Deconstructed carpet and method of manufacture

Abstract

A deconstructed tufted carpet having an at least partially visible primary backing. In aspects, deconstructed carpet can utilize the primary backing layer as a design element of the overall pattern and styling in order to reduce material use, waste and the ounce weight of the finished carpet and to improve the method of carpet construction. In order to expose the primary backing, at least some yarn can be pulled very low in the pattern areas to expose the primary backing layer. It is contemplated that the primary backing layer can have a color that comprises part of the overall pattern and styling of the carpet.

What is claimed is: 
     
         1 . A carpet comprising:
 a primary backing layer having a top surface;   at least one color yarn tufted in and extending upwardly from at least a portion of the top surface of the primary backing layer to form a tufted portion pattern member having a desired pile height that obscures the underlying top surface of the primary backing layer,   wherein a portion of the primary backing layer is at least partially visible and forms an exposed pattern member that forms part of an overall pattern and styling of the carpet.   
     
     
         2 . The carpet of  claim 1 , wherein the carpet is a broadloom carpet. 
     
     
         3 . The carpet of  claim 1 , wherein the carpet is a carpet tile. 
     
     
         4 . The carpet of  claim 1 , wherein the at least one color yarn is tufted in the exposed pattern and is pulled low enough to expose the primary backing layer. 
     
     
         5 . The carpet of  claim 1 , wherein at least the portion of the primary backing layer forming the exposed pattern member has a primary backing color that comprises part of the overall pattern and styling of the carpet. 
     
     
         6 . The carpet of  claim 5 , Wherein the primary backing layer is formed from the primary backing color. 
     
     
         7 . The carpet of  claim 5 , wherein the at least one color yarn comprise at least one type or color of yarn that is selected to achieve a desired contrast in the overall pattern and styling of the carpet. 
     
     
         8 . The carpet of  claim 7 , wherein at least one color yarn is selected to achieve the desired color contrast against the primary backing color. 
     
     
         9 . The carpet of  claim 5 , the primary backing color should differ from the color of the at least one colored yarn therein the tufted portion pattern member in either one of, or a combination of, hue, chroma, and/or value. 
     
     
         10 . The carpet of  claim 9 , wherein the primary backing color differs from color of the at least one color yarn. 
     
     
         11 . The carpet of  claim 1 , wherein the at least one color yarn comprises a plurality of colored yarns. 
     
     
         12 . The carpet of  claim 1 , wherein the pile height of the tufted yarns selectively varies over the tufted portion pattern member. 
     
     
         13 . The carpet of  claim 1 , wherein the portion of the primary backing layer is visible. 
     
     
         14 . The carpet of  claim 1 , wherein the tufted ounce weight of the carpet is between about 6 to about 25 oz. 
     
     
         15 . The carpet of  claim 1 , wherein the tufted ounce weight of the carpet is between about 8 to about 16 oz. 
     
     
         16 . The carpet of  claim 1 , wherein the tufted ounce weight of the carpet is about 10 oz. 
     
     
         17 . A method for forming a deconstructed carpet, comprising:
 providing a primary backing layer having a top surface;   tufting at least one color yarn in the primary backing layer to extend upwardly from at least a portion of the top surface of the primary backing layer to form a tufted portion pattern member having a desired pile height that obscures the underlying top surface of the primary backing layer,   wherein a portion of the primary backing layer is visible and forms an exposed pattern member that forms part of an overall pattern and styling of the carpet.   
     
     
         18 . The method of  claim 17 , wherein the carpet is a broadloom carpet. 
     
     
         19 . The method of  claim 17 , wherein the carpet is a carpet tile. 
     
     
         20 . The method of  claim 17 , further comprising tufting the at least one color yarn in the exposed pattern and pulling selected yarns low enough to expose the primary backing layer. 
     
     
         21 . The method of  claim 17 , further comprising selecting a primary backing color for the primary backing layer. 
     
     
         22 . The method of  claim 21 , further comprising selecting at least one type or color of yarn to achieve a desired contrast in the overall pattern and styling of the carpet. 
     
     
         23 . The method of  claim 22 , wherein at least one color yarn is selected to achieve the desired color contrast against the primary backing color. 
     
     
         24 . The method of  claim 21 , the primary backing color should differ from the color of the at least one colored yarn therein the tufted portion pattern member in either one of, or a combination of, hue, chroma, and/or value. 
     
     
         25 . The method of  claim 24 , wherein the primary backing color differs from color of the at least one color yarn. 
     
     
         26 . The method of  claim 17 , wherein the at least one color yarn comprises a plurality of colored yarns. 
     
     
         27 . The method of  claim 17 , further comprising selectively varying the pile height of the tufted yarns over the tufted portion pattern member.