US20120233951A1

US20120233951A1 - Carpet plank

Info

Publication number: US20120233951A1
Application number: US13/050,291
Authority: US
Inventors: Christopher C. Phillips
Original assignee: SILK ROAD SOURCING LLC
Current assignee: SILK ROAD SOURCING LLC
Priority date: 2011-03-17
Filing date: 2011-03-17
Publication date: 2012-09-20

Abstract

A rectangular carpet plank includes a baseplate having a first side edge opposed from a second side edge; and a carpet layer attached to a top surface of the baseplate. The carpet layer being divided into carpet sections, wherein each carpet section extends from the first side edge to the second side edge; each carpet section has a carpet pattern; and adjacent carpet sections have different carpet patterns.

Description

TECHNICAL FIELD OF THE INVENTION

The technology of the present disclosure relates generally to carpet planks and, more particularly, to carpet planks that when collectively arranged as a floor covering create the visual appearance of conventional carpet tiles.

BACKGROUND

Carpet tiles have been used as a floor covering, especially in non-residential buildings. Conventional carpet tiles consist of squares of carpet (e.g., 12 inch by 12 inch squares or 18 inch by 18 inch squares). The tiles typically are attached to an underlying floor with adhesive. Carpet tiles are typically made to be durable and withstand high traffic volumes. For this purpose, the carpet tiles are typically made from a low profile pile that is secured to a flexible textile or rubber backing. When carpet tiles are installed, adjacent carpet tiles can be rotated 90 degrees or 180 degrees with respect to each other such that variation in pile orientation from tile to tile forms a checkerboard arrangement and visually obscures the seam between carpet tiles.

