HK1171349A - Carpet tiles and methods of producing carpet tiles with diversity of color and texture - Google Patents

Description

Carpet tiles and methods of producing carpet tiles having color and texture diversity

Related application data

The priority OF the U.S. provisional application entitled "carpet tiles AND method OF PRODUCING carpet tiles having COLOR AND TEXTURE diversity" (CARPET TILES AND METHODS OF manufacturing CARPET TILES WITH DIVERSITY OF COLOR AND TEXTURE), filed on 12.6.2009, the contents OF which are incorporated herein by reference.

Technical Field

The present disclosure relates generally to carpet tile and other fabric faced modular flooring and methods of designing modular floor tiles having designs and color schemes that provide various aesthetic and functional advantages.

Background

Indoor designs are always constantly competing and self-referencing. Design elements often replicate or mimic other materials or structures, and the innovative materials and components often seek consensus by mimicking what is conventional and accepted.

When recommending commercial carpet tiles, attempts are always made to hide their modularity and provide a continuous broadloom appearance. The mandatory limitation of broadloom carpet-like continuous appearance has long required carpet tile styles to be consistent in color and pattern, both within the carpet tile and from tile to tile. This may require relatively small design elements. Because of the challenges associated with carpet tile manufacture, some carpet tile manufacturers attempt to achieve uniformity by manufacturing a solid color carpet tile and then further printing pattern elements on the surface of the carpet tile after the solid color carpet tile has been produced and the edge locations have been determined. Careful installation is required so that all carpet tiles "face" the same direction, as is the case during processing of the carpet tiles. The requirement for a broadloom carpet-like appearance without the limitations of conventional carpet tiles meets the novel solutions of the inventions described in U.S. patent No. US6908656 (filed on day 14/2 2001 under the name "orthologenic ambiguous carpet tile") and U.S. patent No. US7083841 (filed on day 7/6 2002 under the name "orthologenic ambiguous carpet tiles having a living curved elements"), both of which are assigned to David oakeney and Sydney Daniel and both of which are incorporated herein by reference in their entirety. In addition, these patents teach the use of a pattern that appears irregular on each carpet tile of a carpet tile pattern, and then randomly orienting the carpet tiles during installation to form a larger, apparently irregular pattern in which the carpet tiles do not appear mispositioned. While the color patterns on the carpet tiles described in these patents all have elements that appear irregular and vary from tile to tile, important other aspects of the carpet tiles are very consistent both on the carpet tiles and from tile to tile.

Carpet tile designers now also design patterns to emphasize, rather than hide, the modularity of the carpet tile. Such carpet tiles are often installed "turned 90 degrees" where each carpet tile is positioned 90 degrees relative to each adjacent carpet tile.

After the limitation that modularity should be hidden is removed, conventional design elements that are avoided by carpet tiles for a long time have become inspirational, such as tile and various types of wood flooring, including parquet and parquet.

For many conventional carpet tile designs, the design properties require that the carpet tiles all use yarns dyed within the same dye batch in a particular installation to avoid visually perceptible differences between adjacent carpet tiles due to differences in dyeing. This presents various problems for installing new carpet tiles and replacing soiled or damaged carpet tiles at installation.

In general, existing design and processing techniques can be improved to better address the need for simulation and carpet tile design based on new sources of inspiration, such as wood flooring, to better address the ever-present problems related to dye batch and to better address the need for increased irregularity or diversity in carpet tile color and/or other pattern attributes.

Disclosure of Invention

The present disclosure provides novel carpet tile patterns and techniques for making carpet tile patterns that provide a diversity of color, texture, and/or other pattern attributes. Such versatility can provide one or more different aesthetic advantages, including but not limited to improved seam concealment in carpet tile installations, improved integration of yarn color dye batches, improved ability to replace used or soiled carpet tiles, easier carpet tile installation and/or improved ability to mimic natural elements such as wood that naturally include a large variety. Specifically, carpet tiles in certain embodiments of the invention are installed in a manner that mimics the appearance of parquet, which has natural variations in the appearance of wood elements.

The exemplary embodiments described herein provide a carpet tile style (multiple carpet tiles manufactured and sold for installation together) wherein the carpet tiles of the style include different numbers of colors used. For example, some carpet tiles may include more light colors than others may include more dark colors. Similarly, another exemplary embodiment provides a carpet tile style wherein the carpet tile includes a different number of textures. For example, tufts of two, three, four or more different pile heights may be used in this pattern. In certain embodiments, carpet tiles are made by tufting to form a fabric and varying the pile height along the length of the fabric. As one particular example, there may be a first portion having lower tufts than the next portion of the fabric such that one carpet tile has lower tufts than the next. In one embodiment, the fabric pattern is varied both with respect to color, for example, along its width, and with respect to texture, for example, along its length, to form carpet tiles having different combinations of color and texture. The aesthetics of a given carpet tile style may be enhanced or altered by alternatively or additionally including a variety of other pattern attributes.

