Artificial Turf Assembly And Process Of Manufacture Thereof

Abstract

A tufted article can have a length along a first axis and width along a second axis that is perpendicular to the first axis. The tufted article can comprise a backing and a plurality of tufts extending through the backing. The plurality of tufts can be distributed among a plurality of tuft sequences. Each tuft sequence can comprise at least one tuft of the plurality of tufts. The tufts of each tuft sequence can be formed sequentially by a single needle of a tufting machine. Each tuft sequence of the plurality of tuft sequences can be spaced from other tuft sequences of the plurality of tuft sequences along at least one of the first axis or the second axis. In some aspects, no tuft sequence of the plurality of tuft sequences extends across the entire length or the entire width of the backing.

1 . A tufted article having a length along a first axis and a width along a second axis that is perpendicular to the first axis, the first and second axes being perpendicular to a vertical axis, the tufted article comprising:
 a backing; and   a plurality of tufts extending through the backing, the plurality of tufts distributed among a plurality of tuft sequences, wherein each tuft sequence comprises at least one tuft of the plurality of tufts, wherein the tufts of each tuft sequence are formed sequentially by a single needle of a tufting machine,   wherein each tuft sequence of the plurality of tuft sequences is spaced from other tuft sequences of the plurality of tuft sequences along at least one of the first axis or the second axis, and   wherein no tuft sequence of the plurality of tuft sequences extends across the entire length or the entire width of the tufted article.   
     
     
         2 . The tufted article of  claim 1 , wherein each tuft sequence of the plurality of tuft sequences comprises from 1 to 10 tufts. 
     
     
         3 . The tufted article of  claim 1 , wherein the plurality of tuft sequences comprises a first plurality of tuft sequences having from 2 to 3 tufts and a second plurality of tuft sequences having from 4 to 7 tufts. 
     
     
         4 . The tufted article of  claim 1 , wherein the tufts of each tuft sequence of the plurality of tuft sequences have a respective pile height, and wherein the pile height of tufts of a first tuft sequence of the plurality of tuft sequences is different than the pile height of tufts of at least a second tuft sequence of the plurality of tuft sequences. 
     
     
         5 . The tufted article of  claim 4 , wherein the pile height of tufts of a third tuft sequence of the plurality of tuft sequences is different than the pile height of tufts of the first and second tuft sequences. 
     
     
         6 . The tufted article of  claim 1 , wherein a first tuft sequence of the plurality of tuft sequences comprises a first yarn, and wherein a second tuft sequence of the plurality of tuft sequences comprises a second yarn that is different from the first yarn in at least one of material, color, texture, denier and cross-section. 
     
     
         7 . The tufted article of  claim 1 , wherein a first tuft sequence of the plurality of tuft sequences extends along a first longitudinal axis, and wherein a second tuft sequence of the plurality of tuft sequences extends along a second longitudinal axis that is oriented at an oblique angle with respect to the first longitudinal axis. 
     
     
         8 . The tufted article of  claim 7 , wherein the first tuft sequence has a length along the first longitudinal axis, wherein the second tuft sequence has a length along the second longitudinal axis, and wherein the length of the first tuft sequence is different than the length of the second tuft sequence. 
     
     
         9 . The tufted article of  claim 1 , wherein a first tuft sequence of the plurality of tuft sequences extends along a first longitudinal axis, and wherein a second tuft sequence of the plurality of tuft sequences extends along a second longitudinal axis that is oriented perpendicular to the first longitudinal axis. 
     
     
         10 . The tufted article of  claim 9 , wherein the first tuft sequence has a length along the first longitudinal axis, wherein the second tuft sequence has a length along the second longitudinal axis, and wherein the length of the first tuft sequence is different than the length of the second tuft sequence. 
     
     
         11 . The tufted article of  claim 1 , wherein a first tuft sequence of the plurality of tuft sequences extends along a first longitudinal axis, and wherein a second tuft sequence of the plurality of tuft sequences extends along a second longitudinal axis that is oriented parallel to the first longitudinal axis. 
     
     
         12 . The tufted article of  claim 11 , wherein the first tuft sequence has a length along the first longitudinal axis, wherein the second tuft sequence has a length along the second longitudinal axis, and wherein the length of the first tuft sequence is different than the length of the second tuft sequence. 
     
     
         13 . The tufted article of  claim 1 , wherein first, second, and third tuft sequences of the plurality of tuft sequences are spaced apart relative to the second axis, wherein the second tuft sequence is positioned between the first and third tuft sequences relative to the second axis, wherein the first tuft sequence is spaced from the second tuft sequence by a first distance along the second axis, and wherein the second tuft sequence is spaced from the third tuft sequence by a second distance along the second axis that is different than the first distance. 
     
     
         14 . The tufted article of  claim 1 , wherein the tufted article has a varying strength along the first axis and the second axis. 
     
     
         15 . The tufted article of  claim 1 , wherein a first number of tufts is intersected by a first cross-sectional plane extending parallel to the first axis, wherein a second number of tufts is intersected by a second cross-sectional plane extending parallel to the first axis, wherein a third number of tufts is intersected by a third cross-sectional plane extending parallel to the second axis, wherein a fourth number of tufts is intersected by a fourth cross-sectional plane extending parallel to the second axis, wherein the first number of tufts is different than the second number of tufts, and wherein the third number of tufts is different than the fourth number of tufts. 
     
     
         16 . The tufted article of  claim 1 , wherein the tufted article is artificial turf. 
     
