HK1204891B - Modular textile system - Google Patents

Description

Modular textile system

The divisional application is the divisional application of the invention patent application with the application number of 200980120745.9, the application date of 2009, 6 and 4 and the invention name of 'modular textile system'.

Cross Reference to Related Applications

This patent application is a partially continuous patent application of international patent application No. pct/US2008/008468 filed on 10/7/2008, requiring the benefit under 35 u.s.c. § 119(e) of U.S. provisional patent application No.61/130,990 filed on 5/7/2008, both of which are incorporated herein by reference in their entirety.

Background

Modular textile systems such as carpet tiles have been used in many flooring fabrics due to ease of installation. Some carpet tiles are designed with small and/or complex patterns in an attempt to obscure the seams between adjacent installed tiles in an attempt to make the resulting installation appear similar to or mimic a broadloom carpet installation. In contrast, often monochrome and simpler or classic design elements are omitted, as such design elements tend to emphasize the modular nature of the carpet tile.

As such, there remains a need for a textile system that does not try to mimic the appearance of a broad carpet installation, and instead allows the designer and/or installer the freedom to create any desired overall design or aesthetic, without being limited to the particular arrangement of tiles or the alignment of the pattern along the seam. As a result, simpler patterns and/or single colors can be used, if desired.

Disclosure of Invention

The present disclosure is generally directed to a modular textile system, a method of making such a system, and a fabric mesh or woven blank for forming such a system. The modular textile system includes a plurality of distinct carpet tiles, each of which includes at least one design area having a pattern defined by a particular set of design elements, features, and/or parameters, such as yarn type (e.g., color, gloss, twist, number of strands, dye type, etc.), number of distinct yarn types, tufting specifications or parameters (e.g., texture, pattern, decorative pattern, relief (pile height), presence of accent elements, etc.), and/or other suitable design elements, features, and/or parameters.

At least one tile includes a design area having a pattern that is substantially similar, and in some cases substantially identical, to the pattern of the design area of at least one other tile, such that the respective tiles are coordinated with one another. The tiles may be installed or arranged in any manner desired by the user without the need to match the pattern along the seams or to align the tiles in a particular direction, e.g., relative to the direction of the tufts. In this way, the modular textile system gives the user considerable flexibility and freedom of creation to obtain the overall aesthetic desired by the user.

In one particular embodiment, the modular textile system includes a plurality of distinct textile tiles including a first tile, a second tile, and a third tile, the first, second, and third tiles collectively including a plurality of design zones extending along a first dimension of the respective tile, the plurality of design zones including a first pair of coordinating design zones defining respective edges of the first and second tiles extending along a first direction, and a second pair of coordinating design zones defining respective edges of the second and third tiles extending along the first direction, the first pair of coordinating design zones being distinct from the second pair of coordinating design zones. The first pair of coordinating design zones coordinate the first and second tiles with each other, the second pair of coordinating design zones coordinate the second and third tiles with each other, and the second tile serves as a coordinating bridge between the first and second tiles so that all distinct tiles coordinate with each other, regardless of their relative position and/or orientation in the installation. The textile system can be used to create a myriad of overall designs and/or patterns that users (e.g., purchasers or viewers) can find harmonious and visually appealing according to their personal preferences.

The modular textile system may be formed in any suitable manner, and in one embodiment the carpet tile is formed or derived from a single web of fabric. The width of the web includes a plurality of discrete design regions including a first design region and a second design region extending the length of the web. The web is divided into a plurality of tiles including a first tile, a second tile, and a third tile that are adjacent to each other across a width of the web. In this case, each of the first and second design zones is divided into respective first and second portions, and the first tile includes the first portion of the first design zone, the second tile includes the second portion of the first design zone and the first portion of the second design zone, and the third tile includes the second portion of the second design zone.

Although some aspects of the present invention are described in connection with tufted fabrics, fabrics formed using other suitable techniques may also be used.

Other features, aspects, and embodiments will become apparent from the following description and the accompanying drawings.

Drawings

The description makes reference to the accompanying drawings, some of which are schematic and in which like reference numerals refer to like parts throughout the several views, and in which:

FIG. 1A schematically depicts a typical modular textile system comprising a plurality of distinct carpet tiles;

FIGS. 1B and 1C schematically depict a typical installation using the textile system of FIG. 1A;

FIGS. 1D and 1E schematically depict a modification of the installation of FIG. 1B;

FIG. 1F schematically depicts a typical fabric mesh that may be used to form the modular textile system of FIG. 1A;

FIG. 2A schematically depicts another typical fabric mesh that may be used to form a modular textile system;

FIG. 2B schematically depicts a typical modular textile system including a plurality of distinct tiles formed from the web of fabric of FIG. 2A;

FIG. 2C schematically depicts a typical installation using the textile system of FIG. 2B;

FIG. 3A schematically depicts yet another exemplary fabric web that may be used to form a modular textile system;

FIG. 3B schematically depicts a typical modular textile system including a plurality of unique tiles formed from the web of fabric of FIG. 3A;

FIG. 3C schematically depicts a typical installation using the textile system of FIG. 3B;

FIG. 4A schematically depicts yet another exemplary fabric web that may be used to form a modular textile system;

FIG. 4B schematically depicts a typical modular textile system including a plurality of unique tiles formed from the web of fabric of FIG. 4A;

fig. 4C schematically depicts a typical installation using the textile system of fig. 4B.

