U.S. patent application number 10/417630 was filed with the patent office on 2003-11-13 for random installation carpet tiles.
Invention is credited to Daniel, Sydney D., Oakey, David D..
Application Number | 20030211274 10/417630 |
Document ID | / |
Family ID | 25128975 |
Filed Date | 2003-11-13 |
United States Patent
Application |
20030211274 |
Kind Code |
A1 |
Daniel, Sydney D. ; et
al. |
November 13, 2003 |
Random installation carpet tiles
Abstract
Carpet tiles having patterns and color schemes that obviate the
need to orient the tiles relative to each other. The tiles exhibit
orthogonal ambiguity, meaning that they may be laid in any
side-by-side orientation with respect to adjacent tiles without
looking out of place to the ordinary viewer and thereby still
achieving an appearance of continuity like broadloom carpet. Each
tile has patterns of shapes having some straight sides and that
appear to be randomly positioned but oriented with some straight
sides parallel to carpet tile sides. The shapes are formed from a
color or combination of colors so that adjacent shapes on each tile
have at least one color in common. Furthermore, each tile has at
least one color in common with every other tile, so that when the
tiles are laid, the colors on adjacent tiles coordinate. All of the
colors have similar intensities so that no one color will
significantly stand out from the other colors. Moreover, because
the pattern on each tile appears random, placement of the tiles on
the floor in any side-by-side orientation simply creates a larger,
apparently random pattern, rendering it impossible for any tile to
look out of place.
Inventors: |
Daniel, Sydney D.;
(LaGrange, GA) ; Oakey, David D.; (LaGrange,
GA) |
Correspondence
Address: |
JOHN S. PRATT, ESQ
KILPATRICK STOCKTON, LLP
1100 PEACHTREE STREET
SUITE 2800
ATLANTA
GA
30309
US
|
Family ID: |
25128975 |
Appl. No.: |
10/417630 |
Filed: |
April 16, 2003 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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10417630 |
Apr 16, 2003 |
|
|
|
09783354 |
Feb 14, 2001 |
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Current U.S.
Class: |
428/44 |
Current CPC
Class: |
Y10T 428/23929 20150401;
A47G 27/0275 20130101; B44F 5/00 20130101; E04F 15/02 20130101;
Y10T 428/23936 20150401; A47G 27/0475 20130101; Y10T 428/16
20150115; B44F 1/08 20130101; B44C 1/28 20130101; Y10T 428/164
20150115 |
Class at
Publication: |
428/44 |
International
Class: |
B32B 003/10 |
Claims
What is claimed is:
1. An orthogonally ambiguous carpet tile.
2. The orthogonally ambiguous carpet tile of claim 1, wherein the
tile has a tufted face.
3. The orthogonally ambiguous carpet tile of claim 1, wherein the
tile has a woven face.
4. The orthogonally ambiguous carpet tile of claim 1, wherein the
tile has a fusion bonded face.
5. An orthogonally ambiguous carpet tile having a pattern
comprising a background color and a first color different from the
background color.
6. The carpet tile of claim 5, wherein the background color and the
first color have similar intensities.
7. The carpet tile of claim 5, wherein the pattern comprises
shapes, at least one of which shapes is formed by at least one
straight line.
8. The carpet tile of claim 7, wherein adjacent shapes comprise at
least one common color.
9. The carpet tile of claim 7, wherein the at least one straight
line is oriented parallel to an edge of the carpet tile.
10. The carpet tile of claim 7, wherein at least one shape
comprises only the background color.
11. The carpet tile of claim 7, wherein a least one shape comprises
the background color and the first color.
12. The carpet tile of claim 7, wherein the pattern further
comprises a second color different from the background color and
the first color.
13. The carpet tile of claim 12, wherein the background color, the
first color, and the second color have similar intensities.
14. The carpet tile of claim 12, wherein at least one shape
comprises only the background color and the second color.
15. The carpet tile of claim 12, wherein at least one shape
comprises the background color, the first color, and the second
color.
16. The carpet tile of claim 12, wherein the pattern further
comprises a third color different from the background color, the
first color, and the second color.
17. The carpet tile of claim 16, wherein the background color, the
first color, the second color, and the third color have similar
intensities.
18. The carpet tile of claim 16, wherein at least one shape
comprises only the background color and the third color.
19. The carpet tile of claim 16, wherein at least one shape
comprises only the background color, the second color, and the
third color.
20. An orthogonally ambiguous carpet tile comprising a pattern of
shapes, at least one of which shapes is formed by a straight line
oriented parallel to an edge of the carpet tile, wherein the shapes
are further formed from at least one of a plurality of colors
comprising at least a background color, a first color, and a second
color, wherein at least one of the shapes is formed from the
background color only, at least one of the shapes is formed from
the background color and the first color only, at least one of the
shapes is formed from the background color and the second color
only, and at least one of the shapes is formed from the background
color, the first color, and the second color, wherein the
background color, the first color, and the second color have
similar intensities and wherein adjacent shapes comprise at least
one common color.