SUMMARY

According to one aspect of the disclosure, a rectangular carpet plank includes a baseplate having a first side edge opposed from a second side edge; and a carpet layer attached to a top surface of the baseplate, the carpet layer being divided into carpet sections, wherein: each carpet section extends from the first side edge to the second side edge; each carpet section having a carpet pattern; and adjacent carpet sections having different carpet patterns.
According to one embodiment of the carpet plank, the carpet plank further includes a first joining element located along the first side edge of the baseplate; and a second joining element located along the second side edge of the baseplate, the first joining element and the second joining element being complementary in shape;
According to one embodiment of the carpet plank, the carpet plank further includes a third joining element located along a first end edge of the baseplate; and a fourth joining element located along a second end edge of the baseplate, the third joining element and fourth joining element being complementary in shape.
According to one embodiment of the carpet plank, the carpet pattern of each carpet section being a color of the carpet.
According to one embodiment of the carpet plank, each carpet section has a pile and the carpet pattern of each carpet section being an orientation of the pile.
According to one embodiment of the carpet plank, the pile is loop pile.
According to one embodiment of the carpet plank, the pile is cut pile or tufted pile.
According to one embodiment of the carpet plank, the pile of one carpet section is rotated 90 degrees with respect to an adjacent carpet section.
According to one embodiment of the carpet plank, the pile of one carpet section is rotated 180 degrees with respect to an adjacent carpet section.
According to one embodiment of the carpet plank, the first joining element extends along the entirety of the first side edge of the baseplate and the second joining element extends along the entirety of the second side edge of the baseplate.
According to one embodiment of the carpet plank, the third joining element extends along the entirety of the first end edge of the baseplate and a fourth joining element extends along the entirety of the second end edge of the baseplate.
According to one embodiment of the carpet plank, the first joining element is a male joining element and the second joining element is a female joining element.
According to one embodiment of the carpet plank, the male joining element is a tongue and the female joining element is a complementary groove.
According to one embodiment of the carpet plank, the joining elements are integrally formed with the baseplate.
According to one embodiment of the carpet plank, the carpet plank is 6 inches by 36 inches.
According to one embodiment of the carpet plank, the carpet layer having a first carpet section at a first end of the baseplate, a second carpet section adjacent the first carpet section, a third carpet section adjacent the second carpet section, and a fourth carpet section adjacent the third carpet section and at a second end of the baseplate opposed to the first end of the baseplate.
According to one embodiment of the carpet plank, the first and third carpet sections having the same carpet pattern and the second and fourth carpet sections having the same carpet pattern.
According to one embodiment of the carpet plank, the first and fourth carpet sections being squares and the second and fourth carpet sections being rectangles that are twice as long as the first and fourth carpet sections.
According to one embodiment of the carpet plank, the carpet layer having a first carpet section at a first end of the baseplate, a second carpet section adjacent the first carpet section, and a third carpet section adjacent the second carpet section and at a second end of the baseplate opposed to the first end of the baseplate.
According to one embodiment of the carpet plank, the first and third carpet sections having the same carpet pattern and the second carpet section having a different carpet pattern then the first and third carpet sections.
According to one embodiment of the carpet plank, the first and third carpet sections being rectangles and the second carpet section being a rectangle that is twice as long as the first and third carpet sections.
According another aspect of the disclosure, a system of carpet planks includes a first of the foregoing carpet planks and a second of the foregoing carpet planks, wherein the first and second carpet planks having the same lengths and widths; and wherein the first and second carpet planks having an equal number of carpet sections, each section being the same in size as a corresponding carpet section of the other plank, and the corresponding carpet sections having different carpet patterns, the first carpet plank being a first carpet plank type and the second carpet plank being a second carpet plank type.
According to one embodiment of the system, carpet planks are arranged in a repeating pattern of rows including a first row and a second row, wherein: the first row of carpet planks alternating between the first carpet plank type and the second carpet plank type; the second row of carpet planks alternating between the first carpet plank type and the second carpet plank type; and each carpet plank of the second row is offset with a corresponding carpet plank of the first carpet plank type of the first row and a corresponding carpet plank of the second carpet plank type of the first row so that carpet sections of the carpet planks from the first row align with carpet sections having the same carpet pattern of the carpet planks from the second row.
According to one embodiment of the system, aligned carpet sections of the same carpet pattern from the rows cooperate to form a square carpet area of the carpet pattern.
According to one embodiment of the system, the repeating pattern further includes a third row and a fourth row, wherein square carpet areas of the carpet pattern in the third and fourth rows are offset with the square carpet areas of the carpet pattern in the first and second rows to form a checkerboard pattern.
According to one embodiment of the system, wherein carpet planks are arranged in a repeating pattern of rows including a first row, a second row, and a third row, wherein: the first row comprises carpet planks of the first carpet plank type; the second row comprises carpet planks of the second carpet plank type, wherein each carpet plank of the second row is offset with two corresponding carpet planks of the first row so that carpet sections of the carpet planks from the first row align with carpet sections having the same carpet pattern of the carpet planks from the second row; and the third row comprises carpet planks of the first carpet plank type, wherein each carpet plank of the third row is offset with two corresponding carpet planks of the second row so that carpet sections of the carpet planks from the second row align with carpet sections having the same carpet pattern of the carpet planks from the third row.
According to one embodiment of the system, aligned carpet sections of the same carpet pattern from the three rows cooperate to form a square carpet area of the carpet pattern.
According to one embodiment of the system, the repeating pattern further includes a fourth row, a fifth row, and a sixth row, wherein square carpet areas of the carpet pattern in the fourth, fifth, and sixth rows are offset with the square carpet areas of carpet pattern in the first, second and third rows to form a checkerboard pattern.
These and further features will be apparent with reference to the following description and attached drawings. In the description and drawings, particular embodiments of the invention have been disclosed in detail as being indicative of some of the ways in which the principles of the invention may be employed, but it is understood that the invention is not limited correspondingly in scope. Rather, the invention includes all changes, modifications and equivalents coming within the scope of the claims appended hereto.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a first representative carpet plank;

FIG. 2 is a top view of the first representative carpet plank;

FIG. 3 is a top view of the first representative carpet plank shown enlarged and partially cut away to more fully show a pile arrangement;

FIG. 4 is an end view of the first representative carpet plank;

FIG. 5 is an opposite end view of the first representative carpet plank;

FIG. 6 is a side view of the first representative carpet plank;

FIG. 7 is an opposite side view of the first representative carpet plank;

FIG. 8 is a perspective view of a second representative carpet plank;

FIG. 9 is a top view of the second representative carpet plank;

FIG. 10 is a top view of the second representative carpet plank shown enlarged and partially cut away to more fully show a pile arrangement;

FIG. 11 is an end view of the second representative carpet plank;

