Broadloom Carpet Patterning for Non-Registered Installation
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Solution Overview
Problem
Conventional carpet installation requires precise registration and matching of adjoining pieces to avoid discontinuities, which is tedious and often results in waste due to the need for same dye lots and specific orientation, complicating the installation process.
Innovation Solution
The carpet design features irregularly colorized pattern members with void areas and varying pile heights, allowing for non-registered and non-matched installation by using a predetermined color pattern that obscures discrete patterns and can be applied without sequencing, enabling butt-to-butt or side-to-side joining without alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If conventional carpet with directional pattern and nap is used, then the carpet has aesthetic appearance and design, but the installation requires precise registration and matching of adjoining pieces which is tedious and time-consuming
Solution Approach 1:
The patent applies asymmetry by designing carpet patterns without directional symmetry or repeating motifs. Each carpet piece features unique, non-matching patterns that eliminate the need for registration during installation. The asymmetric design ensures that no two adjacent pieces need to be aligned, thereby reducing installation time while maintaining aesthetic appearance.
2Shape
If conventional carpet with directional nap is used, then the carpet has visual appeal, but the appearance varies with lighting and viewing conditions if positioned in different directions
Solution Approach 1:
The patent eliminates directional nap and asymmetric patterns that respond differently to lighting based on orientation. By using non-directional, non-repeating designs, the carpet maintains consistent visual appearance regardless of installation direction, thereby improving adaptability while preserving aesthetic appeal.
3Stability of the object's composition
If conventional carpet requiring same dye lot is used, then the color consistency between adjoining pieces is maintained, but the installation complexity increases and waste occurs due to removal and repositioning
Solution Approach 1:
The patent employs color variations within a coordinated palette rather than requiring identical dye lots. Each carpet piece features unique color distributions and patterns that work together aesthetically without needing matching dye lots. This approach maintains visual harmony while simplifying installation and reducing waste from repositioning.
4Shape
If conventional carpet with repeating patterns is used, then the design is aesthetically pleasing, but precise alignment and registration of adjoining pieces is required
Solution Approach 1:
The patent replaces repeating, symmetric patterns with unique, non-repeating asymmetric designs on each carpet piece. This eliminates the need for precise alignment and registration during installation, as there are no patterns that need to match across seams. The asymmetric design maintains aesthetic appeal while removing the requirement for manufacturing precision in alignment.
Data Source
AI summary
A carpet that can be installed onto a flooring surface without the requirement for registration between adjacent broadloom carpet pieces. The carpet comprises a design member that comprises a plurality of pattern members that are colorized and that define a void area, which has a substantially uniform color and pile height.