Border, edge or pattern carpet tile design, manufacture and installation

Abstract

Design and manufacture of tufted articles, carpet tile webs and carpet tiles, and installation of carpet tiles, having different color, pile height, pile texture or other characteristics that, together with similar other such tiles, may be installed to create borders, edges or other multiple-tile designs, usually without any of the tiles looking out of place or improperly oriented relative to nap or the direction the tile is “facing.”

The invention claimed is: 
     
      
       1. A tufted article, comprising: 
       
         a primary backing, 
         yarns tufted into the primary backing to form tufts that protrude from at least one side of the primary backing, wherein:
 (a) in at least a first area of a first portion of the article, tufts of a first yarn color having a maximum tuft height are present, 
 
         (b) in at least a second area of the first portion of the article, tufts of a second yarn color having a maximum tuft height are present, and
 (c) in at least a third area of the first portion of the article interposed between the first area and second area, progressing from the first area to the second area intermediate tufts of the first yarn color are progressively shorter and intermediate tufts of the second yarn color are progressively taller and wherein intermediate tufts of the first yarn color alternate with intermediate tufts of the second yarn color across at least a portion of the third area. 
 
       
      
     
     
      
       2. The tufted article of  claim 1 , further comprising tufts of multiple heights of at least a third color yarn in the first portion of the article. 
      
     
     
      
       3. The tufted article of  claim 2 , further comprising tufts of multiple heights of at least a fourth color yarn in the first portion of the article. 
      
     
     
      
       4. The tufted article of  claim 1 , wherein the article is a carpet tile. 
      
     
     
      
       5. An installation of a plurality of the carpet tiles of  claim 4 . 
      
     
     
      
       6. The installation of  claim 5 , wherein each of the plurality of carpet tiles comprises a pattern and wherein at least some of the carpet tile patterns in the installation are identical. 
      
     
     
      
       7. The installation of  claim 6 , wherein at least two of the carpet tiles with identical patterns are installed in the installation in different rotational orientations. 
      
     
     
      
       8. The installation of  claim 5 , wherein at least some of the plurality of carpet tiles are installed in the installation in different rotational orientations. 
      
     
     
      
       9. The tufted article of  claim 1 , wherein, in a second portion of the article: 
       
         (a) only tufts of the first yarn color are visible adjacent one side of an imaginary boundary line, and 
         (b) only tufts of a second yarn color are visible adjacent the other side of the imaginary boundary line, 
       
       thereby creating at the imaginary boundary line a discernible demarcation between tufts of the first and second yarn colors. 
      
     
     
      
       10. The tufted article of  claim 9 , wherein the article is a carpet tile. 
      
     
     
      
       11. An installation of a plurality of the carpet tiles of  claim 10 . 
      
     
     
      
       12. The installation of  claim 11 , wherein at least some of the plurality of carpet tiles are installed in the installation in different rotational orientations. 
      
     
     
      
       13. The tufted article of  claim 1 , wherein: 
       
         i. tufts of the first yarn color progress from the maximum tuft height in the first area to a minimum tuft height in the second area through a progression of at least three different tuft heights, and 
         ii. tufts of the second yarn color progress from a minimum tuft height in the first area to the maximum height in the second area through a progression of at least three different tuft heights. 
       
      
     
     
      
       14. A tufted carpet tile having a pattern and comprising: 
       
         a. a primary backing, 
         b. first and second yarns tufted into the primary backing to form tufts that protrude from a side of the primary backing, wherein the tufts have a tuft height and wherein:
 i. the first and second yarns are different in appearance with respect to at least one characteristic; 
 ii. a first area of the carpet tile comprises tufts of the first yarns, wherein tufts of the first yarns in the first area comprise a maximum tuft height; 
 iii. a second area of the carpet tile comprises tufts of the second yarns, wherein tufts of the second yarns in the second area comprise a maximum height; and 
 iv. an intermediate area extends between the first and second areas and comprises tufts of the first and second yarns, wherein the tuft height of the first yarns progressively decreases in the intermediate area from the first area toward the second area and wherein the tuft height of the second yarns progressively increases in the intermediate area from the first area toward the second area and wherein tufts of the first yarn alternate with tufts of the second yarn across at least a portion of the intermediate area. 
 