Detailed Description

Fig. 1A schematically depicts a modular textile system 100. System 100 generally includes a plurality of woven tiles, each having a first dimension (e.g., length) L extending in a first direction D1 and a second dimension (e.g., width) W extending in a second direction substantially perpendicular to the first direction. The system 100 includes at least a first tile 102, a second tile 104, and a third tile 106, each of the tiles 102,104,106 having at least one tuft or design field 108,110,112a, 112b, 114,116a, 116b, 118,120,122 extending along a first dimension (e.g., length) L of the respective tile in a first direction D1. Each design zone typically has a first dimension (e.g., length) L that is approximately equal to the first dimension (e.g., length) L of the respective tile and a second dimension (e.g., width) Z (only one of which is labeled) that extends along at least a portion of the second dimension (e.g., width) W of the respective tile 102,104,106 in accordance with a second direction D2.

Each design region 108,110,112a, 112b, 114,116a, 116b, 118,120,122 is characterized by a particular set of visual and/or tactile features (collectively "sensory features") that are perceptible to the user (schematically illustrated in the figures by different fill patterns). The set of specific sensory characteristics associated with each zone generally results from the selection and/or combination of a plurality of design elements, characteristics, and/or parameters, such as yarn type (e.g., color, gloss, twist, number of strands, dye type, etc.), number of distinct yarn types, tufting specifications or parameters (e.g., texture, pattern, decorative pattern, relief (pile height), presence of accent elements, etc.), and/or any other suitable design elements, characteristics, and/or parameters. The particular combination of these design elements, features and/or parameters defines the overall composition (or "zone composition") of each zone.

In the illustrated embodiment, the first tile 102 includes three distinct design zones 108,110,112a (i.e., the design zones have different patterns) having different respective widths Z (only one of which is labeled), the second tile 104 includes three distinct design zones 112b, 114,116a having different respective widths Z (not labeled), and the third tile 106 includes four distinct design zones 116b, 118,120,122 having different respective widths Z (not labeled). However, it should be understood that any tile 102,104,106 may include two or more design regions having distinct patterns, two or more design regions having substantially the same pattern, two or more design regions having substantially similar patterns, or any combination thereof. The differences between the design areas may be more subtle or more pronounced depending on the overall aesthetics desired.

Each design area of each tile 102,104,106 may have any suitable width. Typically, each design region contains at least two coil rows, and more typically, each design region contains several coil rows, such that the resulting design region has a width of at least about 1 inch. In various independent embodiments, for a carpet tile having a length of about 24 inches and a width of about 24 inches, each design area alone may have a width of about 1 inch to about 22 inches, about 3 inches to about 15 inches, or 4 inches to 8 inches. In each additional independent embodiment, each design area may independently have a width of about 1 inch, about 2 inches, about 3 inches, about 4 inches, about 5 inches, about 6 inches, about 7 inches, about 8 inches, about 9 inches, about 10 inches, about 11 inches, about 12 inches, about 13 inches, about 14 inches, about 15 inches, about 16 inches, about 17 inches, about 18 inches, about 19 inches, about 20 inches, about 21 inches, about 22 inches. However, other numbers of tiles, other numbers of design areas, widths of design areas, and arrangements of design areas may be used.

The precise combination of the design areas of the tiles, the relative proportion of each design area of the tiles, and the arrangement or relative location of the design areas of the tiles collectively define the overall composition (or "tile composition") of each tile. In the embodiment schematically illustrated in fig. 1A, each tile 102,104,106 in the modular textile system 100 has a distinct pattern and, thus, a distinct set of resulting sensory characteristics from tile to tile in the modular textile system. The differences between the tiles may be relatively subtle or more pronounced. Thus, for example, two tiles that are distinct may include one or more substantially identical design zones, with the size and/or relative position of one or more such design zones varying between the two tiles. Other pairs of distinct tiles may include design zones that are all not substantially identical, a different number of design zones, and/or a different arrangement of design zones.

For a particular modular textile system, at least one design area of at least one tile has a substantially similar composition to, and in some cases substantially the same composition as, at least one design area of another tile. Also, in some embodiments, at least one design area of each tile has a substantially similar composition, and in some cases substantially the same composition, as at least one design area of another tile. Such a design area may serve as a coordination area that provides a sensory interface between the respective tiles.

For the embodiment illustrated in FIG. 1A, at least one design area of each tile 102,104,106 has substantially the same composition as at least one design area of at least one other tile 102,104, 106. The tiles 102,104 each include a first pair of coordinating zones 112a, 112b, and the tiles 104,106 each include a second pair of coordinating zones 116a, 116 b. As a result, the tiles 102,104 tend to coordinate (i.e., match or mate) with one another, and the tiles 104,106 tend to coordinate with one another. Moreover, because the tile 104 is coordinated with the tile 102 and the tile 106, the tile 104 may act to create a continuous "bridge" or "chain" of coordination between the tiles 102, 106, even if there are no substantially identical patterned design areas on the tiles 102, 106. Thus, the use of the "bridge" tile 104 allows all tiles 102,104,106 to be coordinated with one another. It should be noted that in this embodiment, the different coordination areas 112a, 112b, 116a, 116b abut and/or define respective carpet tile edges extending along the first direction D1. However, the coordination areas may be configured differently, if desired. In some embodiments, the coordination zones may be substantially identical to each other in that their sensory (i.e., visual and/or tactile) features are substantially identical to each other (regardless of the width of the design zone). However, in other embodiments, the coordination areas may appear different, as will be described in more detail in connection with fig. 2A-3C. Nevertheless, there is often sufficient visual engagement between the design zones that such zones are intended to coordinate with one another, as is evident to the user.