21. Floorcovering comprising at least two orthogonally ambiguous
carpet tiles positioned side-by-side.
22. Floorcovering comprising at least two orthogonally ambiguous
carpet tiles positioned side-by-side wherein each tile comprises a
pattern formed by a background color and at least two colors
different from the background color, wherein the background color
and at least one of the at least two colors different from the
background color are the same for the at least two orthogonally
ambiguous carpet tiles.
23. The carpeting of claim 22, wherein the pattern on each of the
at least two orthogonally ambiguous carpet tiles comprises shapes,
at least one shape on each of the at least two orthogonally
ambiguous carpet tiles having a straight side.
24. The carpeting of claim 23, wherein adjacent shapes on each of
the at least two orthogonally ambiguous carpet tiles comprise at
least one common color.
25. A method for designing a pattern for a carpet web usable to
produce orthogonally ambiguous carpet tiles, comprising: a.
selecting a background color for the carpet web; b. using a
plurality of colors, including the background color, to form shapes
on the carpet web; and c. designing and positioning the shapes on
the carpet web so that at least one shape has at least one straight
side parallel to an edge of the carpet web and adjacent shapes have
at least one common color.
26. A method for designing a pattern usable to produce orthogonally
ambiguous square modules, comprising: a. selecting a background
color for the pattern; b. using a plurality of colors, including
the background color, to form shapes in the pattern; and c.
designing and positioning the shapes in the pattern so that at
least one shape has at least one straight side parallel to a module
edge and adjacent shapes have at least one common color.
Description
FIELD OF THE INVENTION
[0001] This invention relates generally to carpet tiles and a
method of designing carpet tiles having patterns and color schemes
that allow for placement of the carpet tiles in any orientation
with respect to adjacent carpet tiles while still achieving the
appearance of broadloom carpet.
BACKGROUND OF THE INVENTION
[0002] Traditionally, proper placement of carpet tiles has been
necessary to give the appearance of seamless broadloom carpet or at
least the appearance of a carpet tile installation in which tiles
are not out of place or misplaced. Conventional carpet tiles,
particularly including tufted, fusion bonded, or woven face carpet
tiles, normally have a "direction" as a result of (1) the pattern
on the tiles and/or (2) the manufacturing process.
[0003] After the carpet web is cut into the tiles, the tiles must
be oriented on the floor so that their pattern aligns with the
patterns on adjacent tiles or with the appearance of adjacent
tiles. Most carpet tiles are square. If a first carpet tile is
placed on the floor, a second tile may be placed in four different
positions relative to each side of the first tile by rotating the
second tile in 90 degree increments relative to the first carpet
tile and by placing the second tile adjacent to each of the four
sides of the first tile. In only one of the second tile's four
rotational positions is the second tile oriented in the same
"direction" as the first tile, so that both tiles are in the same
rotational orientation as they were relative to each other in the
carpet web from which they were cut or as they came off of the
carpet producing machine. Moreover, some patterns used on carpet
tiles require that the second tile be placed only adjacent to a
particular side or sides of the first tile, rather than adjacent to
any of the four sides of the first tile.
[0004] Furthermore, because of the manufacturing process, even
solid color tiles without any pattern usually have a nap
orientation or "direction." Additionally, minor variations in color
require that carpet tiles in a particular installation all use yarn
dyed in the same dye lot to avoid visually discernable differences
between adjacent carpet tiles resulting from variations in
dying.
[0005] Therefore, not only must the patterns of adjacent tiles be
aligned, adjacent tiles must be placed so that the nap is oriented
in the same direction, and it is frequently necessary to insure
that adjacent tiles, and sometimes all tiles in a particular
installation, were dyed or have fiber dyed at the same time. If one
carpet tile in an installation is oriented improperly with respect
to adjacent carpet tiles, it is usually readily apparent that the
tile has been misplaced, thereby destroying the appearance of
continuity of pattern, nap, and color of the entire carpet tile
installation. The carpet installer, therefore, must spend valuable
time during installation ensuring proper orientation of the
tiles.
SUMMARY OF THE INVENTION
[0006] This invention addresses the above-described problems by
providing carpet tiles and a method of making carpet tiles having
patterns and color schemes that obviate the need to orient the
tiles (with respect to pattern or nap) relative to each other and
that generally eliminate the need to match tiles as to dye lot.
Instead, the tiles exhibit orthogonal ambiguity, meaning that tiles
may be laid in any side-by-side orientation with respect to
adjacent tiles without looking out of place to the ordinary viewer
and thereby still achieving an appearance of continuity across the
entire installation as if the tiles were part of a broadloom
web.
