Yarn With Sections Having Different Aesthetic Characteristics, Articles Comprising Same, And Methods Of Making Said Yarn And Articles

This application is a continuation of U.S. patent application Ser. No. 18/075,771, filed Dec. 6, 2022, which claims priority to and the benefit of the filing date of U.S. Provisional Patent Application No. 63/286,323, filed Dec. 6, 2021, which is incorporated herein by reference in its entirety.

FIELD

This disclosure is directed to surface covering articles (e.g., tufted, woven, or knitted surface covering articles) comprising yarns (e.g., engineered yarn structures) having sections with different aesthetic characteristics, and systems and methods for making said yarn and said articles. The yarns can be associated with a primary backing. In some examples, the yarns can be tufted through, woven through, or knitted through the primary backing.

Yarn can be tufted, woven, or knitted into a backing to form surface covering articles, such as, for example, carpet. In order to prevent noticeable flaws in the article, yarns must either (1) be uniform (to avoid variations from uniformity that lead to undesirable looks such as streaks); or (2) have a particular, consistent pattern (to avoid visible deviations from said pattern that are identifiable as a flaw). Both alternatives are associated with their own costs and lead to waste when uniformity and/or pattern requirements are not met.

Moreover, leftover yarn is typically a waste product having a cost associated with disposal thereof. Accordingly, a use for small batches of leftover yarn is desirable.

Yarns can be dyed along their lengths according to a method called “space dying.” However, these space-dyed yarns have long (several centimeter) transitions between dyed sections that can look undesirable in tufted articles. Further, space dying yarn is an expensive process.

Disclosed herein is an article comprising a backing and a plurality of yarns tufted, woven, or knitted through the backing, each yarn defining at least one aesthetic characteristic. The at least one aesthetic characteristic can comprise one or more of luster, color, size, physical attribute associated with material type, or texture. At least one yarn of the plurality of yarns can comprise an engineered yarn structure comprising a first yarn section and a second yarn section. The engineered yarn structure can comprise a transition junction that comprises commingled portions of the first yarn section and the second yarn section. The transition junction can have a length of less than 1 millimeter. The first yarn section can have a first type of a first aesthetic characteristic of the at least one aesthetic characteristic, and the second yarn section can have a second type of the first aesthetic characteristic that is different from the first type. Optionally, the first and second yarn sections can correspond to respective yarn segments that are joined together via the transition junction.

In one aspect, a method can comprise tufting, weaving, or knitting a plurality of yarns through a backing. Each yarn can define at least one aesthetic characteristic, wherein the at least one aesthetic characteristic comprises one or more of luster, color, size, physical attribute associated with material type, or texture. At least one yarn of the plurality of yarns can comprise an engineered yarn structure comprising a first yarn section and a second yarn section. The engineered yarn structure can comprise a transition junction that comprises commingled portions of the first yarn section and the second yarn section. The transition junction can have a length of less than 1 millimeter. The first yarn section can have a first type of a first aesthetic characteristic of the at least one aesthetic characteristic, and the second yarn section can have a second type of the first aesthetic characteristic that is different from the first type. Optionally, the first and second yarn sections can correspond to respective yarn segments that are joined together via the transition junction.

A method can comprise tufting, weaving, or knitting a plurality of yarns through a backing. A first yarn of the plurality of yarns can comprise an engineered yarn structure comprising a first yarn section and a second yarn section. The engineered yarn structure can comprise a transition junction that comprises commingled portions of the first yarn section and the second yarn section. The transition junction can have a length of less than 1 millimeter. The first yarn section can have a first type of a first aesthetic characteristic selected from luster, color, size, physical attribute associated with material type, or texture. The second yarn section can have a second type of the first aesthetic characteristic that is different from the first type.

