Composite Carpet Tile Patterns to Mask Seams and Artifacts
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Solution Overview
Problem
Existing carpet tile patterning systems struggle to create non-repeating patterns that minimize seam discontinuities and manufacturing artifacts, while maintaining a unified design theme and preserving pile orientation, which is essential for aesthetically pleasing and durable flooring.
Innovation Solution
An automated system generates composite patterns using separately configurable pattern layers, where a base layer and overlay layers are digitally superimposed to create unique, yet visually unified, patterns on carpet tiles, incorporating common design elements and allowing for geometric manipulations to enhance randomness and mask manufacturing anomalies.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a repeating pattern is used on carpet tiles, then manufacturing and installation are simplified, but seam discontinuities become visually obtrusive and design lines appear when tiles are viewed at low sight angles
Solution Approach 1:
The patent applies asymmetry by using non-repeating, asymmetric patterns on carpet tiles that prevent the formation of visible design lines and seam discontinuities. The patterns are deliberately designed without symmetry so that when tiles are installed in various orientations, no uniform visual rhythm emerges that would highlight seams or create obtrusive design lines when viewed from different angles.
Solution Approach 2:
The patent implements dynamics by allowing the pattern orientation to vary across different tiles rather than maintaining a fixed, repeating orientation. This dynamic approach ensures that patterns on adjacent tiles are rotated at different angles, preventing the alignment of design elements across seams and eliminating the visual anomalies associated with repeating patterns.
2Stability of the object's composition
If design elements are duplicated in adjacent tiles to create a unified look, then visual consistency is improved, but any imperfections in color matching or alignment become highly visible at seams
Solution Approach 1:
By using asymmetric, non-repeating patterns, the patent ensures that design elements do not align across tile seams. This asymmetry prevents the magnification of manufacturing imperfections that would otherwise be highly visible when identical patterns are repeated across adjacent tiles.
Solution Approach 2:
The patent employs dynamic pattern orientation where each tile can have its pattern rotated at a different angle. This dynamic variation maintains visual interest and unity across the installation while preventing the precise alignment of design elements at seams, thereby reducing the visibility of color matching and alignment imperfections.
3Object-affected harmful factors
If a non-repeating pattern is used to minimize seam discontinuities, then visual appearance is improved, but the complexity of pattern generation and control increases
Solution Approach 1:
The patent applies segmentation by dividing the overall pattern design into modular components that can be independently configured and assembled. This segmentation allows the complex non-repeating pattern generation to be broken down into manageable steps, reducing the overall system complexity while maintaining the non-repeating characteristic that minimizes seam discontinuities.
Solution Approach 2:
The patent uses dynamic pattern generation where the orientation and configuration of patterns on each tile are determined by programmable parameters. This dynamic approach allows the system to automatically generate non-repeating patterns without requiring complex manual design processes, thereby managing system complexity through automation and programmability.
4Object-affected harmful factors
If carpet tiles are installed with various orientations to create visual variety, then seam discontinuities are masked, but pile orientation consistency becomes difficult to maintain
Solution Approach 1:
The patent uses asymmetric patterns that are designed to look aesthetically pleasing in multiple orientations. This allows tiles to be installed with various orientations to mask seam discontinuities while maintaining a consistent visual style throughout the installation, eliminating the need to maintain strict pile orientation consistency.
Solution Approach 2:
The patent implements universality by designing patterns that function effectively regardless of their orientation. The patterns are created to maintain their aesthetic quality when rotated, allowing the carpet tiles to be installed in any orientation without compromising the overall visual appearance or requiring strict pile orientation control.
Data Source
AI summary
An automated system for generating large numbers of digitally-defined patterns suitable for printing on textiles wherein each pattern is individually different but shares one or more unifying design motifs with all other patterns. In the general case, each pattern is comprised of at least two components in the form of separately configurable pattern layers that are digitally superimposed to form a composite pattern that is unique but visually related to all other unique patterns that use pattern layers taken from the same pattern sources.