Non-square rectangular flooring tiles and methods for cutting same

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

The traditional cutting methodology for rectangular carpet tiles often results in off-quality tiles due to skewing, particularly for patterns sensitive to alignment, and limits the ability to manufacture tiles with yarns from differing dye lots, leading to logistical issues in manufacturing and installation.

Innovation Solution

Cutting the carpet web such that the longer edge extends across the width of the web and the shorter edge along the length, reducing the likelihood of skewing and allowing for greater color variability and dye lot mergeability by increasing the number of longitudinal columns of yarn.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If traditional cutting methodology is used with vertical cuts defining the longer edge, then the tile dimensions are achieved, but skewing damages the decorative motif and creates off-quality tiles

Engineering Contradiction:

Improvealignment of cut with carpet webVSAvoidskewing detection

Core Design Contradiction:

Manufacturing precisionVSDifficulty of detecting and measuring

Solution Approach 1:

The patent inverts the traditional cutting approach by having the horizontal cuts define the longer edge L instead of the vertical cuts. This reversal changes the orientation relationship between the cut direction and the decorative motif, thereby reducing the visual impact of skewing on pattern-sensitive tiles.

Inventive Principle:

Principle #13The other way round (Inversion)

2Shape

If rectangular tiles are cut with longer edge defined by vertical cuts, then the desired tile shape is achieved, but the number of longitudinal yarn columns is reduced limiting dye lot variability

Engineering Contradiction:

Improverectangular tile dimensionsVSAvoiddye lot variability

Core Design Contradiction:

ShapeVSAdaptability or versatility

Solution Approach 1:

The patent reverses the conventional assignment of cut directions to tile dimensions. By having horizontal cuts define the longer edge and vertical cuts define the shorter edge, the tile configuration changes to include more longitudinal yarn columns, thereby enabling greater dye lot variability and mergeability.

Inventive Principle:

Principle #13The other way round (Inversion)

3Shape

If square tiles are cut and then cut in half to form rectangular tiles, then rectangular tiles are produced, but additional cutting steps and waste are required

Engineering Contradiction:

Improverectangular tile shapeVSAvoidmanufacturing efficiency

Core Design Contradiction:

ShapeVSProductivity

Solution Approach 1:

The patent performs the rectangular tile configuration action during the primary cutting process from the carpet web, rather than creating square tiles first and then cutting them in half. This preliminary action approach integrates the rectangular shape creation into the main manufacturing flow, eliminating secondary cutting operations and reducing waste.

Inventive Principle:

Principle #10Preliminary action

Data Source

PatentUS12102247B2Non-square rectangular flooring tiles and methods for cutting same

Publication Date: 2024.10.01 INTERFACE INC

AI summary

Methods of cutting a flooring web into rectangular flooring tiles such that at least one vertical cut along the length of the web defines a shorter edge of the rectangular tiles and horizontal cuts across the width of the web define the longer edges of the rectangular tiles.