Patterned tufted articles, surface coverings comprising same, and systems and methods of making and using same

Abstract

A tufted article (e.g., an artificial turf panel) having a backing and a plurality of tufts extending through the backing. The plurality of tufts are distributed among a plurality of patterned regions. Each patterned region has at least one tuft of the plurality of tufts. The tufts of each patterned region differ from the tufts of at least one other patterned region of the tufted article in at least one of color, pile height, yarn type, or yarn density. At least one patterned region creates a longitudinal discontinuity in the color pattern of the tufted article. The tufted article does not have a seam. Complementary side edges of the tufted articles can be secured together to form at least a portion of the surface covering without the need for cutting or the use of inlay components.

What is claimed is: 
     
         1 . A tufted article for a portion of a field, the tufted article having a length along a first longitudinal axis and a width along a second longitudinal axis that is perpendicular to the first longitudinal axis, wherein the first longitudinal axis and the second longitudinal axis are perpendicular to a vertical axis, the tufted article comprising:
 a backing having a continuous structure; and   a plurality of regions, wherein each region comprises a plurality of tufts extending through at least a portion of the backing along the vertical axis, and wherein the plurality of regions form a color pattern,
 wherein a first subset of regions and a second subset of regions of the plurality of regions form a plurality of alternating discontinuities in the color pattern along at least the first longitudinal axis. 
   
     
     
         2 . The tufted article of  claim 1 , wherein the first subset of regions and the second subset of regions of the plurality of regions form a second plurality of alternating discontinuities in the color pattern along the second longitudinal axis. 
     
     
         3 . The tufted article of  claim 1 , wherein the plurality of regions comprise:
 a first tuft sequence extending along the first longitudinal axis, and a second tuft sequence extending along a third longitudinal axis that is at an oblique angle with respect to the first longitudinal axis.   
     
     
         4 . The tufted article of  claim 3 , wherein the first subset of regions and the second subset of regions of the plurality of regions form a third plurality of alternating discontinuities in the color pattern along the third longitudinal axis. 
     
     
         5 . The tufted article of  claim 4 , wherein the oblique angle comprises an acute angle with respect to the first longitudinal axis. 
     
     
         6 . The tufted article of  claim 1 , wherein the color pattern formed by the plurality of regions comprise a graphical pattern. 
     
     
         7 . The tufted article of  claim 6 , wherein the graphical pattern comprises a plurality of shapes including lines, markers, symbols, or any combination of these. 
     
     
         8 . The tufted article of  claim 1 , wherein the first subset of regions of the plurality of regions comprises a first color that is different from a second color of the second subset of regions of the plurality of regions. 
     
     
         9 . The tufted article of  claim 8 , wherein each region of the plurality of regions comprise the plurality of tufts having a same or substantially same color. 
     
     
         10 . The tufted article of  claim 8 , wherein the plurality of alternating discontinuities in the color pattern comprise a first tuft sequence along the first longitudinal axis and a second tuft sequence along a third longitudinal axis that is angled obliquely with respect to the first longitudinal axis. 
     
     
         11 . The tufted article of  claim 1 , wherein the color pattern defined by the plurality of tufts of the plurality of regions represents grass of a sports field. 
     
     
         12 . The tufted article of  claim 1 , wherein regions of the plurality of regions of the tufted article arranged along respective edges of the tufted article align with complementary regions of adjacent tufted articles to define the color pattern when two or more tufted articles form a surface covering. 
     
     
         13 . The tufted article of  claim 12 , wherein corresponding regions of adjacent tufted articles of the two or more tufted articles cooperatively define a continuous pattern along respective complementary edges of the adjacent tufted articles. 
     
     
         14 . The tufted article of  claim 12 , wherein the color pattern comprises a continuous pattern extending from the tufted article to a second tufted article when the second tufted article is in alignment with the tufted article. 
     
     
         15 . A method of manufacturing a tufted article comprising:
 tufting a plurality of tufts through a continuous backing, wherein tufting the plurality of tufts through the continuous backing comprises:
 generating, using one or more sequentially positioned tufting machines, a tufting pattern comprising at least one tufting parameter for a plurality of regions of the tufted article, each tufting machine comprising a first plurality of needles configured to receive a yarn having a first color and a second plurality of needles configured to receive a yarn having a second, different color, 
 wherein generating the tufting pattern comprises tufting alternating discontinuous regions of the plurality of regions to form a color pattern along at least a first longitudinal axis. 
   
     
     
         16 . The method of manufacturing of  claim 15 , wherein generating the tufting pattern further comprises, tufting alternating discontinuous regions of the plurality of regions to form the color pattern along a second longitudinal axis aligned at an oblique angle with respect to the first longitudinal axis. 
     
     
         17 . The method of manufacturing of  claim 16 , wherein generating the tufting pattern comprises:
 generating a first tuft sequence and a second tuft sequence that each extend along the first longitudinal axis or the second longitudinal axis.   
     
     
         18 . The method of manufacturing of  claim 17 , wherein generating the first tuft sequence comprises forming the first tuft sequence by a first needle of a first tufting machine of the one or more sequentially positioned tufting machines, and
 wherein generating the second tuft sequence comprises forming the second tuft sequence by a second needle of a second tufting machine of the one or more sequentially positioned tufting machines.   
     
     
         19 . The method of manufacturing of  claim 17 , wherein generating the tufting pattern comprises tufting the plurality of regions to form a graphical pattern comprising a plurality of shapes including lines, markers, symbols, or any combination of these. 
     
     
         20 . The method of manufacturing of  claim 17 , wherein generating the tufting pattern comprising tufting the plurality of regions of the tufted article such that edges of the tufted article align with complementary regions of adjacent tufted articles to define the color pattern when two or more tufted articles form a surface covering.