Note: Descriptions are shown in the official language in which they were submitted.
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CARPET TILE MANUFACTURING PROCESS
Field of the Invention
[0001] The present invention relates to a carpet tile and a method of its
production wherein a
carpet tile is configured to have a separation of at least one row or track
relative to at least one
second portion and more particularly to carpet tiles and method of production
wherein a
separation appearance is provided by at least one of tip shearing, cutting,
burning, coloring or
otherwise providing the appearance of a separation clearly defined internal to
the boundary edges
of the carpet tile after production of the tile from carpet rolls.
Description of Related Art
[0002] Carpet tile has been made for many years by many different companies.
In making
carpet tile, carpet tile is typically made as carpet and then cut with a press
to a specific dimension
to provide carpet tiles. The edges are then normally trimmed substantially
perpendicularly to an
upper face of the carpet tile and the tile is then ready for distribution and
installation. While
many designs have been created over the years by various manufacturers, the
applicant is
unaware of carpet tile treatment methods performed after cutting the tiles
apart with the one
exception of treating side edges to attempt to ensure that no strands remain
after a die cutting
process which may otherwise leave a somewhat unattractive appearance at the
side edges. More
specifically, the applicant is unaware of any manufacturer that treats any
upper surfaces of cut
tile to provide aesthetically pleasing designs with a separation such as a
track, stripe, or other
design distinguishing at least some internal portions after the tufting
process and after being cut
into tiles.
[0003] Furthermore, although tip shearing carpet from carpet rolls is known in
the art to tip
shear across carpet at a predetermined height relative to the backing, this
process causes the
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highest carpet to be sheared. The tips of these sheared portions are still at
a highest point of the
carpet and can be exposed to wear. When wear occurs, there is a tenancy for
the ends to bend
over, thus distorting the look over time.
[0004] Applicant's U.S. Patent No. 7,146,693 relates to a method of utilizing
an embossed roller
which can cause patterns to be cut into carpet below what would otherwise be
an upper surface
of carpet. While that method is effective at producing patterns in carpet, the
pattern on the roll or
belt is what is produced in the carpet. Changing that pattern would require
replacement with
either another roll or belt. Furthermore, the tip shearing necessarily occurs
in a single direction
relative to a direction the carpet passes through the tip shearing/roller
assembly. Changing
direction of cut relative to the direction of travel for the carpet roll is
not possible.
[0005] Also, in many prior art embodiments, clear separation from treated and
untreated areas
may be difficult as it is difficult to envision a situation where the backing
could instantaneously
change a predetermined height based on an embossed pattern on a roller, but
instead would
appear to take at least a limited distance to make this transition as the
backing cannot make an
instantaneous elevation transition. Finally, using this prior art process on
individual tiles is not
believed possible as an apparent void in equipment is believed to exist which
could handle
individual tiles as opposed to carpet rolls.
[0006] Accordingly, a new method of treating carpet and carpet tile is
perceived to be
advantageous over the prior art in order to provide new designs and
configurations to the
marketplace.
Summary of the Invention
[0007] It is an object of the present invention to provide an improved carpet
tile construction
and method of its manufacture.
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[0008] It is another object of at least some embodiments of the present
invention to provide a
method of tip shearing and/or carving at least a separation into a carpet tile
in at least one
presently preferred embodiment of the present invention.
[0009] It is another object of at least some embodiments of the present
invention to provide at
least one separation internal to edges of the carpet tile after cutting the
carpet tile from a carpet
roll.
[00010] In accordance with a presently preferred embodiment of the present
invention a carpet
after having been cut into a tile is preferably tip sheared or otherwise
treated to provide an
internal separation such as a stripe, track and/or design differentiating
selected lower cut pile
(side first portions) from the uncut or unselected pile (in internal second
portions) separated by a
discontinuity of the separation. The tip shearing process stops at the
discontinuity which can
provide a visible line parallel, or not, to the edge depending upon the
orientation of the carpet
relative to a cutting head during the cutting process. Parallel and/or
intersecting effects may be
provided using more than one cutting head and/or more than one pass.
