Double image overprint carpet components and methods of making same

Abstract

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.

That which is claimed: 
     
         1 . A carpet component comprising:
 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.   
     
     
         2 . The carpet component of  claim 1 , wherein the pattern and the overprint design are offset relative to one another within the carpet component. 
     
     
         3 . The carpet component of  claim 1 , wherein the pattern comprises a plurality of blocks of substantially the same size and wherein each block defines at least one design element and the blocks are arranged so that the design elements in one block are not predictable from design elements in adjoining blocks. 
     
     
         4 . The carpet component of  claim 1 , wherein the texture comprises the pattern repeated in at least one linear direction within the carpet substrate. 
     
     
         5 . The carpet component of  claim 4 , 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. 
     
     
         6 . The carpet component of  claim 4 , wherein the overprint design has a repeating design size and the pattern has a repeating pattern size and wherein the repeating design size is offset relative to the pattern size. 
     
     
         7 . The carpet component of  claim 1 , wherein the pattern comprises tufts having different heights. 
     
     
         8 . The carpet component of  claim 1 , wherein the pattern formed in the carpet substrate is formed by one of (a) different loop height, (b) different cut pile height, (c) selective cut and uncut tufts or a plurality of different yarn types. 
     
     
         9 . The carpet component of  claim 8 , wherein the plurality of different yarn types comprises a sulfonated cationic dyeable fiber and a non-sulfonated cationic dyeable fiber. 
     
     
         10 . A floor covering comprising:
 a plurality of carpet components positioned in to define abutting portions, wherein each of the carpet components comprises:
 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, and 
   wherein the overprint of adjacent carpet components are in alignment along at least some of the abutting portions of the carpet components.   
     
     
         11 . The carpet component of  claim 10 , wherein the pattern formed in the carpet substrate is formed by one of (a) different loop height, (b) different cut pile height, or (c) selective cut and uncut tufts. 
     
     
         12 . The carpet component of  claim 10 , wherein the carpet substrate comprises a plurality of different yarn types. 
     
     
         13 . The carpet component of  claim 12 , wherein the plurality of different yarn types comprises a sulfonated cationic dyeable fiber and a non-sulfonated cationic dyeable fiber. 
     
     
         14 . The carpet component of  claim 10 , wherein the pattern comprises a plurality of blocks of substantially the same size randomly arranged wherein each of the blocks defines a predictable pattern. 
     
     
         15 . The carpet component of  claim 10 , wherein the texture comprises the pattern repeated in a linear direction within the carpet substrate. 
     
     
         16 . The carpet component of  claim 15 , 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. 
     
     
         17 . A method for creating a 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 texture defined by a plurality of repeats of the pattern; and   overprinting a design onto the carpet substrate, wherein the design comprises a predictable combination of design elements, and wherein the design and the pattern of the carpet substrate are not registered.   
     
     
         18 . The method of  claim 17 , 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.   
     
     
         19 . The method of  claim 18 , wherein the step of rearranging the blocks includes varying the orientation of individual blocks. 
     
     
         20 . The method of  claim 17 , 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.   
     
     
         21 . The method of  claim 17 , wherein the step of creating a carpet substrate having a texture comprises one of the follow: (a) forming loops in the carpet substrate of differing heights, (b) forming a pile surface of differing height, (c) selectively cutting at least some tufts formed in the carpet substrate or (d) creating a carpet substrate using a plurality of yarn types.