[0007] "Orthogonally ambiguous" tiles must be positioned in one of
sixteen positions relative to each. Such positioning is achieved by
rotating adjacent tiles in ninety degree increments relative to
each other. A "rotational position indeterminate" carpet web
pattern can be imaged in which any tile can be cut from the web in
any rotational position relative to any other tile cut from the
web, including a rotational position displayed by other than ninety
degree increments (e.g. forty-five degrees). However, cutting tiles
from a web at such orientations would generally produce substantial
waste and be impractical.
[0008] The orthogonally ambiguous tiles of this invention are
produced by first producing a carpet web having a pattern
exhibiting the characteristics described herein and then cutting
the web into tiles in the conventional ways that tiles are
typically cut from a carpet web produced for that purpose. The web
has a pattern of shapes having at least some straight edges that
will parallel the tile edges but that appear to be randomly
oriented and positioned within the pattern. The shapes are formed
from a color or combination of colors so that adjacent shapes on
each tile have at least one color in common. Furthermore, each tile
always has at least one color in common with every other tile, so
that when the tiles are laid, the colors on adjacent tiles
coordinate. All of the colors typically should have similar
intensities so that no one color significantly stands out from the
other colors.
[0009] Because the pattern on each tile appears random, placement
of the tiles on the floor in any orientation simply creates a
larger, apparently random pattern, rendering it impossible for any
tile to look out of place. Such randomness masks the visual effects
of having adjacent carpet tiles with misaligned or
differently-oriented naps and also masks slight color variations
resulting from dye lot differences. The presence, within the
pattern, of shapes with edges parallel to the edges of the tile
insures that, if the shapes are partitioned when the web is cut
into tiles, the partitioned shapes will not appear out of place,
since the shapes of the pattern already include elements, having
straight edges parallel to at least one of the tile edges, similar
to the partitioned shapes, which have a straight edge defined by
the straight edge of a panel. Given the apparent randomness of the
pattern and color scheme, worn or soiled tiles in a particular
installation may easily be replaced with an unused tile without the
new tile looking as dramatically different from the remaining tiles
as often results with tiles with conventional patterns.
[0010] It is thus an object of this invention to provide carpet
tiles that may be laid in any orientation with respect to each
other and still achieve the appearance of a continuous piece of
broadloom carpet.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] The file of this patent contains at least one drawing
executed in color. Copies of this patent with color drawing(s) will
be provided by the Patent and Trademark Office upon request-and
payment of the necessary fee.
[0012] FIG. 1 is a top plan view of a carpet tile web produced in
accordance with one embodiment of this invention.
[0013] FIG. 2 is a top plan view of two carpet tiles produced in
accordance with this invention positioned in a first orientation
relative to each other.
[0014] FIG. 3 is a top plan view of the two carpet tiles
illustrated in FIG. 2 with one of the tiles rotated ninety degrees
from the orientation illustrated in FIG. 2.
DETAILED DESCRIPTION OF THE DRAWINGS
[0015] FIG. 1 illustrates a carpet web 22 having a pattern
consistent with this invention. Longitudinal partition lines 24-26
and horizontal partition lines 27-30 show how the web 22 may be
partitioned into twenty individual carpet tiles 1-20. A number of
factors contribute to the orthogonal ambiguity of each carpet tile,
including pattern shapes and arrangement and shape colors.
[0016] The pattern produced on web 22 produces tiles with shapes
that appear randomly positioned on the tile. Only shapes having
certain characteristics are usable. First, at least some of the
shapes must have straight sides parallel to the "machine" and
"cross-machine" direction of the web 22, and therefore parallel to
the tile edges. For instance, shape 32 in FIG. 1 has a straight
side 34 parallel to longitudinal partition line 24 and therefore
parallel to the edge of tile 1 that will be defined by longitudinal
partition line 24. Similarly, shape 32 has a straight side 36
parallel to horizontal partition line 27, and it, too, will
parallel the edge of tile 1 that will be defined by horizontal
partition line 27. Partition line 24 will pass through and
partition shape 32, thereby resulting in a portion of shape 32
ending up on each of tile 1 and 2. The straight edge of shape 32
that will appear on each of tile 1 and 2 will not appear to be out
of place.
[0017] Size of the shapes within the pattern is also important, as
is lateral position of the shapes within the web. The shapes must
generally be small enough so that several shapes will end up
positioned within each tile. Otherwise, the fraction or fractions
of larger shapes falling on a particular carpet tile would
potentially look odd. Shapes should be positioned laterally within
the web so that longitudinal partition lines 24, 25, and 26 do not
partition a shape so that an oddly narrow portion falls on one of
the tiles.