Fig. 1B illustrates a typical installation 124 including a plurality of each of the carpet tiles 102,104,106 of fig. 1A. For purposes of illustration and not limitation, each type of tile 102,104,106 is labeled as tile a, B, C, respectively. In this typical installation, equal numbers of tiles a, B, C are placed side by side, with the sections being repeated in alignment with one another with the edges of adjacent tiles. The arrangement of tiles may appear "unoriented," that is, the tiles may appear to be randomly oriented in the arrangement relative to other tiles. Although the tiles appear to be placed arbitrarily, because the tiles are coordinated with one another, the overall arrangement of the tiles a, B, C may be perceived by the user as visually harmonious. In another exemplary installation 126 shown in FIG. 1C, the tiles may be arranged in a horizontal fine square stone or brick configuration, which arrangement of tiles may appear to be "directional," that is, the tiles may appear to be oriented in a particular manner. In this embodiment, even if the design zones are not aligned with each other (e.g., forming multiple substantially continuous bands or strips), because the tiles are coordinated with each other, the overall installation may be considered coherent and harmonious (rather than separate or irregular).

It is clear that there are an infinite number of possible arrangements of tiles, each of which may provide a different overall aesthetic or impression, and that different non-directional and directional appearances may be obtained using different mounting methods. Such mounting may be single piece, quarter turn, half turn, horizontal or vertical fretted stone, random, or any other suitable manner or configuration. Of course, it should be understood that whether a particular arrangement of tiles is acceptable or popular (e.g., visually pleasing or harmonious) is subjective, based on the user's personal tastes and preferences. In this way, the carpet tiles may be repositioned, reoriented or manipulated as desired to achieve the desired overall "look and feel" desired by the particular user.

The free placement of the tiles may be simpler for the initial installation of the tiles and the replacement of one or more damaged and/or worn tiles, regardless of the need to match the pattern across the seam or to take into account the direction of the tufts. Furthermore, since the color between the tiles a, B, C may vary, the user does not have to be concerned with the variation between adjacent tiles, for example when changing tiles in a pre-installation. By way of example, fig. 1D and 1E schematically depict the arrangement of the tile of fig. 1B, wherein the center tile (type a) has been replaced by tile B and tile C, respectively. Although the resulting installation 128, 130 in fig. 1D and 1E is slightly different from the original installation shown in fig. 1B, the arrangement of the tiles a, B, C may still be considered harmonious and visually pleasing according to the preferences of the particular user.

If desired, to further simplify installation, the modular textile system 100 may be packaged to include an equal number of tiles a, B, C in each carton. For example, the carton may include 12 tiles, each tile A, B, C including four, respectively. The tiles may also be arranged in ordered stacks within each package, e.g., tiles A, B, C, etc. (or B, C, A, B, C, A, or any other desired ordering). By including the tiles in this manner, the user can remove the tiles from the carton, install them in succession, place and orient them as desired to form an overall design that meets the user's preferences. Alternatively, the tiles a, B, C may be separately packaged to give the user the freedom to access and install the tiles a, B, C in any proportion and/or manner, thereby resulting in an installation that is more tailored to the user's preferences.

Fig. 1F schematically depicts an exemplary method of forming the modular textile system 100 of fig. 1A. In this embodiment, the integral textile web 132 is used to form a plurality of distinct, but coordinated tiles 102,104,106, as described above. However, other methods of forming a modular textile system are envisioned.

The fabric web 132 includes a first dimension M (e.g., length) extending in the machine direction D1 of the machine direction, and a second dimension T (e.g., width) extending in the cross direction D2. The width T of web 132 is divided into a plurality of substantially discrete design regions 108,110,112,114,116,118,120,122 (schematically illustrated using different fill patterns) that extend along the length M of web 132 in accordance with machine direction D1. Each design region may have any suitable width. For example, in each of the various independent embodiments, for a fabric web having a width of about 80 inches, each design zone may individually have a width of about 1 inch to about 44 inches, about 2 inches to about 36 inches, about 6 inches to about 30 inches, about 8 inches to about 16 inches. However, other design area widths and ranges of design area widths are envisioned.

As described above, each design region 108,110,112,114,116,120,122 may be formed using a plurality of design elements, features, and/or parameters, any of which may vary from region to region. The differences in the patterning of each region may be subtle or more pronounced depending on the desired overall aesthetics to be obtained. For example, the different zones may be formed from yarns of a single color or multiple colors as needed to provide the desired overall patterning of each carpet tile and the desired overall aesthetics of the installed modular textile system (fig. 1B-1E). Moreover, the respective colors of the design zones may be selected to provide a range of warm and cool tones in the formed carpet tile. For example, the design area of the fabric mesh 132 may be configured such that a first tile has a design area of a color that is cooler than the color of the design area of a second tile, and the design area of the first tile is also cooler than the color of the design area of a third tile, such that the third tile comprises the warmest color. Countless other possible scenarios are conceivable.