       
      
     
     
      
       15. The tufted carpet tile of  claim 14 , wherein the at least one characteristic is color. 
      
     
     
      
       16. The tufted carpet tile of  claim 14 , wherein the at least one characteristic is texture. 
      
     
     
      
       17. The tufted carpet tile of  claim 14 , wherein the first area comprises no second yarns. 
      
     
     
      
       18. The tufted carpet tile of  claim 14 , wherein the first area comprises second yarns having a minimum tuft height less than the maximum tuft height of the first yarns in the first area. 
      
     
     
      
       19. The tufted carpet tile of  claim 18 , wherein the second yarns in the first area are not visible in the pattern. 
      
     
     
      
       20. The tufted carpet tile of  claim 14 , wherein the second area comprises no first yarns. 
      
     
     
      
       21. The tufted carpet tile of  claim 14 , wherein the second area comprises first yarns having a minimum tuft height less than the maximum tuft height of the second yarns in the second area. 
      
     
     
      
       22. The tufted carpet tile of  claim 21 , wherein the first yarns in the second area are not visible in the pattern. 
      
     
     
      
       23. The tufted carpet tile of  claim 14 , wherein: 
       
         i. tufts of the first yarn progress from the maximum tuft height in the first area to a minimum tuft height in the second area through a progression of at least three different tuft heights; and 
         ii. tufts of the second yarn progress from a minimum tuft height in the first area to the maximum height in the second area through a progression of at least three different tuft heights. 
       
      
     
     
      
       24. An installation of a plurality of the tufted carpet tiles of  claim 14 . 
      
     
     
      
       25. The installation of  claim 24 , wherein at least some of the carpet tile patterns in the installation are identical. 
      
     
     
      
       26. The installation of  claim 25 , wherein at least two of the carpet tiles with identical patterns are installed in the installation in different rotational orientations. 
      
     
     
      
       27. The installation of  claim 24 , wherein at least some of the plurality of carpet tiles are installed in the installation in different rotation orientations. 
      
     
     
      
       28. The tufted carpet tile of  claim 14 , wherein, in a third area of the carpet tile: 
       
         (d) only tufts of the first yarn are visible adjacent one side of an imaginary boundary line, and 
         (e) only tufts of the second yarn are visible adjacent the other side of the imaginary boundary line, 
       
       thereby creating at the imaginary boundary line a discernible demarcation between tufts of the first and second yarns. 
      
     
     
      
       29. An installation of a plurality of the tufted carpet tiles of  claim 28 . 
      
     
     
      
       30. The installation of  claim 29 , wherein each of the plurality of carpet tiles comprises a pattern and wherein at least some of the carpet tile patterns in the installation are identical. 
      
     
     
      
       31. The installation of  claim 30 , wherein at least two of the carpet tiles with identical patterns are installed in the installation in different rotational orientations. 
      
     
     
       32. A method of making a collection of carpet tiles, each tile comprising a tile face and a first edge having a length, a second edge having a length, a third edge having a length, and a fourth edge having a length, wherein the first and third edges of each tile oppose each other and the second and fourth edges of each tile oppose each other, the method comprising:
 tufting a plurality of carpet webs such that each of the plurality of carpet webs bears at least one of a first visual field or a second visual field different from the first visual field; and   cutting the plurality of carpet webs into the collection of carpet tiles comprising:   a. a plurality of first carpet tiles, wherein the tile face of each of the plurality of first carpet tiles comprises a portion of the first visual field extending continuously across the entirety of the tile face of the first carpet tile; and   b. a plurality of the second carpet tiles, wherein the tile face of each of the second carpet tiles comprises:
 i. a first portion that comprises a portion of the first visual field, wherein the first portion of the tile face extends along at least a portion of the length of the first edge of the second carpet tile but does not extend along a portion of the length of the third edge of the second carpet tile; and 
 ii. a second portion that comprises a portion of the second visual field that extends along at least a portion of the length of the third edge of the second carpet tile but does not extend along a portion of the length of the first edge of the second carpet tile; and 
 iii. a third portion interposed between the first portion and the second portion so as to extend along a portion of the length of the second edge and the fourth edge of the second carpet but so as not to extend along either the first edge or the third edge of the second carpet tile, wherein the third portion comprises a non-linear transition from the first visual field to the second visual field in a direction from the first portion towards the second portion such that portions of the first visual field and the second visual field are present within the third portion.  
   
     
     
       33. The method of claim 32, wherein the first portion of the tile face of each of the second carpet tiles extends along the entire length of the first edge of the second carpet tile and along only a portion of the length of the second and fourth edges of the second carpet tile.  
     