In one aspect, a method can comprise forming a yarn comprising an engineered yarn structure comprising a first yarn section and a second yarn section. The engineered yarn structure can comprise a transition junction that comprises commingled portions of the first yarn section and the second yarn section. The transition junction can have a length of less than 1 millimeter. The first yarn section can have a first type of a first aesthetic characteristic of the at least one aesthetic characteristic, and the second yarn section can have a second type of the first aesthetic characteristic that is different from the first type. Optionally, the first and second yarn sections can correspond to respective yarn segments that are joined together via the transition junction.

Additional advantages of the disclosed system and method will be set forth in part in the description which follows, and in part will be understood from the description, or may be learned by practice of the disclosed system and method. The advantages of the disclosed system and method will be realized and attained by means of the elements and combinations particularly pointed out in the appended claims. It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the invention as claimed.

The disclosed articles, systems and methods may be understood more readily by reference to the following detailed description of particular embodiments and the examples included therein and to the Figures and their previous and following description.

It is to be understood that the terminology used herein is for the purpose of describing particular embodiments only and is not intended to limit the scope of the present disclosure which will be limited only by the appended claims.

It must be noted that as used herein and in the appended claims, the singular forms “a,” “an,” and “the” include plural references unless the context clearly dictates otherwise. Thus, for example, reference to “a section” includes one or more of such sections, and so forth.

“Optional” or “optionally” means that the subsequently described event, circumstance, or material may or may not occur or be present, and that the description includes instances where the event, circumstance, or material occurs or is present and instances where it does not occur or is not present.

Ranges may be expressed herein as from “about” one particular value, and/or to “about” another particular value. When such a range is expressed, also specifically contemplated and considered disclosed is the range from the one particular value and/or to the other particular value unless the context specifically indicates otherwise. Similarly, when values are expressed as approximations, by use of the antecedent “about,” it will be understood that the particular value forms another, specifically contemplated embodiment that should be considered disclosed unless the context specifically indicates otherwise. It will be further understood that the endpoints of each of the ranges are significant both in relation to the other endpoint, and independently of the other endpoint unless the context specifically indicates otherwise. Finally, it should be understood that all of the individual values and sub-ranges of values contained within an explicitly disclosed range are also specifically contemplated and should be considered disclosed unless the context specifically indicates otherwise. The foregoing applies regardless of whether in particular cases some or all of these embodiments are explicitly disclosed.

Optionally, in some aspects, when values are approximated by use of the antecedents “about,” “substantially,” or “generally,” it is contemplated that values within up to 15%, up to 10%, up to 5%, or up to 1% (above or below) of the particularly stated value or characteristic can be included within the scope of those aspects.

Unless defined otherwise, all technical and scientific terms used herein have the same meanings as commonly understood by one of skill in the art to which the disclosed apparatus, system, and method belong. Although any apparatus, systems, and methods and materials similar or equivalent to those described herein can be used in the practice or testing of the present apparatus, system, and method, the particularly useful methods, devices, systems, and materials are as described.

Throughout the description and claims of this specification, the word “comprise” and variations of the word, such as “comprising” and “comprises,” means “including but not limited to,” and is not intended to exclude, for example, other additives, components, integers or steps. In particular, in methods stated as comprising one or more steps or operations it is specifically contemplated that each step comprises what is listed (unless that step includes a limiting term such as “consisting of”), meaning that each step is not intended to exclude, for example, other additives, components, integers or steps that are not listed in the step.

It is to be understood that unless otherwise expressly stated, it is in no way intended that any method set forth herein be construed as requiring that its steps be performed in a specific order. Accordingly, where a method claim does not actually recite an order to be followed by its steps or it is not otherwise specifically stated in the claims or descriptions that the steps are to be limited to a specific order, it is in no way intended that an order be inferred, in any respect. This holds for any possible non-express basis for interpretation, including: matters of logic with respect to arrangement of steps or operational flow; plain meaning derived from grammatical organization or punctuation; and the number or type of aspects described in the specification. Thus, words denoting order, such as “first” or “next,” should be interpreted as optional aspects unless plain meaning or logic dictates otherwise.

