Double image overprint carpet components and methods of making same
View Patent ↗Various embodiments of the present invention are directed to carpet components and methods of making the carpet components. In one embodiment, a carpet component is provided. The carpet component includes a carpet substrate having a texture comprising a pattern, wherein the pattern comprises a plurality of adjoining design elements each defining a design and a boundary and wherein the design elements are arranged so that the design of one design element is not predictable from the design of an adjoining design element; and an overprint disposed onto the carpet substrate wherein the overprint comprises a plurality of adjoining design elements each defining a design and a boundary and wherein the design elements are arranged so that the design of at least one design element is predictable from the design of an adjoining design element.
1. A method for creating a single carpet component comprising the steps of:
creating a pattern having an unpredictable combination of design elements; tufting yarn into a primary backing and creating a carpet substrate having a plurality of repeats of the pattern formed by: (a) different loop height, (b) different cut pile height, or (c) selective cut and uncut tufts, and
overprinting a design onto the carpet substrate to form the single carpet component, wherein the design comprises a predictable combination of design elements, and
wherein the relationship between the design and the overall pattern of the carpet substrate is not in register.
2. The method of claim 1 , wherein the step of creating a pattern further comprises the steps of:
dividing a design having a predictable arrangement of design elements into a plurality blocks having substantially similar shapes; and
rearranging the blocks in an unpredictable manner to create the pattern wherein at least some of the design elements are discontinuous at a boundary between individual blocks.
3. The method of claim 2 , wherein the step of rearranging the blocks includes varying the orientation of individual blocks.
4. The method of claim 1 , wherein the step of creating a pattern further comprises the steps of:
dividing a design having a predictable arrangement of design elements into a plurality blocks having substantially similar shapes; and
arranging at least some of the blocks in an unpredictable manner to create the pattern.
5. The method of claim 1 , wherein the pattern is repeated in at least one linear direction within the carpet substrate of the single carpet component.
6. The method of claim 1 , wherein the overprint design is repeated in at least one linear direction within the carpet substrate.
7. The method of claim 6 , wherein the overprint design has a repeating design size and the pattern has a repeating pattern size and wherein the repeating design size is different from the repeating pattern size.
8. The method of claim 1 , wherein the single carpet component is broadloom carpet.
9. The method of claim 2 , wherein a plurality of blocks are arranged to align at least some of the discontinuities at the boundaries.