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 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.   
     
     
         2 . The method of  claim 1 , wherein the carpet is a broadloom carpet. 
     
     
         3 . The method of  claim 1 , wherein the carpet is a carpet tile. 
     
     
         4 . The method of  claim 1 , 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. 
     
     
         5 . The method of  claim 1 , further comprising selecting a primary backing color for the primary backing layer. 
     
     
         6 . The method of  claim 5 , 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. 
     
     
         7 . The method of  claim 6 , wherein at least one color yarn is selected to achieve the desired color contrast against the primary backing color. 
     
     
         8 . The method 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. 
     
     
         9 . The method of  claim 8 , wherein the primary backing color differs from color of the at least one color yarn. 
     
     
         10 . The method of  claim 1 , wherein the at least one color yarn comprises a plurality of colored yarns. 
     
     
         11 . The method of  claim 1 , further comprising selectively varying the pile height of the tufted yarns over the tufted portion pattern member.