These exemplary embodiments are presented not to limit or define the disclosure, but rather to provide exemplary embodiments to assist in understanding the disclosure. Examples are discussed in the detailed description, and further description is given therein. The advantages offered by the various embodiments may be further understood by examining this specification.

Drawings

This patent or application document contains at least one drawing executed in color. Copies of this patent or patent application publication with color drawing(s) will be provided by the office upon request and payment of the necessary fee.

A full and enabling disclosure including the best mode of practicing the appended claims and directed to one of ordinary skill in the art is set forth more particularly in the specification which follows. The specification makes reference to the following drawings, in which the same reference numerals are used throughout the different drawings to designate the same or similar components.

FIGS. 1A-1B are top plan views illustrating certain color features of an exemplary carpet tile fabric pattern.

FIG. 2 is a top plan view illustrating certain textural features of the exemplary carpet tile fabric pattern of FIGS. 1A-1B.

Figure 3 is an illustration of a carpet tile produced with different colors and textures installed turned 90 degrees according to one embodiment of the present invention.

Figure 4 is a diagram of another 90 degree turn mounted carpet tile produced using a different color and texture according to another embodiment of the present invention.

Figure 5 is a diagram of another 90 degree turn mounted carpet tile produced using a different color and texture according to another embodiment of the present invention.

Fig. 6A-6H are diagrams of additional 90 degree turned installed carpet tiles produced using different colors and textures according to other embodiments of the present invention.

Detailed Description

The present invention provides novel carpet tile patterns and techniques for designing and processing carpet tiles with a wide variety of colors, textures, and/or other pattern attributes. Such versatility can provide one or more distinct aesthetic and functional advantages. Certain exemplary embodiments provide a carpet tile style wherein carpet tiles of the style include different numbers of style colors. For example, six colors may be used for one carpet tile style. The use of these colors (e.g., the percentage of each yarn color given) can vary in this style of carpet tile. For example, if the first three of the six colors are lighter than the last three of the six colors, some carpet tiles may include more of the first three colors, while other carpet tiles may include more of the last three colors. Similarly, in one carpet tile style, the carpet tile may include a different number of textures. For example, one style may include four different pile heights: lowest, low, medium, and high pile heights. Some carpet tiles may include tufts of minimum and low pile heights, while other carpet tiles may include tufts of minimum and high pile heights, etc. The different combinations of the four pile heights may exist in different carpet tiles and may vary within a given carpet tile.

One method of producing such patterns includes using a tufting machine to tuft to obtain a fabric having a pattern of colors and textures, wherein the colors and textures used vary across and/or along the fabric pattern. Commercial carpet tiles can be processed using a variety of techniques, but essentially the vast majority of such products are made by tufting carpet yarns into tufts, primarily using tufting machines. The fabric produced by the tufting machine is typically about six feet or two meters wide and is referred to herein as the "fabric" of the carpet tile. After the fabric is produced, a secondary backing layer is bonded to the underside of the fabric to provide stability, rigidity, weight and other desired properties, and the backed fabric is then slit into carpet tiles. These carpet tiles are typically 18 inches or half square meters so that a column of four carpet tiles can typically be cut on the backed fabric.

1A-1B are top plan views illustrating certain color features of an exemplary carpet tile web. Such carpet tile fabrics may be made, for example, using a cut loop tufting machine. Fig. 1A shows three colors used variably over the cut portion of the fabric pattern. Each of the colors shown in fig. 1A represents a yarn color, and the yarn may actually have one or more colors therein, such as a single color yarn, a spiral striped yarn, a variegated yarn, and the like. However, each yarn color typically has a color attribute such as lightness or darkness that may be different relative to the other yarn colors used in the fabric color pattern. In fig. 1A, the colors representing the darker yarns are present in the left portion of the fabric pattern, while the colors representing the lighter yarns are present in the right portion of the pattern. In this exemplary case, the number of light and dark yarns gradually changes over the fabric pattern. In other embodiments, the number of light and dark yarns (or other color attributes that vary) may change abruptly across the color pattern of the fabric. In still other embodiments, the color attribute may be changed over the fabric pattern and then changed back one or more times. However, the yarn color attributes typically vary such that carpet tiles cut from different carpet tile locations on the fabric pattern differ with respect to the color attribute. In the example of fig. 1A, a carpet tile cut from the left portion of the fabric will have yarns that appear darker, while a carpet tile cut from the right portion of the fabric will have yarns that appear lighter. Of course, a staggered arrangement is also possible.

