Asymmetrical carpet tile design, manufacture and installation

• US 7,350,443 B2
• Filed: 03/10/2005
• Issued: 04/01/2008
• Est. Priority Date: 06/07/2002
• Status: Expired due to Term

• Current Assignee: Interface Incorporated
• Original Assignee: Interface Incorporated
• Inventors: Jones, William N., Hall, Jerry C., Oakey, David D.
• Primary Examiner(s): JUSKA, CHERYL ANN
• Application Number:
  US11/077,444
• Publication Number:
  US 20050210791A1
• Time in Patent Office: 1,118 Days
• Field of Search: 83/13, 83/39, 428/48, 428/88, 428/92
• US Class Current: 83/13
• CPC Class Codes: A47G 27/0275 Surface patterning of carpet modules, e.g. of carpet tiles
• CPC Class Codes: A47G 27/0293 Mat modules for interlocking engagement
• CPC Class Codes: B44C 3/12 Uniting ornamental elements to structures, e.g. mosaic plates
• CPC Class Codes: Y10T 428/16 Two dimensionally sectional layer
• CPC Class Codes: Y10T 428/164 Continuous two dimensionally sectional layer
• CPC Class Codes: Y10T 428/23929 Edge feature or configured or discontinuous surface
• CPC Class Codes: Y10T 428/23943 Flock surface
• CPC Class Codes: Y10T 428/23957 Particular shape or structure of pile
• CPC Class Codes: Y10T 428/24802 Discontinuous or differential coating, impregnation or bond [e.g., artwork, printing, retouched photograph, etc.]
• CPC Class Codes: Y10T 83/04 Processes
• CPC Class Codes: Y10T 83/0524 Plural cutting steps

Abstract

Design and manufacture of floor covering webs for, design, manufacture and installation of, asymmetrical carpet tiles having a prominent design element not intersected by a tile edge. Bands or regions define “frames” around what will become central carpet tile areas so that design elements positioned within the frames will not be intersected by a tile edge and may also be at least a predetermined distance from each tile edge. Design elements also may be positioned differing distances from each of at least one pair of opposed tile edges.

Claims

1. A method of producing carpet tiles comprising:

(a) producing a floor covering web carrying a design by;

(i) selecting a web width and length and defining a web blank,

(ii) defining within the web blank cutting frames, wherein adjacent cutting frames define cutting regions, and

(iii) positioning within each of a plurality of the cutting frames on the web blank at least one design element; and

(b) cutting the web along cutting lines located at any position within the cutting regions to form carpet tiles having tile edges,

wherein none of the cutting frames are invaded during cutting and wherein each carpet tile cut from the web comprises a pattern having at least one design element positioned at least a predetermined distance from each tile edge.

2. The method of claim 1, wherein positioning within each of the plurality of the cutting frames on the web blank at least one design element further comprises positioning the at least one design element a predetermined distance from the cutting frame.

3. The method of claim 2, wherein positioning the at least one design element a predetermined distance from the cutting frame comprises defining a visual frame within each cutting frame and positioning the at least one design element within the visual frame.

4. A method of producing carpet tiles comprising:

(a) producing a floor covering web carrying a design by;

(i) selecting a web width and length and defining a web blank,

(ii) defining within the web blank cutting frames having edges, wherein adjacent cutting frames define cutting regions,

(iii) defining a visual frame within each cutting frame and positioned a predetermined distance from the cutting frame within which the visual frame is defined; and

(iv) positioning within each visual frame at least one design element; and

(b) cutting the web along cutting lines within the cutting regions to form carpet tiles having tile edges,

wherein none of the cutting frames are invaded during cutting and wherein each carpet tile cut from the web comprises a pattern having at least one design element positioned at least the predetermined distance from each tile edge.

5. A method for producing carpet tiles that, when assembled on a floor, present a visually continuous appearance of visually perceptible design elements on a relatively uniform background region, the method comprising:

(a) tufting a floor covering web having a relatively uniform background region and visibly identifiable design elements positioned within cutting frames on the web, wherein adjacent cutting frames define cutting regions, and

(b) cutting the web along cutting lines located at any position within the cutting regions to form carpet tiles having tile edges and no design elements positioned less than a predetermined distance from any tile edge.

6. The method of claim 5, further comprising assembling the carpet tiles on the floor abutting each other and without regard to the location the tiles occupied on the web before the web was cut into tiles.

7. The method of claim 6, wherein assembling the carpet tiles further is done without regard to the rotational position the tiles occupied on the web before the web was cut into tiles.

8. A method for producing carpet tiles comprising:

(a) tufting a floor covering web having a background region and design elements positioned entirely within cutting frames on the web, wherein adjacent cutting frames define cutting regions, and

(b) cutting the web along cutting lines located at any position within the cutting regions to form carpet tiles having tile edges,

wherein each carpet tile consists of (i) a portion of the background region which covers the entire tile face except for (ii) a design element positioned no less than a predetermined distance from each tile edge.

9. A method for producing carpet tiles comprising:

(a) tufting a floor covering web having a background region and design elements positioned entirely within cutting frames on the web, wherein adjacent cutting frames define cutting regions, and

(b) cutting the web along cutting lines located within the cutting regions to form carpet tiles, each comprising tile edges, a portion of the background region and at least one design element, wherein no design element is positioned less than a predetermined distance from any tile edge.