Fabric mesh 132 may be distributed or divided into a plurality of tiles, as schematically illustrated in fig. 1F by dashed lines. In this embodiment, the textile web 132 is divided into three generally square tiles 102,104,106 that are generally adjacent to each other across the width T of the textile web 132. At least one design area, and in this embodiment two design areas 112,116, are divided into respective first portions 112a, 116a and respective second portions 112b, 116b, such that the area 112 is shared between the two tiles 102,104 and the area 116 is shared between the tiles 104,106, as discussed in connection with FIG. 1A. Specifically, the tile 102 includes a first portion 112a of the design area 112 and the tile 104 includes a second portion 112b of the design area 112. Similarly, the tile 104 includes a first portion 116a of the design area 116 and the tile 106 includes a second portion 116b of the design area 116. The design sections 112,116 may be divided into equal or unequal portions, and thus, the respective pairs of partial design sections 112a, 112b and 116a, 116b may have equal or unequal widths. As discussed in connection with FIG. 1A, the design areas 112a, 112b and 116a, 116b serve as a coordinating area for the tiles 102,104, 106. The remaining design regions 108,110,114,118,120,122 may be separate or distinct design regions.

The length M of the web 132 may also be divided (i.e., cut) into a plurality of tiles similar to the tiles 102,104, 106. For illustrative purposes, each tile located in the leftmost position (e.g., tile 102) may be designated as tile "a", each tile located in the middle position (e.g., tile 104) may be designated as tile "B", and each tile located in the rightmost position (e.g., tile 106) may be designated as tile "C". Each tile a has substantially the same composition as each other tile a, each tile B has substantially the same composition as each other tile B, and each tile C has substantially the same composition as each other tile C. However, in some embodiments, one or more design zones may differ in appearance from tile to tile, and thus, each tile cut along the length of the web may not be exactly the same in appearance as every other tile of the same type (i.e., in the same location, e.g., tile a, tile B, tile C). Further, as previously described, each pair of coordination areas may not be identical in appearance. For example, the coordination areas may have slightly different appearances caused by the variability of the tufting process, may have somewhat different patterns or configurations of decorative patterns (when present), and/or include one or more additional design features or elements, as will be described in detail below.

For example, fig. 2A-3C depict different fabric webs, modular textile systems, and modular textile installations in which particular types of carpet tiles and/or coordination areas differ in appearance. The different fabric webs, modular textile systems, and modular textile installations include features similar to the fabric webs, modular textile systems, and modular textile installations shown in fig. 1A-1F, except for notable changes and variations that will be appreciated by those skilled in the art. For simplicity, like feature reference numerals are used to replace "1" with "2" (fig. 2A-2C) or "3" (fig. 3A-3C) before the figures. It should be noted that the number of design regions, the arrangement of the design regions, the width of each region, etc. may vary in each embodiment, and the illustrated embodiments are not intended to be limited in any way.

In the embodiment illustrated in fig. 2A, the design area 212 includes a design element or decorative pattern 234, and the design element or decorative pattern 234 includes a plurality of rectangles and squares, some of which partially overlap each other. However, any suitable decorative pattern may be used in accordance with this disclosure. The decorative pattern may be simple or complex, subtle or prominent, and may also include colors that are consistent and/or contrasting with the remaining colors of the modular textile system. For example, the background of the design region may have a color that is consistent with the remaining design regions, while the decorative pattern has a more prominent color relative to the background. Alternatively, the decorative pattern may have a color consistent with the remaining design zones, while the background has a more prominent color. By way of example, the background 236 of the design region 212 and the different other design regions 208, 210, 214, 216, 218, 220, 222 may include different shades of brown, while the decorative pattern 234 may include a red color or another color that is visually more prominent than the brown shade of the remaining design regions. Alternatively, the decorative pattern 234 and the different other design regions 208, 210, 214, 216, 218, 220, 222 may include different shades of brown, while the background 236 of the design region 212 may include red or another color that is visually more prominent than the brown shade of the remaining design regions and decorative pattern. In other embodiments, the decorative pattern and background of a particular design region have a color that is consistent with the other design regions. In yet other embodiments, the decorative pattern and background of a particular design region have a more prominent color than other design regions. Countless possibilities can be imagined.

It should be understood that the regions comprising the decorative pattern are common regions and the resulting coordinated regions, while having substantially the same pattern, may have slight differences in appearance from one another. The degree to which the respective portions of the common area differ in appearance may depend on a number of factors including, but not limited to, the arrangement of the zones across the web, the width of each zone, the size, shape and configuration of the decorative pattern within the zone, the length and width of the repeating units of the decorative pattern, and the size of the carpet tile cut from the web. For example, because the decorative pattern 234 of FIG. 2A is not symmetrical along the boundary between the first and second tiles 202,204 (i.e., along the dashed line), the resulting coordination areas 212A, 212B may comprise different arrangements of squares and rectangles, as shown in FIG. 2B. However, the areas 212a, 212b may still be used as a coordinating zone because the areas are similar enough that a sensory engagement is formed between the tiles 202, 204.