Programmable
controllers and/or other positioners may be utilized to assist in positioning
the cutting head
and/or tile so that one or more designs can be cut or otherwise provided
internal to edges of
carpet tiles once cut from rolls of carpet.
[00011] Other methods of creating the illusion of a line of various selected
widths or even
varying widths can include carving, burning, or otherwise defining an internal
line by treating
side portions. Furthermore, dripping and/or overdying, a design and/or
creating a line could also
be provided. When utilized with other similarly prepared tiles, a series of
designs can provide
additional effects, or even cooperating effects, which heretofore is not
believed to have been
done in the prior art.
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Brief Description of the Drawings
[00012] The particular features and advantages of the invention as well as
other objects will
become apparent from the following description taken in connection with the
accompanying
drawings in which:
Figure 1 is a diagrammic representation of a prior art method of cutting
carpet tiles from
a roll of carpet;
Figure 2 is a top perspective view of a process of producing framed carpet
tiles in
accordance with a presently preferred embodiment of the present invention;
Figure 3A is a cross-sectional view taken along line A-A of Figure 2;
Figure 3B is a cross-sectional view showing an alternative embodiment of a
processed
carpet tile;
Figure 4A is a top plan view of an alternative embodiment of a framed carpet
tile similar
to that shown in Fig. 3B, but processed on all four sides;
Figure 4B is a top plan view of a framed carpet tile produced from the process
shown in
Figure 2;
Figure 5 is a cross-sectional showing a further alternative embodiment of a
processed
carpet tile;
Figure 6 is a top plan view of a second alternatively preferred carpet tile
embodiment;
Figure 7 is a top plan view of a third alternatively preferred embodiment with
a single
side treatment;
Figure 8 is a top plan view of a fourth alternatively preferred embodiment
with treated
adjacent sides;
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Figure 9 is a top plan view of a fifth alternatively preferred embodiment with
three of
four sides treated;
Figure 10 is a top plan view of a sixth alternatively preferred embodiment
with treated
opposite sides;
Figure 11 is a top perspective view of another alternatively preferred
equipment showing
the process of producing framed carpet tiles in accordance with a presently
preferred
embodiment of the present invention; and
Figures 12A-12G are top plan views of various embodiments formed using the
equipment
shown in Figure 11.
Detailed Description of the Preferred Embodiment
[00013] Figure 1 shows a prior art diagrammic representation of a method of
making carpet tiles
as would be known by one of ordinary skill in the art. Carpet from a roll 12
is directed to a
die 14 where individual carpet tiles are produced by cutting. In the prior
art, trimming edges
with an edger to attempt to remove loose yarn was performed, but there was not
believed to be a
further effort to tip shear or otherwise treat upper surface portions of
carpet tiles 10 once cut with
the die 14.
[00014] The applicant has developed a manufacturing process 20 from which
carpet tiles such
as carpet tiles 10 shown in Fig. 1 are processed to produce a processed carpet
tile as discussed in
more detail below. Various reference numbers have been used throughout the
description to
refer to carpet tile at different stages of processing and to various
alternative embodiments of
processed carpet tile as set out in more detail below and as shown in the
Figures. A carpet tile to
be processed such as a carpet tile 10 shown in Fig. 1 can be placed at entry
22 and directed
towards a first station 24 which is illustrated treating upper surfaces on one
of the four sides 26
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of a carpet tile referred to by reference no. 28 and it proceeds through the
process 20.
Specifically, instead of being located to treat an edge of the carpet tile
edger 30, an edger 32 or
other treatment apparatus has been turned 90 degrees relative to edger 30. In
this manner edger
32 effectively tip shears an outer or side portion 34 seen in Figure 3A. Edger
30 then edges the
side as has been known in the prior art which potentially removes strands of
yarn but does not tip
shear or otherwise treat an upper surface of the carpet internal to edge 36 as
is contemplated by
the presently preferred embodiment. In some embodiments this is a finished
product.