FIG. 1B shows three colors used in varying fashion on the loop pile portion of the fabric color pattern. In a pattern using both cut and loop pile portions, the color properties can be varied on one or both portions by controlling the thread take-up of that portion as shown in the given example. Each of the colors shown in fig. 1B represents a yarn color, and the yarn may actually have one or more colors therein, such as a single color yarn, a spiral striped yarn, a variegated yarn, and the like. However, each yarn color typically has a color attribute such as lightness or darkness that may be different relative to the other yarn colors used in the fabric color pattern. In FIG. 1B, as in FIG. 1A, the colors representing more darker yarns are present in the left portion of the fabric pattern, while the colors representing more lighter yarns are present in the right portion of the pattern. Exemplary color attributes include color value, hue, saturation, and other attributes known and used by carpet tile designers and processors.

Alternative embodiments may of course implement the difference in pattern color attributes in a different manner than described in the previous examples. For example, carpet fabric may be produced with other types of tufting machines to have a certain pattern. As another example, the color used may alternatively or additionally vary along the length of the tufting machine. In addition, two or more separate carpet fabrics may be used to produce a single style of carpet tile. In such a pattern, as one example, the color pattern of one mechanical fabric may include darker yarns and the color pattern of another mechanical fabric may include lighter yarns. Carpet tile patterns may also be printed, sewn, or otherwise formed.

FIG. 2 is a top plan view illustrating certain textural features in the exemplary carpet tile fabric of FIGS. 1A-1B. In this exemplary embodiment, the texture differences are achieved by varying the pattern of yarn pile heights along the length of the fabric. Figure 2 shows a tuft height fabric pattern repeat of approximately four carpet tiles width and eight carpet tiles length. The tuft-height fabric pattern repeats longitudinally, that is the tufting machine can start tufting at the top of the tuft-height fabric pattern shown in fig. 2 and after reaching the bottom again start at the top without destroying the tufted fabric, thereby producing a longer fabric than the pattern shown in fig. 2, but wherein the tuft-height fabric pattern shown in fig. 2 repeats along the length. Carpet tiles cut from such a web may vary with respect to their relative position along the length of the web, that is, the length of the pattern repeat may not correspond to an integer multiple of the length of the carpet tile. This variability can further enhance the variability of the texture of the resulting carpet tile.

In fig. 2, different colors indicate different pile heights for the yarns to be tufted. In this exemplary embodiment there are four pile heights, each corresponding to a drawing color. Here, white represents the lowest pile height, e.g., 0.310 cm, which is used in this example for all of the cut yarns (i.e., those portions whose color is determined by the fabric color pattern in fig. 1A). Three other colors (light, medium, and dark) are used to indicate the pile height of the yarns in the loop yarns (i.e., those portions whose yarn colors are determined by the fabric color pattern in fig. 1B). In fig. 2, light colors represent low pile heights (e.g., 0.550 cm), medium colors represent medium pile heights (e.g., 0.600 cm), and dark colors represent high pile heights (e.g., 0.700 cm).

In fig. 2, the lowest, low, medium and high pile heights vary along the length of the fabric. The lowest pile height (i.e., the portion indicated by white) is present along the entire length 208 of the fabric tuft height pattern repeat. However, low pile height is used for only portion 204, medium pile height is used for only portion 202, and high pile height is used for only portion 206. These portions 202,204,206 may be positioned and/or sized such that at least a portion of a carpet tile cut from the resulting fabric will include only one of low, medium, and high pile heights. These portions may be positioned and/or sized to avoid significant pile height differences in some or all of the patterns so that carpet tiles cut from the web, for example, do not have both low and high loop pile tufts. Avoiding such extreme differences can help to soften the appearance of the carpet and avoid the appearance of horizontal lines to an undesirable degree. The location, size and/or arrangement of the different pile heights in a given design may of course also be modified for additional functional and aesthetic reasons.

3-5 are illustrations of carpet tiles produced with different colors and textures turned to a 90 degree installation according to other embodiments.

Fig. 6A-6H are diagrams of other carpet tiles produced with a variety of colors and textures for other installations according to still other embodiments of the invention. As shown in fig. 6A, carpet tile 602 includes more lighter colored yarns than carpet tile 604, while carpet tile 604 includes more darker colored yarns than carpet tile 602.