In some embodiments, the decorative pattern may be located entirely within one tile of a pair of tiles that includes a common zone, such that the resulting coordinated zones of the tiles may be substantially different in appearance. For example, in the embodiment shown in fig. 3A, the fabric mesh 332 includes a decorative pattern 334, the decorative pattern 334 includes a variable width curve, and a portion of the decorative pattern 334 generally resembles a blade. When the web 332 of fabric is cut into tiles 302,304,306 (FIG. 3B), the entire decorative pattern 334 is located in the area 312a of the tile 302, as opposed to the background 336, while the area 312B of the tile 304 includes only the background 336. Nevertheless, since the background 336 of each region 312a, 312b has substantially the same composition, and since the regions 312a, 312b have substantially similar overall compositions, there is sufficient visual engagement between the backgrounds of the regions, which makes it apparent that the regions attempt to coordinate with one another,

in some cases, such as described above with respect to areas 312a, 312B of fig. 3B, the coordination areas are significantly different in appearance, and the visual engagement between the tiles having the coordination areas may be enhanced, if desired. According to one exemplary method, the color of the decorative pattern may be incorporated into the background of the common zone, for example, by adjusting the tuft height of the yarns in the background to provide a spot color profile comprising the tuft color. The appearance of the tuft color in the background may provide additional sensory engagement and/or reinforce other sensory engagement between the areas. For example, the decorative pattern 334 is purple and the background may be tufted to include a purple color mixed with other background colors. The appearance of purple color in the decorative pattern 334 and the background 336 results in continuity between the decorative pattern 334 and the background 336 and thus between the regions 312a, 312 b.

It should also be understood that the appearance of a particular area may vary from tile to tile depending on the decorative pattern selected and the length of the repeating units of the decorative pattern. For example, in the embodiment illustrated in fig. 3A, the repeating unit R of the decorative pattern 334 spans the length of both tiles 302a, 302 b. As a result, the modular textile system 300 includes two visually distinct tiles a1, a2 (fig. 3B). Nevertheless, it is apparent to an observer that modular textile system 300 typically includes three types of carpet tiles, even though each carpet tile that includes decorative pattern 334 (i.e., carpet tile a) may not be exactly the same in appearance.

Any tile may be provided with one or more additional design elements or features having a more prominent appearance, if desired. Any number, shape and arrangement of such elements as desired may be used to achieve the desired visual impression or effect. For example, additional design elements may include a tape, a strip, a pair of parallel lines, a twisted pair of short lines, a spool, a wave, a curve, or any other suitable shape. The design elements may be used to alter the aesthetics of the textile system, facilitate the coordination of carpet tiles, or other suitable purposes.

For example, in the embodiment shown in fig. 2A, a plurality of weighted strips 238, 240,242,244, 246,248 extend along the length M of the web 232 in the zones 210, 214, 216, 218, 220. (it should be noted that the embodiment shown in fig. 3A-3C includes similar weighting strips 348, 350, 352, 354, 356, 358, which are not discussed separately herein.) each weighting strip may have a color that is different from the remainder of the respective zone, and thus, the weighting strips serve as contrasting ("control") elements or features within the respective zone (and/or with respect to other zones of the modular textile system). By way of example, the accent bars 238, 240,242,244, 246,248 may be red, yellow, white, black, blue, green, blue-violet, or any other suitable color, while the remainder of the fabric mesh 232 may generally comprise the colors of the tonal range of the earth. Alternatively, the highlight bar may generally have the same chromaticity as the rest of the area, but a different color (i.e., a different value or color saturation), such that the outline of the highlight bar is more subtle.

In the illustrated embodiment, the weight strips are positioned such that when the web 232 is cut into tiles, the tile 202 has one weight strip 238, the tile 204 has three weight strips 240,242,244, and the tile 206 has two weight strips 246, 248. At least some of the weighted strips of different tiles are of substantially the same color so that each tile is coordinated with every other tile. In one embodiment, the accent bars on different tiles may be configured as follows:

carpet tile 202 ═ weight bar 238 (color 1)

Tile 204 — highlight bar 240 (color 2), highlight bar 242 (color 3), and highlight bar 244 (color 1); and

tile 206 is a highlight bar 246 (color 4) and a highlight bar 248 (color 3), where colors 1,2,3, and 4 may be any suitable color. As such, the accent bar 238 of tile 202 matches one accent bar 244 of tile 204, and one accent bar 242 of tile 204 matches one accent bar 248 of tile 206. Because the tile 204 includes weighted strips having the same color as the weighted strips of the tiles 202,206, the weighted strips of the tile 204 may provide additional continuity between the tiles 202,206, thereby enhancing the bridging capability of the tile 204. However, other arrangements of the elements may be used.

The design elements are used in a common area of the fabric web, and in some embodiments, the design elements may be placed entirely within one tile, such that the resulting coordinated areas differ in appearance. For example, in fig. 2A and 2B, the weighted strips 242,244 are positioned entirely within the area 216a of the tile 204 relative to the background 250, while the area 216B of the tile 206 includes only the background 250. Nevertheless, since such regions are substantially similar in composition and appearance, the regions may still serve as a coordination area, as it is apparent to the user that such regions attempt to coordinate with each other.