FIG. 12 is an opposite end view of the second representative carpet plank;

FIG. 13 is a side view of the second representative carpet plank;

FIG. 14 is an opposite side view of the second representative carpet plank;

FIG. 15 is a perspective view of a third representative carpet plank;

FIG. 16 is a top view of the third representative carpet plank;

FIG. 17 is a top view of the third representative carpet plank shown enlarged and partially cut away to more fully show a pile arrangement;

FIG. 18 is an end view of the third representative carpet plank;

FIG. 19 is an opposite end view of the third representative carpet plank;

FIG. 20 is a side view of the third representative carpet plank;

FIG. 21 is an opposite side view of the third representative carpet plank;

FIG. 22 is a schematic view of a floor covering assembly made up of carpet planks;

FIG. 23 is a partially exploded view of the floor covering assembly of FIG. 22;

FIG. 24 is a schematic view of another representative carpet plank;

FIG. 25 is a schematic view of a representative carpet plank that compliments the carpet plank of FIG. 24;

FIG. 26 is a schematic view of another representative carpet plank;

FIG. 27 is a schematic view of a representative carpet plank that compliments the carpet plank of FIG. 26;

FIG. 28 is a schematic view of another representative carpet plank;

FIG. 29 is a schematic view of a representative carpet plank that compliments the carpet plank of FIG. 28; and

FIG. 30 is a schematic view of a floor covering assembly made up of the carpet planks of FIGS. 28 and 29.