[00015] In other embodiments, the carpet proceeds from the first station 24 to
the first turning
station 38 which turns the carpet tile 28 ninety degrees to the position shown
in the first station
24 as it is fed into the second treatment station 40 where a second side
portion is treated. Once
again, this could be a finished product or could then proceed to a second
turning station 42 then
to a third treatment station 44 and then possibly to a third turning station
46 and to a fourth
treatment station 48 before being deposited as a framed carpet tile 50 as
illustrated in Figure 2.
The third treatment station 44 shows an alternatively preferred feature
relative to the other three
cutting stations 24,40,48 in that the cutter 52 is located on a slide 54 so
that it can slide in and out
to create various effects in the frame such as scalloped edges 56 shown in
Figure 6 or even points
58 or other features as would be desired. It also provides for adjustable
thicknesses of side
portions 34 and/or desired placements of frame 70 relative to carpet tile
perimeter 102. Although
only the third treatment station 44 is shown having this capability, those of
ordinary skill would
know all the treatment stations 24,40,44,48 could have this capability in
other embodiments.
[00016] Additionally, although four separate cutting stations 24,40,44,48 are
illustrated as
would be understood by one of ordinary skill in the art, it may be possible to
have two stations
operate at the same time such as cutting parallel side portions at the same
time (i.e., opposing
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sides) such as to provide the embodiment illustrated in Figure 10.
Furthermore, in other
manufacturing practices, it may be possible to have one or more treatment
stations perform all of
the desired treatments in one or more steps. The applicant has found that the
process 20
illustrated has been found to be a particularly attractive way of producing an
attractive framed
carpet tile 50 and that portions of the process so attractive for the
embodiments of Figures 7-10.
[00017] As one can see from Figure 3A, which reflects the cross section A-A in
Figure 2 of a
carpet tile 28 as it is proceeding through the process 20, the cutter 32 cuts
side portion 34 to a
depth 64 lower than an elevation 66 of uncut portion 68 thereby providing a
noticeable
separation 70 forming a portion of a frame intermediate the side portion 64
and the interior
portion 68 (it will be understood that other portions of the interior portion
68 will be treated
through the process 20). This separation 70 can be better seen as interior
parallel lines in Figure
4B which can define a rectangle to provide a framed tile 50 as shown in Figure
2, and 4B which
in some embodiments is shown in a square internal to and centrally disposed
relative to external
square design of the perimeter 72 of the framed tile 50 shown in Figure 4B.
The perimeter of
framed tile 50 has first, second, third and fourth edges 51,53,55,57. The
alternate embodiment
of a framed carpet tile 90 shown in Figure 4A has a perimeter 74 which is
identical to that of
perimeter 72 but can be of any other shape as carpet tiles are known to be
produced. The internal
frame perimeter 76 is rectangular but not square due to a difference in the
thickness of side
portions 34 as cut during the process 20. Additionally, as shown in Figures 4A
and 3B, more
than one elevation differential illustrated as first depth 78 and second depth
80 can provide a
second frame perimeter 80 or even just separate line 80 which may not be a
compete perimeter
but may instead proceed from first edge 82 to second edge 84 such as if
segments 86 and 88 are
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not cut to first depth 78 as would be understood by one of ordinary skill in
the art. This could
add even further additional effects which gave rise to the embodiments of
Figures 7-10.
[00018] It may be important for one of ordinary skill in the art to remember
that a design has
likely been tufted into the carpet tiles 50,90 during the tufting process
and/or over dyed either
before the process 20 or after so that the effect of creating at least a
portion of the internal frame
designed by perimeter 70 and 76 as well as 56 and 58 in the embodiment of
Figure 6 is believed
to add dramatic effects than previously performed methods.
[00019] Figure 5 shows a cross-sectional view of another embodiment which
could be similar to
that illustrated in 4B where a portion 92 is cut, carved, burned or otherwise
provided a depth 94
into the carpet to distinguish section 92 from adjacent sections 96 and 98. In
addition to cutting
and carving, other frames may be provided in other embodiments in conjunction
with removal of
carpet as has been described above or with coloring by dripping or otherwise
providing a
coloration of a post treatment after cutting the tiles 10 in a new manner that
has not believed to
have been previously performed in the prior art. Discontinuity can result from
post tufting
coloring, carving, burning, cutting, etc., to create a visible discernment
from interior portion
68and at least a portion of side portion 34.