It should be appreciated that the presence of design elements (e.g., patterns, decorative patterns, contrasting elements, or other design elements), and/or the modification of the coordination zone, may provide new visual "dimensions" for the modular textile system while maintaining continuity between different distinct carpet tiles throughout the installation, as schematically illustrated in the exemplary installation 224,324 of fig. 2C and 3C. Moreover, the modular textile system of the present disclosure allows designers to use patterns or decorative patterns that may have overwhelming advantages in typical broadloom installations. For example, if the decorative pattern 234 is repeated continuously across the length and width of the fabric web, the overall appearance of the installation may be too "distracted" to some observers. However, when the same decorative pattern 234 is used in accordance with the modular textile system of the present invention, some segments of the decorative pattern 234 may have a more subtle, more limited appearance, and in some cases may advantageously resemble decorative inlays.

In one of the above embodiments, the arrangement of the areas on each tile and on the web is asymmetrical. However, a symmetrical arrangement may be used if desired. For example, FIG. 4A illustrates a textile web 400 that includes a plurality of design areas arranged such that each of the formed tiles includes a substantially symmetrically arranged area. Specifically, width T of web 400 is divided into seven discrete design regions 402,404,406,408,410,412,414 that extend along length M of web 400 in the machine direction. Zone 402,414 has a substantially equal width Z1, zone 404,408,412 has a substantially equal width Z2, and zones 406 and 410 have a substantially equal width Z3 (approximately twice width Z1), such that each tile 416,418,420 of the three tile system 422 (FIG. 4B) includes a design zone 404,408,412 having a width Z2 centered along the width of the respective tile 416,418,420, and the respective two edge zones 402,406a, 406B, 410a, 410B, 414 have a width Z1 and are disposed on either side of the respective central zone 404,408,412.

As noted above, carpet tile 416,418,420 may be installed in any suitable manner. In one exemplary non-directional installation 424 as shown in FIG. 4C, the arrangement of the tiles resembles a square weave. However, other configurations are envisioned. Further, in other embodiments, the tiles 416,418,420 may include one or more design elements or features (e.g., decorative patterns or other elements) as needed to achieve the desired aesthetics of the modular textile system 422.

Some aspects of the present disclosure may be illustrated with reference to the following examples, but are not to be construed as being limited in any way.

Example 1

Various modular textile systems similar to the system 100 of fig. 1A are prepared with different color designs (i.e., color schemes) according to the method described in connection with fig. 1F. The fabric mesh is about 72 inches (about 1.83 meters) wide. The width of the web was cut into three tiles, each having a width of about 24 inches (about 0.6 meters) and a length of about 24 inches (about 0.6 meters).

For each color design used, the design area can be characterized as follows:

108-very textured, about 4.75 inches (about 0.121 meters) wide

110-very tall ribs, about 6.375 inches (about 0.162 meters) wide

112-pinstripe pattern, width about 17.5 inches (about 0.33 meter)

114-very tall relief pattern, about 6.125 inches (about 0.156 meters) wide

116- "tweed" style flush terry weave approximately 17.5 inches wide (approximately 0.445 meters)

118-very tall ribs, high shin, light cut pile, width of about 6.4375 inches (about 0.164 meters)

120- "Sisala" style weave having a width of about 11.625 inches (about 0.295 meters)

122-very coarse, about 1.875 inches wide (about 0.048 meters)

When cut into carpet tiles, area 112a has a width of about 13 inches (about 0.33 meters), area 112b has a width of about 4.5 inches (about 0.114 meters), area 116a has a width of about 13.25 inches (about 0.337 meters), and area 116b has a width of about 4.25 inches (about 0.108 meters).

Additionally, carpet tile type a is formed using a cooler color, carpet tile type C is formed using a warmer color, and carpet tile type B is formed using a color that is between the colors of carpet tiles a and C. The tiles are installed using a variety of techniques to form a myriad of different overall designs.

It should be noted that while the above description is made with respect to a modular textile system comprising three distinct tile designs, other numbers of tile designs are contemplated. As such, a system may include two, three, four, five, or any other suitable number of distinct carpet tile styles. In such systems, a myriad of other packaging techniques may be used to facilitate installation and/or to assist the installer in creating a desired aesthetic.

Further, it should be understood that a myriad of other methods may be used to form a modular textile system consistent with the present disclosure. For example, the fabric web may be provided with a plurality of tiles of one type (e.g., a, B or C) that repeat across the web, and the web may be individually cut into tiles. In such a method, the number of distinct tiles may generally equal the number of textile webs (e.g., three distinct tiles, three textile webs). In another embodiment comprising four distinct tiles, two or more webs of fabric may be used to create each tile type. For example, one web may be used to prepare carpet tiles types a and B, while the other web is used to prepare carpet tiles types C and D. The tiles may be sorted or compiled and provided to the user as desired. Thus, a myriad of other possible scenarios are contemplated.

