Composite Carpet Tile Patterning for Random Seam-Blending Layouts
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Solution Overview
Problem
Existing carpet tile patterning systems face challenges in creating non-repeating patterns that minimize seam discontinuities and patterning artifacts, while maintaining visual unity and coherence, especially when installed over large areas, due to inherent design and manufacturing issues such as alignment of design elements and periodic non-uniformities.
Innovation Solution
An automated system generates composite patterns for carpet tiles using a base layer and overlay patterns, where each tile has a unique composite pattern with a unifying design motif, allowing for random or pseudo-random appearances that mask imperfections and maintain visual coherence through the use of algorithms and digitally-defined patterns, ensuring a unified appearance across multiple tiles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If design elements are duplicated in adjacent tiles to create continuity, then visual unity is improved, but seam discontinuities become more obtrusive due to pattern mismatches
Solution Approach 1:
The patent applies local quality by varying pattern elements specifically at seam regions while maintaining continuity of dominant design motifs. Different tile positions receive differentiated pattern treatments to mask seam discontinuities while preserving overall visual unity through shared color palettes and motif types.
Solution Approach 2:
The patent introduces asymmetry by deliberately varying pattern elements between adjacent tiles rather than using perfect duplication. This includes randomizing motif positions, sizes, and orientations within each tile to create visual diversity that obscures seam lines while maintaining cohesive design language through controlled parameter ranges.
2Ease of manufacture
If a small repeating pattern is used to simplify manufacturing, then ease of manufacture is improved, but large-scale pattern anomalies appear when viewed at shallow angles
Solution Approach 1:
The patent segments the overall pattern into multiple independent pattern layers that can be manufactured separately and then combined. This allows each layer to be produced using standard repeating patterns while the superposition of multiple layers creates a complex overall design that eliminates large-scale anomalies and design lines when viewed from various angles.
Solution Approach 2:
The patent transitions from two-dimensional repeating patterns to a multi-layered dimensional structure. By stacking multiple pattern layers with different orientations, frequencies, and transparency levels, the system creates a rich visual texture that prevents the formation of conspicuous design lines while maintaining manufacturing simplicity through standardized layer production.
3Productivity
If periodic patterning is used to simplify production, then productivity is improved, but periodic non-uniformities create visible streaks and bands
Solution Approach 1:
The patent employs periodic action by using repeating pattern units that are deliberately designed with varying parameters. Each repeating unit contains controlled variations in motif density, size, and orientation that prevent the accumulation of visible streaks and bands over large areas, while still allowing high-speed periodic production through automated patterning systems.
Solution Approach 2:
The patent applies parameter changes by systematically varying key pattern parameters (such as motif size, spacing, orientation, and color intensity) across different pattern units. These controlled parameter variations disrupt the formation of periodic non-uniformities and visible artifacts while maintaining production efficiency through algorithmic generation and automated application.
4Object-affected harmful factors
If unique patterns are generated for each tile to mask artifacts, then visual quality is improved, but device complexity increases due to automated pattern generation requirements
Solution Approach 1:
The patent implements self-service by enabling the patterning system to automatically generate unique tile patterns through algorithmic processes that use predefined design rules and randomization. The system self-adjusts pattern parameters based on input conditions without requiring manual design intervention for each tile, thereby masking artifacts while managing complexity through automation and standardized generation protocols.
Data Source
AI summary
Provided herein is a process for randomly patterning a plurality of carpet tiles, each tile having a composite pattern containing at least a base pattern and an overlay pattern. When installed, the random order of patterning results in random tile placement and an overall random appearance. The overlay patterns are randomly chosen from a library of patterns until each individual pattern has been used to create a tile series. The overlay patterns may be manipulated by rotating, mirror-imaging, rotating and mirror-imaging, or repositioning to produce additional variations and increase the number of tiles in the series. The base pattern may optionally be manipulated before being incorporated into the composite pattern. A tile collection, containing such randomly ordered composite patterns, is also described.