The term “yarn” as used herein refers to a continuous strand or bundle of fibers. Such yarns can include, for example and without limitation, monofilament yarns, cut yarns, looped yarns, fibrillated yarns, multifilament yarns, twisted yarns, wrapped yarns, staple yarns, and the like. Optionally, yarns can be textured using conventional methods. “Yarns” as disclosed herein are capable of being independently delivered to a backing structure (for example, via tufting). A yarn can be a single end yarn (single ply yarn) or a multiple end yarn (e.g., a plied yarn) that includes plurality of single end yarns that are entangled or otherwise commingled with one another (for example, by air entanglement, twisting, wrapping, and the like) such that the single end yarns are no longer individually or independently moveable. For example, a plurality of single end yarns can be twisted together to form a plied yarn (e.g., a two-ply yarn can include two single end yarns that are twisted together). Each single end yarn can be formed from at least one filament (optionally, a plurality of filaments). Thus, within a multiple end yarn, each single end yarn that makes up the multiple end yarn can include a respective filament or plurality of filaments.

Disclosed herein with reference tois a yarnhaving an engineered yarn structure comprising a first yarn sectionand a second yarn section, with a transition junctioncomprising commingled portions of the first yarn section and the second yarn section. The yarncan further comprise a third yarn section. A transition junctioncan comprise commingled portions of the second yarn section and the third yarn section. As used herein, the term “commingled” refers to a structural arrangement in which respective components are mingled or amalgamated together. The yarncan comprise any number of yarn sections (e.g., 2-20 sections or 3-10 sections) with a respective transition junction at least partially formed by commingled portions of sequential and/or adjacent yarn sections.

Optionally, at least one of (optionally, each of) the transition junctions (e.g., the transition junctionand/or the transition junction) can have a length of less than ten millimeters, less than four millimeters, less than 2 millimeters, or less than one millimeter. As further described herein, each yarn section of yarncan correspond to a respective yarn segment, which can optionally be embodied as a discarded or leftover portion of yarn or a non-compliant (off-specification) portion of yarn. More generally, it is contemplated that each yarn segment (that forms a respective yarn section) can correspond to a discrete length of yarn that is joined with other discrete lengths of yarn (other yarn segments) to form a yarn structure as disclosed herein.

The yarncan define one or more aesthetic characteristics. The one or more aesthetic characteristics can comprise one or more of a color, a luster, a size (e.g., a diameter and/or a number of fibers), a physical attribute associated with material type, or a texture. In further aspects, the at least one aesthetic characteristic can be a function of a polymer type(s) and/or a shrinkage rate. Each yarn section (e.g., the first, second, and third sections,,) can have a respective type of each aesthetic characteristic associated therewith. For example, the first yarn sectioncan have a first type of a first aesthetic characteristic, and the second yarn sectioncan have a second type of the first aesthetic characteristic. The third yarn sectioncan have a third type of the first aesthetic characteristic. In one example, the first aesthetic characteristic is a color. Thus, the first yarn sectioncan have a first color, and the second yarn sectioncan have a second color. In another example, the first aesthetic characteristic can be a luster. In this example, the first yarn sectioncan have a first luster, and the second yarn sectioncan have a second luster. In some examples, each yarn section can define a first aesthetic characteristic and a second aesthetic characteristic. In some aspects, the first and second yarn sections,can have different types of the first aesthetic characteristic. In further aspects, the first and second yarn sections can further have the same or different types of the second aesthetic characteristic.