It should also be noted that any of the various fabric webs described or contemplated herein may be used as a roll product, either alone or in combination with a carpet tile. Because the fabric web includes many design areas and design elements, the resulting installation may have a multi-dimensional appearance that is typically only traditionally achieved using custom design, manufacturing, and/or installation techniques.

It should be understood that any of a variety of textile systems (e.g., as part of a textile family) may be displayed or visualized alone or in combination with other textile systems. For example, one or more textile systems may be displayed or visualized in a book or loose-leaf cover, including actual carpet samples or swatches, images of carpet samples, photographs of carpet tiles in use, and/or any other product information that may be reviewed by a potential purchaser.

Since each textile system includes a plurality of distinct tiles, it should be appreciated that the presentation including implementation of a textile sample is more cumbersome than the presentation having only one distinct tile pattern. This is particularly true when a series of textile systems exist, for example, providing a particular style among a plurality of color schemes. In this case, it may be more advantageous to prepare samples that are smaller in size than would typically be used. Such a sample may be formed from a scaled down version of the web such that the relative proportions of each design region and design element remain in the sample. In this manner, a potential purchaser may view the entire textile system at one or more color schemes without the need for an overly extensive sample specification or loose-leaf covers.

Alternatively or additionally, the display or presentation may include one or more "virtual" samples. A virtual sample is a generally accurate image or appearance printed or otherwise presented on a tangible medium such as paper, as described in U.S. patent application publication No. us2007-0298382a1, published on 27/12/2007, which is incorporated by reference herein in its entirety. Multiple virtual samples may be provided for each tile style and/or color scheme so that one or more samples may be removed without making the display incomplete. Such samples may be used to simulate various arrangements of distinct tiles, to envision various installation techniques, or for any other suitable purpose.

It will be readily appreciated by those skilled in the art, in view of the foregoing disclosure, that the present invention has broad utility and use. Although specific embodiments or aspects are disclosed, it is to be understood that this disclosure is only illustrative and exemplary of the present invention and is made merely for the purpose of providing a full and enabling disclosure of the invention, the best mode known to the inventors for carrying out the invention at the time the inventors make the invention. It will also be appreciated that aesthetic or visually pleasing or ideal conditions are inherently subjective, varying depending on his or her personal tastes, and therefore no single one of the arrangements envisioned by the present invention will receive all of the person's appearance expectations or appreciation.

Many modifications, variations, modifications and equivalent arrangements will be apparent from or reasonably suggested by the present invention and the foregoing detailed description thereof without departing from the substance or scope of the present invention. It will be appreciated that various elements discussed with reference to the embodiments may be interchanged to create new embodiments within the scope of the present invention, and accordingly, all subject matter contained in the above description or shown in the accompanying drawings will be understood to be illustrative only and not to be construed as limiting or excluding any other embodiments, adaptations, variations, modifications and equivalent arrangements of the present invention.

Claims (37)

1. A method of making a modular textile system, the method comprising:

dividing a web having a length and a width into a plurality of tile areas having substantially equal sizes and including a first tile area, a second tile area, and a third tile area positioned across the width of the web,

wherein the fabric web comprises a plurality of discrete design zones along a width of the fabric web, each of the plurality of design zones having a width and extending along a length of the fabric web, the plurality of design zones comprising:

a first design area including a decorative pattern, and

a second design area that does not include a decorative pattern,

wherein the step of dividing the web into a plurality of tile areas comprises dividing the web into a plurality of tile areas such that

The first design area is adapted to be divided between the first and second tile areas such that the first and second tile areas each comprise a portion of the first design area, an

The second design area is adapted to be divided between the second tile area and the third tile area such that the second tile area and the third tile area each comprise a portion of the second design area.

2. The method of claim 1, wherein a portion of the first design area assigned to the first tile area and a portion of the first design area assigned to the second tile area have different appearances.

3. The method of claim 1, wherein the decorative pattern extends substantially across a width of the first design region.

4. The method of claim 1, wherein the decorative pattern extends partially across a width of the first design zone such that only a portion of the first design zone assigned to the first tile area comprises the decorative pattern.

5. The method of claim 1,

a portion of the first design zone assigned to the first tile area includes a decorative pattern and a background, an

A portion of the first design zone assigned to the second tile area includes background but no decorative pattern.

6. The method of claim 1,

a portion of a first design area assigned to the first tile area, and

a portion of the first design zone assigned to the second tile area each includes a decorative pattern and a background.

7. The method of claim 1,

each design region of the plurality of design regions has a width of at least 2.54 centimeters.

8. The method of claim 1,

at least one design region of the plurality of design regions includes a design element comprising a band, a strip, a curve, or any other suitable shape.

9. The method according to any one of claims 1-8, further comprising:

the fabric web is divided such that the first, second and third tile areas each form a first, second and third tile of the modular textile system.

10. A modular textile system formed by the method of claim 9, wherein the modular textile system includes a first tile, a second tile, and a third tile.

