Interlocking carpet tile
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Solution Overview
Problem
Flat woven carpet tiles often result in visible misalignments and gaps due to small discrepancies in installation, especially under time pressure, and are prone to misorientation, leading to an uneven visual appearance and potential re-laying needs.
Innovation Solution
Design of flat woven carpet tiles with indentations and protrusions along all edges, where no section is oriented parallel to the warp or weft direction, ensuring stable interlocking and minimizing the risk of misalignment, using laser cutting for precise edges and slight melting of fibers to prevent loose fibers and enhance cohesion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If carpet tiles are installed quickly under time pressure, then installation productivity increases, but misalignment and gaps between tiles worsen
Solution Approach 1:
The edge of the carpet tile is segmented into multiple sections, where at least one section is oriented at an angle between 10-70 degrees relative to the warp and weft directions. This segmentation creates multiple interlocking points along the edge, distributing the alignment requirements across several contact zones rather than a single line, thereby maintaining precision even during rapid installation
Solution Approach 2:
The edge configuration introduces asymmetric orientation of sections relative to the traditional warp-weft alignment. By angling at least one edge section away from the standard grid alignment, the design creates a more forgiving interlocking geometry that reduces sensitivity to installation errors while maintaining visual coherence
2Ease of manufacture
If carpet tiles use traditional warp-weft parallel edges, then manufacturing and installation are simple, but visible gaps and misalignments occur
Solution Approach 1:
Instead of strictly straight edges parallel to warp and weft, the design incorporates angled sections that create a slightly curved or zigzag edge profile when viewed from above. This curved geometry allows the edges to interlock more effectively, distributing contact points and reducing visible gaps while remaining compatible with standard laser cutting capabilities
3Shape
If flat woven carpet tiles are used without pile, then the carpet appears seamless when well-aligned, but any misalignment or gap becomes clearly visible
Solution Approach 1:
The angled edge sections are pre-configured during manufacturing to create an interlocking geometry that actively guides proper alignment during installation. The angled sections act as mechanical guides that naturally steer the tiles into correct positioning, preventing misalignment before it can manifest as visible gaps in the flat woven surface
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution provides a seamless and coherent carpet appearance, reduces the risk of tiles sliding apart, and eliminates the need for arrow orientations during installation, ensuring a continuous look and improved handling and durability.
Implementation Method 1
using laser cutting for precise edges and slight melting of fibers to prevent loose fibers and enhance cohesion
Implementation Method 2
slight melting of fibers to prevent loose fibers and enhance cohesion
Data Source
AI summary
The invention relates to a flat woven carpet tile (1) with a warp direction and a weft direction. The carpet tile (1) has three or more edges extending along a circumference of the carpet tile. The carpet tile comprises a plurality of indentations (12) and protrusions (13) along all edges. The indentations (12) and protrusions (13) are shaped, dimensioned and located so that the carpet tile (1) is adapted to be joined with abutting identically shaped carpet tiles by mutual interlocking of pairs of mating indentations and protrusions along all the edges in order to form a seamless and coherent carpet. At least some of the protrusions (13) comprise transversely extending gripping elements (14) and the mating indentations (12) comprise corresponding transversely extending notches (15). The gripping elements (14) and notches (15) are dimensioned so that a good interlocking is ensured even if a pulling force is applied in a plane of the carpet tiles in a direction in which the pulling force would otherwise pull the carpet tiles apart. The present invention also relates to a method of manufacturing such a carpet tile, and in particular a method comprising use of laser cutting.