[00020] Figure 6 shows an internal perimeter 59 similar to perimeters 70,76 in
that which would
be defined by segments such as 56 and 58. This perimeter 59 is not parallel to
edges like
51,53,55,37. Perimeter 59 could be provided as could be shown in Figure 2 at
third station 44 or
otherwise to provide a non-linear treatment to side portions to provide this
or other frame types.
Furthermore, although the internal perimeter defined by 56 and 58 is not
linear, it is possible that
a second perimeter 100 could be created which is (or is not) linear in
conjunction with the non-
linear internal perimeters defined by segments 56,58 or others.
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1000211 Frames such as looking at Figure 4B could include the entire side
portion 34 as well as
a discontinuity 70. In other embodiments it may just include the discontinuity
70 and/or other
portions such as the cut portion 92 carved in Figure 5 which may be cut,
burned, or otherwise
provided. In yet other embodiments, still other frames may further distinguish
internal portion
68 relative to side portions 34 or portion side portions 34 as would be
understood in the art.
Frames as here defined do not include tufted differences such as if a square
pattern were tufted
internal to a side portion such as with high and low loops as technology
exists to be able to
provide that as a design. Furthermore, frames may be provided prior to cutting
into tile such as
by carving or tip shearing the side portions 34 relative to non-tip sheared
internal portions 68
and then cutting into carpet tile in other embodiments.
[00022] In the presently preferred embodiment, cutters such as shown at
32,102,52 and 104 are
utilized to provide the side portion 34 relative to interior portions 68. The
applicant has used a
cutting head which is about 2 to 4 inches across which terminates at a sharp
cut at junction 70
relative to uncut portion 68 as shown in Figure 3A. Depending on its placement
side portions 34
have been set from 1/4 to 4 inches but other dimensions are also possible.
Other embodiments
may utilize other structures for treatment stations including carvers,
burners, applicators, etc., as
would be known by those of ordinary skill in the art. The cutters 32,102,52
and 104 are edgers
such as edger 30,106,108 and 110 turned 90 degrees to the normal positioning
used to trim loose
unkempt yarns from edges 51,53,55,57 and not the upper surface of the carpet
tile 50.
[00023] By providing this method of treating carpet tiles, new and exciting
textures and designs
are believed to be available to the market which have not previously been
provided.
[00024] While the framed carpet tiles 90,50 and 101 provide unique products
for the
marketplace, the applicant discovered while making the framed tiles 90,50,
101, that all four
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sides need not necessarily be treated to provide unique effects presently
unavailable in the
market. Specifically, Figures 7-10 show additional embodiments that can be
taken at various
stages of the manufacturing process as shown in Figure 2.
[00025] Figure 7 shows tile 110 having separation 112 distinguishing first
portion 114 from
second portion 116. Just like has been described above, the preferred method
is to tip shear
anywhere from about a quarter inch to up to several inches, such as four, from
edge 118 to
provide first portion 114 as a band defined by separation 112 relative to
second portion 116. It is
important to remember that in many embodiments, a design of some type will
have been tufted
and/or dyed into the carpet tile 110 whereby the band provides an additional
aesthetic element.
When tile 110 is combined with similar or dissimilar tiles 110, such as tiles
120, 160, and/or 180,
striking effects can be created whether or not the other tiles 110, 120, 160
or 180 are provided
with similar or dissimilar designs and/or coloration schemes.
[00026] Separation 112 may be gradual in other embodiments, but in the
illustrated embodiment
of Figure 7 is where the edger 32 tip sheared first portion 114 relative to
non-treated portion 116.
Separation 112 need not be parallel to edge 118 in all embodiments, and need
not necessarily be
linear in all embodiments, either.
[00027] Using the same basic methodology of making the tile 110 of Figure 7,
tile 120 of Figure
8 can be made with treatment of third portion 122 relative to at least one of
first and second
portions 124, 126, respectively. In the illustrated embodiment first and third
portions 122, 124
are treated to a similar height so there is no distinguishable separation
there between, but this
need not be the case for all embodiments. Separations 128 and 130 separate
first and third
portions 122, 124 from second portion 126. In the illustrated embodiment an
"L" shape or
"chevron" shape is provided which provides somewhat unique effects when
combined with any
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of the other effects and/or tiles 40,50, 102 of embodiments of Figures 7-10
and/or 4A, 4B and/or
6.