Each yarn section can comprise a plurality of fibers. The transition junctioncan be formed by splicing (e.g., air splicing) the first yarn section to the second yarn section. Although air splicing is one specific method for joining (and commingling) the yarn sections, it is contemplated that any conventional splicing or yarn joining method can be employed. In addition to, or as an alternative to air splicing, it is contemplated that the transition junctions can be formed by wrap splicing, mechanical knotting, twisting, entanglement (e.g., air entanglement), or combinations thereof. Accordingly, the transition junctioncan comprise fibers of the first yarn sectioncommingled with fibers of the second yarn section. Thus, the transition junctioncan comprise aesthetic characteristics associated with each of the first yarn section and the second yarn section. Thus, unlike conventional yarn splicing, wherein yarns of the same aesthetic characteristics are joined, the adjacent yarn sections can have different aesthetic characteristics, with the different aesthetic characteristics mixed within each transition junction.

Optionally, the yarncan comprise sequential yarn sections that are joined at respective transition junctions and that alternate between the first and second type of the first aesthetic characteristic. Thus, the first and third yarn sections,can share the same type of first aesthetic characteristic, with the second yarn sectionbeing different from the first and third sections. Optionally, the first and third yarn sections,can be identical in terms of aesthetic characteristics. In further aspects, the first aesthetic characteristic of the third yarn section can be a third type that is different from the respective first aesthetic characteristics of the first and second yarn sections,.

In some aspects, each section (e.g., the first, second, and third yarn sections,,) can have the same length. In further aspects, each yarn section can have a different length. In yet further aspects, some yarn sections can have the same length, and other yarn sections can have a different length. For example, the first yarn sectioncan have a first length L, the second yarn sectioncan have a second length L, and the third yarn sectioncan have a third length L. Optionally, the first length Lcan be different from the second length L. It is contemplated that the length of each yarn section can be randomly generated or selected during formation of the yarnas further disclosed herein. Thus, each of the first length Land the second length Lcan be randomly generated. In various optional aspects, the length of each segment can be from about 800 meters to about 5000 meters, or from about 1000 meters to about 3000 meters.

In some optional aspects, the first aesthetic characteristic can be uniform along each yarn section. In other aspects, the first aesthetic characteristic can vary along at least one yarn section of the yarn. In some optional aspects, the first aesthetic characteristic can be uniform through a cross section of the yarn, which can contrast to, for example, yarn that has aesthetic characteristics imparted through dying of the yarn.

Referring also to, the yarncan be formed into a yarn packagecomprising a bobbin(or tube) with the yarn wound therearound.

Referring also to, an articlecan comprise a backing(e.g., a primary backing) and a plurality of yarnstufted, woven, or knitted therethrough. At least one yarn of the plurality yarnscan be in accordance with the yarnas disclosed herein. Accordingly, at least one yarn of the plurality of yarnscan be a yarncomprising an engineered yarn structure having a first yarn sectionand a second yarn section. The engineered yarn structure can comprise a transition junctioncomprising commingled portions of the first yarn sectionand the second yarn section. The transition junction can have a length of less than ten millimeters, less than four millimeters, less than two millimeters, or less than one millimeter.

Optionally, yarn(s)of the plurality of yarnscan further comprise a third yarn sectionand a transition junctionthat comprises commingled portions of the second and third yarn sections,. The yarncan comprise any number of yarn sections (e.g., 2-20 sections or 3-10 sections). The transition junctioncan have a length of less than ten millimeters, less than four millimeters, less than 2 millimeters, or less than one millimeter.