A method of generating a pattern on a tufting machine is also provided. Tufting machines plant a fabric having a pattern of colors and textures. The weave pattern may be repeated along the length of the fabric so that eventually many carpet tiles may be cut along the length of the fabric after the secondary backing is attached. In one exemplary embodiment, the color properties of the yarns vary along the width of the fabric pattern. For example, six yarn colors may be used for the fabric pattern. One side of the fabric may include a higher percentage of light colored yarns than the other side of the fabric. As a specific example, the amount of lighter yarns within the pattern may increase from left to right, while the amount of darker yarns decreases from right to left across the pattern. In the alternative or in addition, other color characteristics may be varied throughout or on the fabric pattern, including but not limited to hue, color value, and/or color saturation, to enhance apparent color differences throughout or on the fabric. In another embodiment, the fabric pattern includes a difference in pile height along the length of the fabric to create a difference in texture between different carpet tiles.

In general, the variety in color, texture, and/or other characteristics of carpet tiles constructed from these exemplary carpet fabrics may provide one or more of the various benefits described above as well as other benefits that will occur to those skilled in the art of carpet tile design and processing. For example, in some instances, it may be desirable for a carpet tile to mimic the appearance of a natural element. As one particular example, it may be desirable for carpet tiles to mimic the irregularities of wood grain to impart an appearance similar to a wood floor surface. In other cases, the use of the diversity of colors, textures, and/or other features disclosed herein allows carpet tiles to mimic differences that might otherwise exist with respect to yarn dye lot differences, thereby making carpet tile styles better suited for selective replacement with carpet tiles that are not made using the same yarn dye lot. Similarly, the effects of wear on the carpet tiles may also become less noticeable due to the variety of carpet tile styles, and differences in wear (e.g., between hallways and corners) may also become less noticeable. The patterns disclosed herein and created using the features and design principles described herein are not generally "fuzzy orthogonal," a term used in U.S. patent US6908656 (filed 2/14/2001 under the name of "orthogonal array tile") and U.S. patent US7083841 (filed 6/7/2002 under the name of "orthogonal array tile with a virtual curved array") both to David oakeney and Sydney Daniel.

The disclosed embodiments are merely illustrative. In short, the techniques and other features described herein are useful in a variety of different contexts and should not be limited by the specific description provided herein. It should also be noted that embodiments may include patterns and methods that differ from those disclosed herein. The illustrated features are merely exemplary and should not be taken as indicating any critical or essential components, features, or method steps for any embodiment or as limiting the scope of the disclosure. The foregoing description of the embodiments has been presented only for the purposes of illustration and description and is not intended to be exhaustive or to limit the disclosure to the precise forms disclosed. Various modifications and alterations may become apparent to those skilled in the art without departing from the spirit and scope of the present disclosure.

Claims (20)

1. A carpet fabric made for processing carpet tiles, the carpet fabric comprising:

a carpet fabric width substantially corresponding to a tufting machine width for making a carpet fabric; and

a length of carpet fabric corresponding to a direction of tufting by the tufting machine, such that the yarns are tufted substantially in the tufting direction to form a fabric face,

wherein the fabric face includes a varying texture such that tiles cut from a first location along the width or length have more texture than tiles cut from a second location along the width or length, wherein if one tile includes a greater difference between its highest and lowest tufts, then that tile has more texture than another tile.

2. The carpet web of claim 1, wherein the texture varies along the length of the carpet web such that carpet tiles cut from the first location, the second location, the third location, and the fourth location along the length of the carpet web all differ in texture from one another.

3. The carpet fabric of claim 1, wherein:

carpet tiles cut from a first location along the length of the carpet fabric have more texture than carpet tiles cut from a second location along the length of the carpet fabric;

carpet tiles cut from the second location along the length of the carpet fabric have more texture than carpet tiles cut from the third location along the length of the carpet fabric; and is

Carpet tiles cut from the third location along the length of the carpet fabric have more texture than carpet tiles cut from the fourth location along the length of the carpet fabric.

4. The carpet web of claim 3, wherein along the length of the carpet web the first location is adjacent to the second location, the second location is adjacent to the third location, and the third location is adjacent to the fourth location.