[00028] Separations 128 and 130 are shown parallel to edges 132 and 134 in the
illustrated
embodiment. Other embodiments may include these and/or additional effects.
[00029] Figure 9 shows a "U" or "C" style tile 160 with first, third and
fourth portions 142, 146,
148 separated from second portion 144 by separations 150, 152, 154. Additional
separations
could separate any of the first, third or fourth portion 142, 146, 148 from
each other such as by
varying the amount of tip shearing, or other treatment process.
[00030] Figure 10 shows two treated portions 162, 164 spaced by untreated
portion 166 as can
be visually distinguished by separations 168, 170.
1000311 As one skilled in the art will quickly recognize, the installer will
have a host of new
options when selecting from the embodiments of Figures 4A, 4B, 6, and 7-10
especially if
features from those respective embodiments are combined together. The
embodiments of Figure
7-10 can be made using the process 20 of Figure 2 by simply de-activating
selected cutters 32,
102, 52 and/or 104 may not be utilized at a particular station. Of course the
number of stations
24, 40, 44, 48 can be reduced as well as would be understood by those of
ordinary skill in the art.
[00032] Figure 11 shows an alternative embodiment of a carpet tile treatment
station 200 which
can be utilized to treat individual tiles in the presently preferred
embodiment. Carpet tile
treatment station 200 has one or more treatment devices 202,204 which impart
one or more
separations 206,208 to distinguish first portion 210 relative to second
portion 212 in the
embodiment of a cutter. The cutter can tip shear first portion 210 relative to
the second portion
212 and thereby establish separations 206,208 distinguishing the two portions
at the upper
surface 214 of carpet tile 216 where the treatment agents 202,204 are
configured to treat the
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carpet tile 216. In the illustrated embodiments treatment agents 204,206 may
be positionable
about respective axes 218 and 220 either by being manually set in a desired
position and/or being
programmably controllable and/or otherwise positionable such as with
controller 222 which
could be computer PLC or other controller 222 coupled to a Servo and/or other
device and
possibly may also adjust the relative elevation of treatment agents 202,204
such as by having
piston members 224,226 extend or retract treatment devices 202,204 relative to
the upper surface
214 of the carpet tile 216. Heights may be preset, adjustable and/or
programmably adjustable.
[00033] Furthermore, it may be possible to move the treatment devices 202,204
or not relative
to the carpet upper surface 214 the carpet tile 216 such as with extension
arms 228,230 or
otherwise. Extension arms 228,230 may be movable along axis 232 and/or
parallel to axis 232
and/or movable parallel to or on the axis 234 as would be obvious to one of
ordinary skill in the
art. The illustrated embodiment shows just one mechanism of three dimensional
movement of
treatment devices 202,204. Two dimensional movement and/or three dimensional
movement
through other mechanisms may also be desirable and/or provided in other
embodiments and
which could be accomplished by means as known to those of ordinary skill in
the art.
[00034] In addition to and/or instead of moving the treatment devices 202,204,
carpet tiles can
be moved such as are shown in Figure 2 relative to the treatment device such
as with a turntable
or moving station 236. Moving station 236 preferably provides a support 238 to
which a carpet
tile 216 can be placed. Retainers 240,242 may be utilized to maintain the
carpet tile 216 in
contact with support 238 and can take various forms such as clamps, framed
ends or other
mechanisms as known to those of ordinary skill in the art.
[00035] It may also be possible that texture of an upper surface of support
238 may sufficiently
cooperate with a lower surface of carpet tile 216 to hold the carpet tile 216
in a desired location
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during treatment. Treatment station 236 may have a post member 244 at least
partially rotatable
around an axis 246. Axis 246 may be movable or fixed depending on the various
embodiments
utilized. In the illustrated embodiment post 244 is movable parallel to axis
232 and 234 such that
possibly in combination with controller 222 so that the desired movement of
the carpet tile 216
relative to the treatment devices 202,204 could be affected as so desired.