Each yarn section (e.g., the first, second, and third yarn sections,,) of the yarn(s)of the plurality of yarnscan define at least one aesthetic characteristic. The at least one aesthetic characteristic can comprise one or more of a color, a luster, a size (e.g., a diameter or a number of fibers), or a texture. Each yarn section can have a respective type of each aesthetic characteristic associated therewith. For example, the first yarn sectioncan have a first type of a first aesthetic characteristic, and the second yarn sectioncan have a second type of the first aesthetic characteristic. When provided, the third yarn sectioncan have a third type of the first aesthetic characteristic. In one example, the first aesthetic characteristic is a color. Thus, the first yarn sectioncan have a first color, and the second yarn section can have a second color. In another example, the first aesthetic characteristic can be a luster. The first yarn sectioncan have a first luster, and the second yarn section can have a second luster. In some examples, each yarn section can define a first aesthetic characteristic and a second aesthetic characteristic. The first and second yarn sections,can have different types of the first aesthetic characteristic. The first and second yarn sections,can further have the same or different types of the second aesthetic characteristic. Optionally, yarn sections can differ in combinations of one or several aesthetic characteristics (e.g., color, luster, size, texture, polymer, or shrinkage). Optionally, the yarn sections can differ due to different material properties. For example, each yarn section can comprise, or consist of, or consist essentially of nylon 6, nylon 66, polyethylene terephthalate (PET), polypropylene, wool, or a combination thereof. Yarns made of different materials can have different aesthetic characteristics. Each yarn section can comprise any number of yarn plies (e.g., the number of yarn plies can be the same as or different from adjacent sections or other sections of the same yarn).

Optionally, the at least one yarnof the plurality of yarnscan comprise sequential yarn sections that are joined at respective transition junctions and that alternate between the first and second type of the first aesthetic characteristic. Thus, for example, the first and third yarn sections,of the at least one yarncan share the same type of first aesthetic characteristic (e.g., a first type of the first aesthetic characteristic), with the first aesthetic characteristic of the second section(e.g., a second type of the first aesthetic characteristic) being different from the first aesthetic characteristic of the first and third yarn sections,. Optionally, the first and third yarn sections,can be identical in terms of aesthetic characteristics. In further aspects, the first aesthetic characteristic of the third yarn sectioncan be a third type that is different from the respective first aesthetic characteristics of the first and second yarn sections,.

Optionally, some (e.g., at least 20%, between 20% and 80%, or up to 80%) of the yarns or all the yarns of the articlecan be in accordance with the yarnas disclosed herein. Each respective yarncan be tufted into a respective row using conventional tufting methods. Each yarncan form tuftsin respective rowsthat extend along a tufting axis. The articlecan have a tufting axisalong which each rowextends. Similarly, in further aspects, each yarncan be woven or knitted into respective rows using conventional weaving or knitting methods.

A yarncan form a plurality of tuftswithin a single row. The yarncan be tufted by a single needle (e.g., a single needle of a needle bar) to form the plurality of tuftswithin the single row. The tuftsof the single rowcan comprise tufts formed from the first yarn sectionand the second yarn section. In some aspects, a portion of the tuftswithin a rowcan consist of the first yarn section and a portion of the tufts of the row can consist of the second yarn section. The transition junctioncan be disposed within the single rowand can be positioned at a location (e.g., within a tuft) between tuftsformed entirely from the first yarn sectionand tufts formed entirely from the second yarn section. Optionally, in some aspects, the yarncan further comprise a third yarn section and a second transition junctionformed by commingled portions of the second and third yarn sections. In these aspects, it is contemplated that a portion of the tuftswithin the rowcan consist of the third yarn section, with the second transition junction disposed within the rowand positioned at a location (e.g., within a tuft) between tufts formed entirely from the second yarn section and tufts formed entirely from the third yarn section. In exemplary aspects, the tuftswithin each rowcan be loop or cut pile or combinations of loop and cut pile.

In some aspects, the articlecan have at least a first yarnand a second yarn, each having a structure in accordance with yarn. A first yarn sectionof the first yarnand a first yarn sectionof the second yarncan each have a respective starting location,along the tufting axisat which the respective sections begin. Optionally, the starting locationof the first yarn sectionof the first yarncan be axially offset from the starting locationof the first yarn sectionof the second yarnalong the tufting axis. Alternatively, the starting locations,can be in alignment or even or substantially even along the tufting axis.