11. A method of making a modular textile system, the method comprising:

forming a fabric web, the fabric web having a length and a width, wherein forming the fabric web comprises forming the fabric web such that the fabric web comprises a plurality of design zones across the width of the fabric web, the plurality of design zones each extending along the length of the fabric web, and

dividing the web into a plurality of tiles having substantially equal sizes and comprising a first tile, a second tile, and a third tile positioned across a width of the web, wherein the step of dividing the web into the plurality of tiles comprises dividing the web into the plurality of tiles such that

The first design area is adapted to be divided between the first tile and the second tile such that the first tile and the second tile each comprise a respective portion of the first design area, an

The second design area is adapted to be divided between the second tile and the third tile, such that the second tile and the third tile each comprise a respective portion of the second design area,

wherein the first design area of the first tile and the first design area of the second tile have different appearances.

12. The method of claim 11, wherein the portion of the first design area assigned to the first tile and the portion of the first design area assigned to the second tile have different appearances.

13. The method of claim 11, wherein the first design region of the fabric web includes a decorative pattern configured such that the decorative pattern is

A portion of the first design area assigned to the first tile, and

the portions of the first design zone that are assigned to the second tile each include a decorative pattern.

14. The method of claim 11, wherein the first design region of the fabric web includes a decorative pattern configured such that the decorative pattern is

Only the portion of the first design zone assigned to the first tile includes a decorative pattern.

15. The method of claim 11,

the portion of the first design zone assigned to the first tile includes a decorative pattern and a background, an

The portion of the first design zone that is assigned to the second tile includes background but not decorative patterns.

16. The method of claim 11,

the respective portions of the first design area that are assigned to the first tile and the second tile each include a decorative pattern and a background.

17. The method of claim 11,

each design region of the plurality of design regions has a width of at least 2.54 centimeters.

18. The method of claim 11,

at least one design region of the plurality of design regions includes a design element comprising a band, a strip, a curve, or any other suitable shape.

19. A modular textile system formed by the method of any of claims 11-18, wherein the modular textile system comprises a first tile, a second tile, and a third tile.

20. A method of making a modular textile system, the method comprising:

cutting a web having a length and a width into a plurality of tiles having substantially equal sizes and comprising a first tile, a second tile, and a third tile abutting one another across the width of the web, wherein the web comprises a plurality of discrete design zones each comprising a portion of the width of the web and extending along the length of the web, and

wherein the step of dividing the web into a plurality of tiles comprises dividing the web into a plurality of tiles such that

The first design area is adapted to be divided between the first tile and the second tile such that the first tile and the second tile each comprise a portion of the first design area, an

The second design area is adapted to be divided between the second tile and the third tile, such that the second tile and the third tile each comprise a portion of the second design area,

wherein the first design region includes a decorative pattern that is not included in the second design region.

21. The method of claim 20, wherein the portion of the first design area of the first tile and the portion of the first design area of the second tile have different appearances.

22. The method of claim 20, wherein the decorative pattern extends substantially across the width of the first design region such that

A portion of the first design area of the first tile, and

the portions of the first design zone of the second tile each include a decorative pattern.

23. The method of claim 20, wherein only a portion of the first design area of the first tile comprises a decorative pattern.

24. The method of claim 20,

the portion of the first design area of the first tile includes a decorative pattern and a background, an

The portion of the first design area of the second tile includes a background but does not include a decorative pattern.

25. The method of claim 20,

the portions of the respective first design areas of the first and second tiles include a decorative pattern and a background.

26. The method of claim 20,

each design region of the plurality of design regions has a width of at least 2.54 centimeters.

27. The method of claim 20,

at least one design region of the plurality of design regions includes a design element comprising a band, a strip, a curve, or any other suitable shape.

28. A modular textile system formed by the method of any of claims 20-27, wherein the modular textile system comprises a first tile, a second tile, and a third tile.

29. A method of making a modular textile system, the method comprising:

distributing a web of fabric into a plurality of tile areas, the web of fabric including a plurality of discrete design zones positioned along a width of the web of fabric, the plurality of design zones each extending along a length of the web of fabric,

wherein the plurality of tile areas are of substantially equal size and include a first tile area, a second tile area, and a third tile area positioned across a width of the web of fabric, and

wherein the step of distributing the web into a plurality of tile areas comprises distributing the web into a plurality of tile areas such that

The first design area is adapted to be divided between the first and second tile areas,

the second design area is adapted to be divided between the second tile area and a third tile area,

wherein the first design region includes a decorative pattern that is not included in the second design region, an

Splitting the web such that the first, second and third tile areas each form a first, second and third tile of the modular textile system, thereby

The first tile and the second tile each include a portion of a first design area, an

The second tile and the third tile each include a portion of the second design area.

30. The method of claim 29, wherein the portion of the first design area of the first tile and the portion of the first design area of the second tile have different appearances.

31. The method of claim 29,

a portion of the first design area of the first tile, and

a portion of the first design zone of the second tile each includes a decorative pattern.

32. The method of claim 29, wherein only the first tile includes a decorative pattern.

33. The method of claim 29,

the first tile includes a decorative pattern and a background, an

The second tile includes a background but no decorative pattern.

34. The method of claim 29,

the first tile and the second tile each include a decorative pattern and a background.

35. The method of claim 29,

each design region of the plurality of design regions has a width of at least 2.54 centimeters.

36. The method of claim 29,

at least one design region of the plurality of design regions includes a design element comprising a band, a strip, a curve, or any other suitable shape.

37. A modular textile system formed from the method of any of claims 29-36, wherein the modular textile system comprises a first tile, a second tile, and a third tile.