Patterned carpet and method

Abstract

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 woven pile dyed flooring, comprising the steps of: 
 weaving a woven pile carpet substrate with a carpet. yarn, said woven pile carpet substrate having a pile face,    dyeing a design or pattern on at least the pile face of the woven pile carpet substrate by application of dye at discrete locations across the pile face of the woven pile carpet substrate,    and cutting or forming the dyed woven pile carpet substrate into at least one completed item or product selected from the group consisting of an area rug, runner, carpet tile, and carpet.    
   
   
       2 . The method as recited in  claim 1 , wherein the woven pile substrate is at least one of a woven loop or cut pile carpet substrate.  
   
   
       3 . A woven pile dyed flooring product produced by the method of  claim 1 .  
   
   
       4 . A method of producing woven pile printed flooring, comprising the steps of: 
 weaving a woven pile carpet substrate with a carpet yarn, said woven pile carpet substrate having a pile face;    printing a design or pattern on at least the pile face of the woven pile carpet substrate;    and cutting or forming the printed woven pile carpet substrate into at least one completed item or product selected from the group consisting of an area rug, runner, carpet tile, and carpet.    
   
   
       5 . The method as recited in  claim 4 , wherein the DPI of the printed design or pattern is at least 10×10 and the number of yarns per inch of the woven pile carpet substrate is less than 10×10.  
   
   
       6 . A woven pile printed flooring product produced by the method of  claim 4 .  
   
   
       7 . A woven pile flooring material or item, such as, broadloom carpet, wall to wall carpet, an area rug, carpet, rug, runner, broadloom, or the like having at least one of a background color, design, pattern, over color, or the like printed or dyed on a woven pile carpet substrate having a face yarn which is at least one of all white (no dye applied), pre-dyed with a single color, pre-dyed with multiple colors, naturally colored, chemically treated or combinations thereof.  
   
   
       8 . A method of producing woven pile flooring, such as area rugs, runners, carpets, rugs, broadloom, wall to wall, carpet tiles, or the like, comprising the steps of: 
 chemically treating a woven pile substrate having a face yarn which is at least one of all white (no dye applied), pre-dyed with a single color, pre-dyed with multiple colors, and naturally colored to absorb dyes differently in selected, random or arbitrary areas of the carpet,    dyeing or printing at least one of a background color, design, pattern, border, or combinations thereof on the treated substrate,    and cutting or forming the dyed or printed substrate into a completed item or product such as an area rug, runner, carpet tile, carpet, rug or the like.    
   
   
       9 . The method as recited in  claim 8 , wherein the substrate is at least one of a loop pile or cut pile woven carpet substrate.  
   
   
       10 . The method as recited in  claim 8 , wherein the DPI of the applied design, pattern, border or color is greater than the DPI of the woven pile substrate.  
   
   
       11 . A flooring product, such as an area rug, runner, carpet, rug, or the like produced by the process of  claim 8 .  
   
   
       12 . The method as recited in  claim 1 , wherein the DPI of the applied design or pattern is greater than the DPI of the woven pile carpet substrate.  
   
   
       13 . The method as recited in  claim 1 , wherein the aspect ratio of the applied design or pattern is square.  
   
   
       14 . The method as recited in  claim 13 , wherein the aspect ratio of the woven pile carpet substrate is rectangular.  
   
   
       15 . The method as recited in  claim 1 , wherein the DPI of the applied design or pattern is at least 10×10.  
   
   
       16 . The method as recited in  claim 1 , wherein the DPI of the woven pile substrate is less than 10×10.  
   
   
       17 . The method as recited in  claim 1 , further comprising the step of applying a backing to the woven pile carpet substrate.  
   
   
       18 . The method as recited in  claim 4 , further comprising the step of applying a backing to the woven pile carpet substrate.  
   
   
       19 . The method as recited in  claim 8 , further comprising the step of applying a backing to the woven pile carpet substrate.