In some aspects, each yarn section (e.g., the first, second, and third yarn sections,,) of one or more yarns of the plurality of yarnscan have the same length. In further aspects, each yarn section of one or more yarns of the plurality of yarnscan have a different length. In yet further aspects, some yarn sections of one or more yarns of the plurality of yarnscan have the same length, and other yarn sections of the same yarns can have a different length. For example, and with reference to, for at least one yarn of the plurality of yarns, the first yarn sectioncan have a first length L, the second yarn sectioncan have a second length L, and the third yarn sectioncan have a third length L. Optionally, the first length Lcan be different from the second length L. It is contemplated that the length of each yarn section can be randomly generated during formation of the yarns. Thus, each of the first length Land the second length Lcan be randomly generated. In various optional aspects, the length of each yarn can be from about 800 meters to about 5000 meters, or from about 1000 meters to about 3000 meters.

Optionally, adjacent (side-by-side or parallel) yarn sections of adjacent yarns can have different lengths. For example, the first and second yarnscan be adjacent each other. As shown, the first yarncan have a first yarn section, and the second yarncan have a second yarn section, wherein the first yarn sectionand first yarn sectionare adjacent. The first yarn sectionsandcan optionally have different lengths. This can advantageously prevent patterns forming in the tufted, woven, or knitted article.

Referring to, a method can comprise tufting, weaving, or knitting the plurality of yarnsthrough a backing, wherein each yarn defines an aesthetic characteristic or a plurality of aesthetic characteristics. One or more yarns of the plurality of yarns can be embodied as yarnas disclosed herein. Thus, the one or more yarns can each comprise an engineered yarn structure having a first yarn sectionand a second yarn section. The engineered yarn structure can comprise a transition junctionhaving commingled portions of the first and second yarn sections, wherein the transition junction has a length of less than ten millimeters, less than four millimeters, less than two millimeters, or less than one millimeter. Optionally, some (e.g., at least 20%, between 20% and 80%, or up to 80%) of the yarns or all the yarnscan be in accordance with the yarnas disclosed herein.

The method can comprise drawing the plurality of yarns from respective yarn packages, wherein at least one yarn package of the respective yarn packages comprises a plurality of sections, wherein each section of the plurality of sections differs from adjacent sections by the aesthetic characteristic. The yarn packages can, for example, be positioned on a creel that feeds the yarn of the yarn packages into a textile machine (e.g., a tufting machine, a weaving machine, or a knitting machine). In exemplary aspects, it is contemplated that each section of the plurality of sections of a yarn packagecan correspond to a respective yarn section in a yarn.

Referring to, the backingcan be moved along the tufting axis, and the plurality of yarnscan be tufted through the backing to form a plurality of rows that extend along the tufting axis. Optionally, the plurality of yarns can be tufted so that respective yarn sections of two yarns (e.g., adjacent yarn sections,of the first and second yarns) can have respective starting locations,along the tufting axis, with the starting location of the first section of the first yarn in a location that is axially offset from the starting locationof the first section of the second yarn along the tufting axis. Although it should be understood that knitting and weaving have respective knitting and weaving axes, for conciseness, these axes are referred to herein generally as tufting axes.

A method can comprise forming a yarncomprising an engineered yarn structure having a first yarn sectionand a second yarn section,. The engineered yarn structure can comprise a transition junctionthat comprises commingled portions of the first and second yarn sections. The transition junction can have a length of less than 4 millimeters, less than 2 millimeters, or less than 1 millimeter. The first yarn sectioncan have a first type of a first aesthetic characteristic, and the second yarn sectioncan have a second type of the first aesthetic characteristic that is different from the first type. Forming the yarncan comprise splicing or otherwise securely coupling a first yarn segment with a second yarn segment (e.g., via a transition junction), wherein the first yarn segment has the first type of the first aesthetic characteristic, and wherein the second yarn segment has the second type of the first aesthetic characteristic. As further described herein, the first and second yarn sections can correspond to respective yarn segments that are joined together to produce a unitary yarn structure. Optionally, the first and second yarn segments can be leftover yarns (or portions of yarns) or yarn that is off specification from an intended specification. Thus, instead of disposing of leftover or off-specification yarns as waste, the first and second yarn segments can be formed into yarn.