     
         17 . A method of manufacturing a tufted article, the method comprising:
 tufting a plurality of tuft sequences through a backing having length extending along a first axis and a width extending along a second axis that is perpendicular to the first axis, each tuft sequence comprising at least one tuft, wherein the tufts of each tuft sequence are formed sequentially by a single needle of a tufting machine,   wherein each tuft sequence of the plurality of tuft sequences is spaced from other tuft sequences of the plurality of tuft sequences along at least one of the first axis or the second axis, and   wherein no tuft sequence of the plurality of tuft sequences extends across the entire length or the entire width of the backing.   
     
     
         18 . The method of  claim 17 , wherein a first tuft sequence of the plurality of tuft sequences comprises a first yarn, and wherein a second tuft sequence of the plurality of tuft sequences comprises a second yarn that is different from the first yarn in at least one of material, color, texture, denier and cross-section. 
     
     
         19 . The method of  claim 17 , wherein a first tuft sequence of the plurality of tuft sequences extends along a first longitudinal axis, wherein a second tuft sequence of the plurality of tuft sequences extends along a second longitudinal axis that is oriented at an oblique angle with respect to the first longitudinal axis, wherein the first tuft sequence is formed by a first needle of a first tufting machine that defines a first tufting zone, wherein the second tuft sequence is formed by a second needle of a second tufting machine that defines a second tufting zone, and wherein a rotational orientation of the backing relative to the first tufting machine is different than a rotational orientation of the backing relative to the second tufting machine. 
     
     
         20 . The method of  claim 17 , wherein a first tuft sequence of the plurality of tuft sequences extends along a first longitudinal axis, wherein a second tuft sequence of the plurality of tuft sequences extends along a second longitudinal axis that is oriented perpendicular to the first longitudinal axis, wherein the first tuft sequence is formed by a first needle of a first tufting machine that defines a first tufting zone, wherein the second tuft sequence is formed by a second needle of a second tufting machine that defines a second tufting zone, and wherein a rotational orientation of the backing with respect to the first tufting machine is different than a rotational orientation of the backing with respect to the second tufting machine. 
     
     
         21 . The method of  claim 17 , wherein a first tuft sequence of the plurality of tuft sequences extends along a first longitudinal axis, and wherein a second tuft sequence of the plurality of tuft sequences extends along a second longitudinal axis that is oriented parallel to the first longitudinal axis. 
     
     
         22 . The method of  claim 17 , wherein first, second, and third tuft sequences of the plurality of tuft sequences are spaced apart relative to the second axis, wherein the second tuft sequence is positioned between the first and third tuft sequences relative to the second axis, wherein the first tuft sequence is spaced from the second tuft sequence by a first distance along the second axis, and wherein the second tuft sequence is spaced from the third tuft sequence by a second distance along the second axis that is different than the first distance. 
     
     
         23 . The method of  claim 22 , wherein at least one of the first, second, or third tuft sequences is tufted using a first tufting machine having a first gauge spacing between respective needles of the first tufting machine, and wherein at least one other tuft sequence of the first, second, or third tuft sequences is tufted using a second tufting machine having a second gauge spacing between respective needles of the second tuning machine, wherein the second gauge spacing is different than the first gauge spacing. 
     
     
         24 . The method of  claim 22 , wherein at least two of the first, second, and third tuft sequences are collinear relative to the first axis. 
     
     
         25 . The method of  claim 17 , wherein the tufted article is artificial turf. 
     
     
         26 . A system comprising:
 at least one tufting machine, each tufting machine defining a respective tufting zone and comprising a plurality of needles that are configured to deliver yarn into a backing to form a plurality of tufts that extend through the backing, the backing having a length along a first axis and a width along a second axis that is perpendicular to the first axis; and   a backing feed roll that is configured to feed the backing through at least a first tufting machine of the at least one tufting machine; and   at least one controller, wherein each controller of the at least one controller is communicatively coupled with at least one tufting machine of the at least one tufting machine,   wherein the at least one controller is configured to cause the at least one tufting machine to selectively control delivery of yarn into the backing to produce a plurality of tuft sequences, wherein each tuft sequence comprises at least one tuft of the plurality of tufts, wherein the tufts of each tuft sequence are formed sequentially by a single needle of a tufting machine,   wherein each tuft sequence of the plurality of tuft sequences is spaced from other tuft sequences of the plurality of tuft sequences along at least one of the first axis or the second axis, and   wherein no tuft sequence of the plurality of tuft sequences extends across the entire length or the entire width of the backing.   
     
     
         27 . The system of  claim 26 , wherein the controller comprises:
 at least one processor; and   a memory in communication with the at least one processor, wherein the memory comprises instructions that, when executed by the at least one processor, cause the processor to cause the at least one tufting machine to selectively form the plurality of tuft sequences.   
     
     
         28 . The system of  claim 27 , wherein the memory comprises instructions that, when executed by the at least one processor, cause the processor to generate a tufting pattern comprising at least one randomized parameter, wherein the at least one randomized parameter comprises at least one of a spacing between adjacent tuft sequences relative to the second axis, a tuft sequence length, a number of tufts per tuft sequence, a tuft pile height, or a yarn type for a selected position in the backing. 
     
     
         29 . The system of  claim 26 , wherein the at least one tufting machine comprises a plurality of tuning machines, and wherein a first tuning machine of the plurality of tufting machines is rotationally offset from a second tufting machine of the plurality of tufting machines.