is pre-dyed with a single or multiple colors or where the yarn is treated chemically. The carpet can, for example, be made with any conventional loom weaving process or hand weaving process, for example Wilton, Axminster, spool, spool gripper, and Chenille looms, hand gun tufted, or any other conventional method.
1. A method of producing sisal-like surface texture woven flooring, comprising this steps of
weaving a woven carpet substrate with a carpet yarn such that the carpet substrate comprises a plurality of interwoven carpet yarns defining a user contact surface having a sisal-like surface texture including a plurality of raised knuckles with interstitial depressors between the raised knuckles,
jet dyeing a design or pattern on the woven carpet substrate by application of a plurality of cooperating dye points at a number of dots per inch (DPI) across the woven carpet; and
cutting or forming the dyed or printed woven carpet substrate into a completed item or product having a sisal-like surface texture, wherein said item or product is selected from the group consisting of an area rug, runner, floor mat, carpet tile, and carpet, wherein the DPI of the applied design or pattern is greater than the number of yarns per inch of the woven carpet substrate.
2. The method as recited in claim 1 , wherein the DPI of the design is at least 10×10 and the number of yarns per inch of the woven carpet is less than 10×10.
3. A flooring product produced by the method of claim 1 .
4. A method of producing a flooring having a woven sisal-like surface texture, comprising the steps of:
chemically treating a woven carpet substrate having a face formed from a plurality of interwoven carpet yarns suck that said carpet substrate is adapted to absorb dyes differently in different areas of the carpet, wherein the interwoven carpet yarns define a user contact surface having a sisal-like surface texture including a plurality of raised knuckles with interstitial depressions between the raised knuckles and the number of yarns per inch of the woven carpet is less than 10×10,
jet dyeing a design or patient on the treated substrate by application of a plurality of cooperating dye points at a number of dots per inch (DPI) across the woven carpet,
and cutting or forming the dyed or printed substrate into a completed item or product selected from the group consisting of an area rug, runner, floor mat, carpet tile and carpet, wherein the DPI of the applied design or pattern is greater than the number of carpet yarns per inch of the carpet substrate.
5. A flaming product produced by the method of claim 4 .
6. The method of claim 4 wherein the DPI of the applied design or pattern is 10×10 or greater.