     
       34. The method of claim 32, wherein the second portion of the tile face of each of the second carpet tiles extends along the entire length of the third edge of the second carpet tile and along only a portion of the length of the second and fourth edges of the second carpet tile.  
     
     
       35. The method of claim 32, wherein at least one of the first visual field or the second visual field is devoid of pattern.  
     
     
       36. The method of claim 32, wherein at least one of the first visual field or the second visual field comprises a pattern of shapes.  
     
     
       37. The method of claim 32, wherein cutting the plurality of carpet webs into the collection of carpet tiles further comprises cutting the plurality of carpet webs into the collection of carpet tiles further comprising a plurality of third carpet tiles, wherein the tile face of each of the third carpet tiles comprises a portion of the second visual field formed via tufting and extending continuously across the entirety of the tile face of the third carpet tile.  
     
     
       38. The method of claim 32, wherein at least some of the plurality of first carpet tiles and the plurality of second carpet tiles are cut from a single one of the plurality of carpet webs.  
     
     
       39. An installation of the collection of carpet tiles made pursuant to the method of claim 32, the first and second carpet tiles of the collection of carpet tiles positioned on a floor adjacent and abutting such that:
 at least some of the first carpet tiles abut either the first, second, or fourth edge of adjacent second carpet tiles; and   at least some of the second carpet tiles abut each other.    
     
     
       40. The installation of claim 39, wherein the second or fourth edges of the at least some of the abutting second carpet tiles abut such that the first portions of the abutting second carpet tiles are adjacent, the second portions of the abutting second carpet tiles are adjacent, and the third portions of the abutting second carpet tiles are adjacent.  
     
     
       41. The installation of claim 39, wherein the plurality of first carpet tiles and the plurality of second carpet tiles comprise a rotational orientation when cut from the plurality of carpet webs and wherein the rotational orientations of at least some of the abutting carpet tiles in the installation are not aligned.  
     
     
       42. The installation of claim 39, wherein the at least some first carpet tiles abut at least one other first carpet tile.  
     
     
       43. The installation of claim 39, wherein other of the first carpet tiles abut only other first carpet tiles.  
     
     
       44. The installation of claim 39, wherein the at least some first carpet tiles abut the first edge of an adjacent second carpet tile.  
     
     
       45. An installation of the collection of carpet tiles formed by the method of claim 37, the plurality of the first carpet tiles, the plurality of the second carpet tiles, and the plurality of the third carpet tiles positioned on a floor adjacent and abutting such that:
 at least some of the first carpet tiles abut either the first, second, or fourth edge of an adjacent second carpet tile;   at least some second carpet tiles abut each other; and   at least some of the third carpet tiles abut either the second, third, or fourth edge of an adjacent second carpet tile.    
     
     
       46. The installation of claim 45, wherein the second or fourth edges of the abutting second carpet tiles abut such that the first portions of the abutting second carpet tiles are adjacent, the second portions of the abutting second carpet tiles are adjacent, and the third portions of the abutting second carpet tiles are adjacent.  
     
     
       47. The installation of claim 45, wherein the plurality of first carpet tiles, the plurality of second carpet tiles, and the plurality of third carpet tiles comprise a rotational orientations when cut from the plurality of carpet webs and wherein the rotational orientation of at least some of the abutting carpet tiles in the installation are not aligned. 
     
     
       48. The installation of claim 45, wherein the at least some of the first carpet tiles abut at least one other first carpet tile.  
     
     
       49. The installation of claim 45, wherein the at least some of the third carpet tiles abut at least one other third carpet tile.  
     
     
       50. The installation of claim 45, wherein no first carpet tile is adjacent a third carpet tile in the installation.  
     
     
       51. The installation of claim 45, wherein other of the first carpet tiles abut only other first carpet tiles.  
     
     
       52. The installation of claim 45, wherein other of the third carpet tiles abut only other third carpet tiles.  
     
     
       53. The installation of claim 46, wherein:
 the at least some first carpet tiles abut the first edge of the adjacent second carpet tile; and   the at least some third carpet tiles abut the third edge of the adjacent second carpet tile.    
     
     
       54. A method of installing on a flooring surface the collection of carpet tiles made pursuant to the method of claim 32, wherein the plurality of first carpet tiles and the plurality of second carpet tiles comprise a rotational orientation when cut from the plurality of carpet webs, the method comprising positioning the plurality of second carpet tiles on the flooring surface such that some of the plurality of second carpet tiles abut at least one of a first carpet tile or another of the plurality of second carpet tiles, wherein the rotational orientations of at least some of the abutting carpet tiles are different.  
     