In some optional aspects, an apparatuscan be configured to form the yarn. The apparatuscan assemble a plurality of yarns to form the yarn. The apparatuscan receive yarn from a yarn supplycomprising a plurality of yarns. The type of each aesthetic characteristic of each yarncan optionally be uniform along its length. Each yarncan optionally be leftover yarn or yarn that is off specification from an intended specification. The apparatuscan comprise an assembler(e.g., an air splicer or a heat splicer) that is configured to selectively assemble yarnsfrom the yarn supplyto form a yarn. The apparatuscan optionally be in communication with a winderthat is configured to wind yarn from the apparatusinto a yarn package.

The apparatuscan be in communication with a controllerthat determines which yarnthe apparatus draws from. Thus, the controller can determine, based on the yarnsin the yarn supply, the aesthetic characteristics of each segment of the yarnby determining the yarnfrom which the apparatusis drawing. The controllercan further determine the length of each segment formed by the apparatus. Optionally, the controllercan be integral to the apparatus. In further aspects, the controllercan be separate from and in communication with the apparatus.

In some aspects, the controllercan use a randomization algorithm to randomly select between yarnsof the yarn supply, thereby causing the first section of at least one yarn of the at least one yarn to have a random type of aesthetic characteristic. In further aspects, the controllercan randomly generate a length of the yarnto be formed into a segment of yarn. For example, a randomized time can be generated, and the apparatuscan draw yarn from a given yarnfor the randomized time.

It is contemplated that randomization of the aesthetic characteristic(s) of each yarn segment and/or length can be particularly advantageous in avoiding undesirable features in a tufted, woven, or knitted article. For example, it can be understood that if all lengths of segments of yarn are identical, patterns repeat along the article (along the tufting axisin which each yarn forms tufts). Similarly, if ends of adjacent yarns are aligned and segments of adjacent yarns have the same length, thick lines that are perpendicular to the tufting axisin which each yarn forms tufts would appear. That is, tufts formed from different-looking yarns next to each other appear to blend together to provide the appearance of a color gradient, whereas multiple yarns of the same aesthetic characteristic(s) across the tufted article transverse to the tufting axisform a noticeable elongate portion that stands out and does not blend with the rest of the tufted article, and can be perceived as undesirable. Similarly, randomization of the aesthetic characteristic(s) can avoid unintentional streaks formed by adjacent yarns having the same aesthetic characteristic(s). Randomization of the aesthetic characteristic(s) can further avoid a need for an operator to order yarn packages in a particular order on a creel that feeds a tufting apparatus.

It can be understood that the disclosed systems and methods can form tufted, woven, or knitted articles having desirable aesthetic patterns. For example, as shown in, the articles can have random or seemingly random patterns. In exemplary aspects, the random or seemingly random patterns can result from the selection and joining of sections of available leftover or off-specification yarn, which can provide an unpredictable and/or random combination of aesthetic properties and sizes. Further, the disclosed articles do not undesirably form long runs from inadvertent alignment of multiple yarns of identical aesthetic characteristic types (e.g., the same color) as can be the case in other patterns where operators are required to introduce randomness. Moreover, as further described herein, the disclosed systems and methods enable use of leftover or off-specification yarn, thereby reducing waste.

In view of the described products, systems, and methods and variations thereof, herein below are described certain more particularly described aspects of the invention. These particularly recited aspects should not however be interpreted to have any limiting effect on any different claims containing different or more general teachings described herein, or that the “particular” aspects are somehow limited in some way other than the inherent meanings of the language literally used therein.

Aspect 1: An article comprising:

Aspect 2: The article of aspect 1, wherein the first aesthetic characteristic is color, wherein the first type is a first color, and wherein the second type is a second color.