[0018] Each tile preferably has the same background color. At least
one color, different from the background color, is used to form the
shapes on the tile. Regardless of how many colors are used, all of
the colors should have similar intensities so that no one color
significantly stands out from the other colors. Note that multiple
shapes may be, and preferably should be, formed on each tile. It is
important, however, that each shape have at least one color in
common with adjacent shapes on the tile. Use of multiple shapes and
colors contributes to the apparent random quality of the pattern,
thereby making an installation of such tiles appear to be
continuous without regard to the orthogonal orientation of the
tiles within the installation.
[0019] While the adjacent shapes of each tile have at least one
color in common, additionally, each tile preferably has at least
one color in common (in addition to the background color) with
every other tile, so that when the tiles are laid, the colors on
adjacent tiles will coordinate.
[0020] Because the pattern on each tile appears random, placement
of the tiles on the floor in any orientation simply creates a
larger, apparently random pattern, rendering it impossible for any
tile to look out of place. Such apparent randomness obviates the
need to align the nap or "direction" of adjacent tiles, as
misaligned naps further enhance the random appearance of the
carpeting. Such randomness also masks color variation resulting
from dye lot differences.
[0021] In summary, the "rules" for creating a pattern in accordance
with this invention are:
[0022] 1. Utilization of a background color for the entire web from
which tiles will be cut.
[0023] 2. Utilization of a pattern of shapes on the web formed by
colors of approximately the same intensity as the background color
and each other.
[0024] 3. Utilization of shapes small enough for several to appear
on each tile.
[0025] 4. Utilization of shapes having straight edges parallel to
the tile edges.
[0026] 5. Utilization of a pattern causing each tile cut from the
web to have at least 1 color in common with each other tile.
[0027] The carpet web 22 shown in FIG. 1 practices these rules and
may be formed by a conventional carpet tufting machine. For
example, a tufting machine having two rows of needles may be used.
One row of needles may be threaded up with a single background
color that is present across the entire carpet web 22. The second
row of needles may be threaded with yarns of other colors as
described below. The pattern of shapes is created on the carpet web
by controlling the height of the yarn. The farther the yarn is
pushed through the primary backing, the greater its height in the
finished carpet tile and the more predominant the color of the yarn
is to the ordinary observer. In the pattern shown in FIG. 1, the
background yarn A tufts have a uniform height across their entire
pattern, so that at least some background yarn A is visible in all
areas of the pattern, and some areas show only background yarn
A.
[0028] For ease of manufacture, in the embodiment shown in FIG. 1
the color scheme of the carpet web 22 is symmetrical about the
longitudinal partition line (and also longitudinal axis) 25 of the
carpet web 22. This means that the two side-by-side tiles 1 and 2
on one side of a production line can be boxed together, while the
two side-by-side tiles 3 and 4 on the other side of the production
line can be boxed together, and all boxes will have the same
proportions of tiles having a particular color combination. This
symmetry would not be necessary if tiles from the entire line were
used to fill all of the boxes or other packages of tiles produced
together.
[0029] The background color A (in this instance, yellow) is tufted
over the entirety of the carpet web 22. The patterns of the outer
portions BC of the web 22 are further formed from alternating
colors B and C (light green and dark green, respectively, in this
embodiment). Directly adjacent the outer portions BC, the patterns
of middle portions CD are further formed from alternating colors C
and D (dark green and blue, respectively, in this embodiment).
Finally, the patterns of center portion DE are further formed from
alternating colors D and E (blue and purple, respectively, in this
embodiment).
[0030] While the carpet web 22 may be divided into any number of
tiles, the carpet web 22 of FIG. 1 is divided into tiles 1-20 so
that at least part of each tile has the color schemes of at least
two of the portions--BC, CD, and DE. For example, outer portion BC
and middle portion CD make up tile 1. In this embodiment, the
shapes of tile 1 are made from: (1) the background color A only;
(2) the background color A and color B only; (3) the background
color A and color C only; (4) the background color A, color B, and
color C; (5) the background color A and color D only; and (6) the
background color A, color C, and color D. In this way, adjacent
shapes of each tile have at least one common color.
[0031] Moreover, adjacent tiles have at least one color in common
(in addition to the background color). For example, tile 1 and tile
2 have both color C and color D in common. When the tiles are
placed on the floor, therefore, the colors on these adjacent tiles
blend to facilitate the appearance of continuity.
[0032] The foregoing is provided for the purpose of illustrating,
explaining and describing embodiments of the present invention.
Further modifications and adaptations to these embodiments will be
apparent to those skilled in the art and may be made without
departing from the spirit of the invention or the scope of the
following claims. For instance, different shapes and sizes of
shapes than those illustrated can be used. Similarly, a wide
variety of color combinations are possible. Furthermore, while the
embodiment described above is tufted, the face fabric could also be
woven on a conventional or computer controlled Jacquard or other
loom, and the face fabric could be fusion bonded or formed in other
manners. This invention could also be used for modular flooring or
surface covering materials other than carpet tile, such as vinyl
tile.
* * * * *