Carpet using unused yarn

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Quick Facts

Patent No.: US 7,341,772
App. No.: 10/782,631
Granted: Mar 11, 2008
Kind: B2

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Abstract

A carpet is described which has a particular yarn pattern which permits the use of different types of yarn such as unused yarn to form a carpet having a visually consistent appearance from manufacturing run to manufacturing run even though different types of yarns may be present. Other aspects of the invention are also described.

Claims (47)

1. A carpet tile comprising a yarn pattern having a pattern 1 of [A-B-C-D] and a pattern 2 of [E-F-G-H], wherein yarn A-D of pattern 1 is in any order and yarn E-H of pattern 2 is in any order, and said orders, once established, are maintained throughout said carpet tile, and wherein

A is a yarn with a color having a 6-10 on the Munsell value scale and a red hue;

B is a yarn with a color having a 6-10 on the Munsell value scale and a yellow hue;

C is a yarn with a color having a 6-10 on the Munsell value scale and a blue hue;

D is a yarn with a color having a 6-10 on the Munsell value scale and is a spaced dye yarn with a neutral color;

E is a yarn with a color having a 1-5 on the Munsell value scale and a red hue;

F is a yarn with a color having a 1-5 on the Munsell value scale and a yellow hue;

G is a yarn with a color having a 1-5 on the Munsell value scale and a blue hue;

H is a yarn with a color having a 1-5 on the Munsell value scale and is a spaced dye yarn with a neutral color,

and wherein at least two of yarns A-H differ by Munsell value scale number from at least two corresponding yarns A-H throughout the carpet tile; wherein the carpet tile is capable of being interchanged with carpet tiles from various lots in which said pattern 1 and pattern 2 are established; wherein said carpet tile produces a visually acceptable effect; and wherein said pattern 1 and pattern 2 are alternating throughout said carpet tile.

2. A series of carpet tiles comprising the carpet tile of claim 1 .

3. The carpet tile of claim 1 , wherein at least one of yarn A-H comprises leftover waste yarn.

4. The carpet tile of claim 1 , wherein at least two of yarn A-H comprises leftover waste yarn.

5. The carpet tile of claim 1 , wherein at least three of yarn A-H comprises leftover waste yarn.

6. The carpet tile of claim 1 , wherein each of yarn A-H comprises leftover waste yarn.

7. The carpet tile of claim 1 , wherein said pattern 1 is first used in said pattern and said pattern 2 is second and said pattern 1 and said pattern 2 are repeated in that order.

8. The carpet tile of claim 1 , wherein said pattern 2 is first and said pattern 1 is second and this order of patterns is repeated.

9. The carpet tile of claim 1 , wherein said carpet tile comprises a primary carpet layer having a pile side and an underside with a plurality of yarn projecting outwardly from said pile side.

10. The carpet tile of claim 9 , wherein said carpet tile further comprises at least one secondary backing and at least one intermediate layer and at least one pre-coat layer wherein said pre-coat layer secures the yarns to said primary backing.

11. The carpet tile of claim 10 , wherein said intermediate layer comprises at least one polymer layer or at least one reinforcement layer, or both.

12. The carpet tile of claim 9 , wherein said carpet tile further comprises a foam cushion layer.

13. The carpet tile of claim 12 , wherein said foam cushion layer comprises polyurethane.

14. The carpet tile of claim 10 , wherein an adhesive is located on the back of the carpet tile.

15. The carpet tile of claim 1 , wherein said yarn comprises nylon yarn, a wool yarn, a polyester yarn, or polypropylene yarn.

16. The carpet tile of claim 15 , wherein said nylon yarn is a filament nylon yarn.

17. The carpet tile of claim 16 , wherein said filament nylon yarn is a single yarn, a twisted yarn, an air entangled yarn, a twist reversible yarn, or a combination thereof.

18. The carpet tile of claim 1 , wherein said carpet tile is tufted on a tufting machine having a gauge range of from about ½ inch to about 1/20 inch.

19. The carpet tile of claim 18 , wherein said tufting machine has a gauge of about 1/10″ and includes a stitch rate of from about 5 stitches to about 20 stitches per inch.

20. A carpet tile comprising a yarn pattern having pattern 1 having at least three yarns selected from yarn A through yarn D and having pattern 2 having at least three yarns selected from yarn E through yarn H, wherein pattern 1 is in any order and wherein pattern 2 is in any order and said orders, once established, are maintained throughout said carpet, and wherein