     
       55. The method of claim 54, wherein the method comprises positioning the plurality of second carpet tiles on the flooring surface such that some of the plurality of second carpet tiles abut other of the plurality of second carpet tiles such that the first portions of the abutting second carpet tiles are adjacent, the second portions of the abutting second carpet tiles are adjacent, and the third portions of the abutting second carpet tiles are adjacent.  
     
     
       56. A collection of carpet tiles, each tile in the collection of carpet tiles comprising a tile face and a first edge having a length, a second edge having a length, a third edge having a length, and a fourth edge having a length, wherein the first and third edges of each tile oppose each other and the second and fourth edges of each tile oppose each other, wherein the collection of carpet tiles comprises:
 a. a plurality of first carpet tiles, wherein the tile face of each of the plurality of first carpet tiles comprises a portion of a first visual field formed via tufting and extending continuously across the entirety of the tile face of the first carpet tile; and   b. a plurality of second carpet tiles, wherein the tile face of each of the second carpet tiles comprises:
 i. a first portion that comprises a portion of the first visual field, wherein the first portion of the tile face extends along at least a portion of the length of the first edge of the second carpet tile but does not extend along a portion of the length of the third edge of the second carpet tile; and 
 ii. a second portion that comprises a portion of a second visual field different from the first visual field, wherein the second portion of the tile face extends along at least a portion of the length of the third edge of the second carpet tile but does not extend along a portion of the length of the first edge of the second carpet tile; and 
 iii. a third portion interposed between the first portion and the second portion so as to extend along a portion of the length of the second edge and the fourth edge of the second carpet tile but so as not to extend along either the first edge or the third edge of the second carpet tile, wherein the third portion comprises a non-linear transition from the first visual field to the second visual field in a direction from the first portion towards the second portion such that portions of the first visual field and the second visual field are present within the third portion, 
   wherein portions of the first and second visual fields on the tile face of each second carpet tile is formed via tufting.    
     
     
       57. The collection of carpet tiles of claim 56, further comprising a plurality of third carpet tiles, wherein the tile face of each of the third carpet tiles comprises a portion of the second visual field formed via tufting and extending continuously across the entirety of the tile face of the third carpet tile.  
     
     
       58. The collection of carpet tiles of claim 56, wherein the first portion of the tile face of each second carpet tile extends across the entirety of the length of the first edge of the second carpet tile and the second portion of the tile face of each second carpet tile extends across the entirety of the length of the third edge of the second carpet tile.  
     
     
       59. An installation of the collection of carpet tiles of claim 56, the first and second carpet tiles of the collection of carpet tiles positioned on a floor adjacent and abutting such that:
 at least some of the first carpet tiles abut either the first, second, or fourth edge of adjacent second carpet tiles; and   at least some of the second carpet tiles abut each other such that the second or fourth edges of the abutting second carpet tiles abut such that the first portions of the abutting second carpet tiles are adjacent, the second portions of the abutting second carpet tiles are adjacent, and the third portions of the abutting second carpet tiles are adjacent.    
     
     
       60. The installation of claim 59, wherein each of the plurality of first carpet tiles and second carpet tiles comprises a rotational orientation created during manufacture and wherein the rotational orientations of at least some of the abutting carpet tiles in the installation are not aligned.  
     
     
       61. An installation of the collection of carpet tiles of claim 57, the plurality of the first carpet tiles, the plurality of the second carpet tiles, and the plurality of the third carpet tiles positioned on a floor adjacent and abutting such that:
 at least some of the first carpet tiles abut either the first, second, or fourth edge of an adjacent second carpet tile;   at least some second carpet tiles abut each other such that the second or fourth edges of the abutting second carpet tiles abut such that the first portions of the abutting second carpet tiles are adjacent, the second portions of the abutting second carpet tiles are adjacent, and the third portions of the abutting second carpet tiles are adjacent; and   at least some of the third carpet tiles abut either the second, third, or fourth edge of an adjacent second carpet tile.    
     
     
       62. The installation of claim 61, wherein each of the plurality of first carpet tiles, second carpet tiles, and third carpet tiles comprises a rotational orientation created during manufacture and wherein the rotational orientations of at least some of the abutting carpet tiles in the installation are not aligned.