5. A carpet fabric for making carpet tiles, the carpet fabric comprising yarns that together comprise a fabric face, the fabric face comprising:

a color attribute that varies along a first dimension of the carpet fabric such that carpet tiles cut from a first location along the first dimension differ in color attribute as compared to carpet tiles cut from a second location along the first dimension that is different from the first location; and

a texture that varies along a second dimension of the carpet web such that carpet tiles cut from the first section along the second dimension have more texture than carpet tiles cut from the second section along the second dimension, wherein one carpet tile has more texture than another carpet tile if it includes a greater difference between the highest and lowest tufts; and is

Wherein the first dimension of the carpet fabric is substantially perpendicular to the second dimension of the carpet fabric.

6. The carpet fabric of claim 5, wherein the color attributes relate to color lightness and color darkness, wherein carpet tiles cut from a first location along a first dimension have a higher percentage of lighter colored yarns than carpet tiles cut from a second location along the first dimension.

7. The carpet web of claim 5, wherein the color attributes vary across the first dimension of the carpet web such that carpet tiles cut along the first dimension from the first location, the second location, the third location, and the fourth location all differ from one another in color attributes.

8. The carpet fabric of claim 5, wherein the color attributes relate to color lightness and color darkness, wherein:

carpet tiles cut from a first location along a first dimension have a higher percentage of lighter colored yarns than carpet tiles cut from a second location along the first dimension;

carpet tiles cut from a second location along the first dimension have a higher percentage of lighter colored yarns than carpet tiles cut from a third location along the first dimension; and is

The carpet tile cut from the third location along the first dimension has a higher percentage of lighter colored yarns than the carpet tile cut from the fourth location along the first dimension;

wherein the first location is adjacent to the second location, the second location is adjacent to the third location, and the third location is adjacent to the fourth location.

9. The carpet fabric of claim 5, wherein:

the first dimension is a carpet fabric width corresponding to a tufting machine width for making a carpet fabric; and is

The second dimension is a length of carpet fabric corresponding to a direction of tufting by the tufting machine such that the yarns are tufted substantially in the direction of tufting by the tufting machine.

10. The carpet fabric of claim 5, wherein the color attribute is hue or color saturation.

11. The carpet fabric of claim 5, wherein the yarns comprise yarns of six different colors.

12. The carpet fabric of claim 5, wherein the fabric face comprises at least three different yarn pile heights.

13. A plurality of carpet tiles cut from the carpet fabric, each of the plurality of carpet tiles including a color attribute,

wherein the second color attribute of the second set of carpet tiles cut from the second column of carpet fabric is stronger than the first color attribute of the first set of carpet tiles cut from the first column of carpet fabric, and

wherein the third color attribute of the third set of carpet tiles cut from the third column of carpet web is stronger than the second color attribute of carpet tiles cut from the second column of carpet web, and

wherein the first column adjoins the second column and the second column adjoins the third column over a width of the carpet fabric substantially corresponding to a width of a tufting machine used for making the carpet fabric.

14. The plurality of carpet tiles of claim 13, wherein each of the plurality of carpet tiles comprises a plurality of lighter colored yarns and darker colored yarns, and wherein the first set of carpet tiles comprises a higher percentage of lighter colored yarns than the second set of carpet tiles, and the second set of carpet tiles comprises a higher percentage of lighter colored yarns than the third set of carpet tiles.

15. The plurality of carpet tiles of claim 13, wherein each of the plurality of carpet tiles comprises a plurality of lighter colored yarns and darker colored yarns, and wherein the first set of carpet tiles comprises a higher percentage of lighter colored yarns than the second set of carpet tiles, and the third set of carpet tiles comprises a higher percentage of lighter colored yarns than the second set of carpet tiles.

16. The plurality of carpet tiles of claim 13, wherein the carpet tiles comprise different textures, wherein one carpet tile has more texture than another carpet tile if the carpet tile comprises a greater difference between its highest and lowest tufts.

17. Carpet tiles cut from a carpet web, the carpet tiles comprising:

a first set of carpet tiles comprising tufts of a low pile height and tufts of a medium pile height;

a second set of carpet tiles comprising tufts of intermediate pile height and tufts of high pile height, wherein said second set of carpet tiles is substantially free of tufts having low pile height.

18. The carpet tile of claim 17, wherein the first set of carpet tiles is from a first location along the width of the carpet web and the second set of carpet tiles is from a second location along the width of the carpet web different from the first location.

19. The carpet tile of claim 17, further comprising:

a third group of carpet tiles comprising tufts of low pile height and high pile height, wherein said third group of carpet tiles are substantially free of yarns having an intermediate pile height.

20. The carpet tile of claim 19, wherein the first, second, and third sets of carpet tiles are from different locations along the width of the carpet fabric.