Conveyors and/or other
moving station components could be employed with other embodiments. Controller
222 may be
provided with a plurality of design options such as from a storage device to
assist in providing a
particular design on carpet tile 216.
[00036] In the illustrated embodiment of Figure 11, either or both of the
treatment devices
202,204 and the carpet tile 216 can be moved in relative relationship relative
to one another.
Post 244 also is illustrated having a piston style construction whereby
elevational adjustment of
the upper surface 214 of the carpet tile 216 relative to the treatment devices
202,204 can be
provided. Other elevation adjustment mechanisms could be employed in other
embodiments.
[00037] Exemplary embodiments and designs are shown in Figures 12A-12G, but
still others
can be created. Specifically, Figure 12A shows a first portion 250
distinguished from second
portions 252,254 by a first separation 256 and second separation 258.
[00038] Figure 12B shows a construction with first portion 260 separated from
second portions
262,264 by first separation 266 and second separation 268 as well as a third
separation 270
separated from second portion 264 and another second portion 272 by third
separation 274 and
fourth separation 276. Notice that the third portion 270 and first portion 260
are different widths
in these illustrative embodiments. The applicant envisions widths could vary
in range of about
half an inch to about three inches depending on the particular treatment
device 202,204 selected
for that particular application. Still other widths could be selected. About
three inches or less
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has been found to be particularly attractive for some embodiments in that once
subjected to wear
by foot traffic, a portion of the foot traffic is still directed to second
portions such as 262,264,272
which can absorb a significant portion of the load to thereby prevent untimely
wear of the tip
sheared portions. If a cutter is utilized, first portion 260 and third portion
270 could be protected
from excessive traffic thereby potentially prolonging the life of the carpet
tile illustrated in
Figure 12B.
[00039] In both Figures 12A and 12B, the first portion 260 and third portion
270 run from first
side edge 278 to third side edge 280 which are parallel to side edges 282 and
284. In other
embodiments, this may not necessarily be the case. Figure 12C shows another
alternative
embodiment which a "plus" style design is illustrated with first separations
290 separated from
second portions 292,294,296 and 298.
[00040] Figure 12D shows yet another embodiment in which first portions 300
and 302 are
shown separated from second portions 304,306,308,310 by illustrated
separations. Note that first
portion 302 is cut deeper relative to upper surface 214 shown in Figure 11 and
first portion 300
thereby giving yet another effect. This design also is provided on a diagonal
and may be cut on
the diagonal for at least some embodiments.
[00041] Figure 12E shows designs provided on carpet tile need not necessarily
extend from side
edge to side edge but can be internal to the carpet tile 320. In this design
first portion 322
represents a circle cut internal to the carpet tile 320. Third portion 324 and
first portion 322 are
separated from second portions 326,328 and 330. Of course, in other
embodiments a single
circle could be provided, other circles provided and/or even more circles
could be provided to
distinguish from second portions. The treatment devices 202,204 and/or carpet
tiles 320 can be
moved relative to one another to assist in providing the design.
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[00042] Figure 12F shows another embodiment in which it would be understood by
those of
ordinary skill in the art that carpet tile 340 could cooperate with similar
tiles 340 to provide a
continuous design. Quarter circles 342 of first portions 344 are distinguished
from second
portion 346 and 348. To form a circle configuration the first portion 344
would combine with
three other carpet tiles 340 meeting at a common corner. Of course, all the
other designs and
configurations could also be provided as would be understood by those of
ordinary skill in the
art.
[00043] Figure 12G shows an oval 350 internal to carpet tile 352 having first
portion 354
separated from second portion 356 and 358. Utilizing this technology, a whole
host of different
designs could be provided having varying effects. It is important to remember
that these
embodiments as utilized with the treatment station 200 shown in Figure 11 that
all carpet tile
treatment preferably occurs after the carpet tile is created from rolls of
carpet.
[00044] Having thus set forth the nature of the invention, what is claimed
herein is:
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