DETAILED DESCRIPTION OF EMBODIMENTS

Embodiments will now be described with reference to the drawings, wherein like reference numerals are used to refer to like elements throughout. It will be understood that the figures are not necessarily to scale.
Features that are described and/or illustrated with respect to one embodiment may be used in the same way or in a similar way in one or more other embodiments and/or in combination with or instead of the features of the other embodiments.
Referring to FIGS. 1 and 2, a rectangular carpet plank 10 is shown. The plank 10 includes a rigid baseplate 12 and a carpet layer 14 secured to the top surface of the baseplate 12. The bottom surface of the baseplate 12 may rest directly on an underlying floor (e.g., a concrete floor, a wood subfloor, etc.) or there may be an intermediate layer of material between the baseplate 12 and the underlying floor. The baseplate 12 may be made of polyvinylchloride (PVC), medium density fiberboard (MDF), high-density fiberboard (HDF), a polymer material, or other suitable material. The baseplate 12 may be machined, injection molded, or formed by other suitable means. The carpet layer 14 may be attached to the baseplate with adhesive, a chemical process, mechanical fasteners (e.g., tacks or staples), heat welding, radio frequency (RF) welding, as part of an in-mold molding process, or other suitable attachment technique. The carpet layer 14 may be made from a range of materials. For instance, the raised surface of the carpet, or pile, may be made from Nylon, olefin, polypropylene, polyester (polyethylene terephthalate, commonly abbreviated PET), wool, etc. The backing may be made from a suitable synthetic or natural material and may be in the form of a textile or a mat. The pile may be attached to the backing by weaving, adhesive, chemical bonding or thermal bonding, for example.
With additional reference to FIGS. 3-7, the baseplate 12 has a first side edge 20 that opposes a second side edge 22. The side edges 20, 22 are the longer pair of edges of the baseplate 12. A first joining element 24 is located along the first side edge 20 of the baseplate 12 and a second joining element 26 is located along the second side edge 22 of the baseplate 12, the first joining element 24 and second joining element 26 being complementary in shape. A third joining element (not illustrated) may also be located along a first end edge 32 and a fourth joining element (not illustrated) that is complementary in shape to the third joining element may be located along a second end edge 36 of the base plate 12. Alternatively, and as depicted in the figures, the end edges 32, 36, which are the shorter pair of edges of the baseplate 12, are planar. The first and second joining elements 24, 26 may respectively extend along the entirety of the first and second side edges 20, 22 of the baseplate 12. If present, the third and fourth joining elements may respectively extend along the entirety of the first and second end edges 32, 36 of the baseplate.
As best shown in FIGS. 4 and 5, for example, one of the joining elements (e.g., the first joining element 24) may be a male joining element, such as a tongue, and the other of the joining elements (e.g., the second joining element 26) may be a female joining element, such as a groove that is complementary to the tongue. If present, third and fourth joining elements may be made in the same manner. The complementary locking elements of adjacent carpet planks 10 may be engaged with each other to join the carpet planks 10 to one another without a substantial gap therebetween. The joining elements may be integrally formed with the baseplate 12 during the manufacture of the baseplate 12, or the joining elements may be separately formed and subsequently attached to the baseplate 12. The joining elements lock adjacent carpet planks 10 together to minimize their separation during normal use as a flooring cover. If needed for installation purposes, individual carpet planks 10 may be cut with a saw. In another embodiment, instead of using joining elements, the carpet planks 10 may be placed on a floor in an arrangement as described below and secured using mechanical fasteners (e.g., nails) or with adhesive. In still another embodiment, the baseplate 12 may be omitted in favor of a strip of carpet with the below-described carpet sections. Methods of floor covering installation using any of the disclosed embodiments of carpet planks 10 will be apparent from the following to result in a floor covering with a checkerboard appearance.
The carpet layer 14 is divided into one or more carpet sections. In the embodiment of FIGS. 1-7, there are four carpet sections, which are labeled with references numerals 40, 42, 44, and 46 in the appended figures. Each carpet section 40, 42, 44 and 46 extends contiguously from a first side edge 20 of the baseplate 12 to an opposing second side edge 22 of the baseplate 12. Also, the first carpet section 40 is at the first end 32 of the baseplate 12, the second carpet section 42 is adjacent the first carpet section 40, the third carpet section 44 is adjacent the second carpet section 42, and the fourth carpet section 46 is adjacent the third carpet section 44 and is at the second end 36 of the baseplate 12.
Each carpet section 40, 42, 44, 46 may have a carpet pattern. A carpet pattern of a carpet section 40, 42, 44, 46 is a decorative scheme that achieves a visual characteristic for the carpet section 40, 42, 44, 46. The carpet pattern for a carpet section 40, 42, 44, 46 may be established by an arrangement (e.g., orientation) of pile of the carpet section, by a variation in the pile within the carpet section (e.g., by use of two or more pile types), by a color of the carpet section, by a design (e.g., colored stripes) within the carpet section, and/or by any other appropriate means.
In one embodiment, the pattern for a carpet section 40, 42, 44, 46 is achieved using an orientation or other arrangement of the pile. For example, the pile may be aligned in straight rows of loops as shown in FIGS. 1-7, may be arranged in offset rows of loops, may have in a non-uniform, but oriented, arrangement of loops as shown in FIGS. 8-14, or may be an arrangement of tufts with a directional nap as shown in FIGS. 15-21.
Adjacent carpet sections 40, 42, 44, 46 may have a different pattern. For instance, in the embodiments of FIGS. 1-21, the carpet plank 10 has four carpet sections 40, 42, 44 and 46 where the respective patterns are achieved with various pile orientations. The first carpet section 40 at the end 32 is rotated 90 degrees with respect to the adjacent second carpet section 42. The next, or third, carpet section 44 is rotated 90 degrees with respect to the second carpet section 42 so as to have the same pile orientation as the first carpet section 40. The fourth carpet section 46 at the other end 36 is rotated 90 degrees with respect to the third carpet section 44 to have the same pile orientation as the second carpet section 42.
To exemplify this pattern arrangement for the carpet layer 14, reference is made to the embodiment of FIGS. 1 to 7. In this embodiment, the pile of the carpet layer 14 is loop pile with the loops arranged in straight rows. The loops of the carpet sections 40 and 44 have the loops oriented so that the fibers are disposed in the direction across the width of the carpet plank 10 (in the direction from side edge 20 to side edge 22). Therefore, the ends of the loops for carpet section 40 are visible in FIGS. 6 and 7 and the sides of the loops for carpet section 40 are visible in FIG. 5. The loops of the carpet sections 42 and 46 have the loops oriented so that the fibers are disposed in the direction along the length of the carpet plank 10 (in the direction from end 32 to end 36). Therefore, the ends of the loops for carpet section 46 are visible in FIG. 4 and the sides of the loops for carpet sections 42 and 46 are visible in FIGS. 6 and 7.
In the embodiment of FIGS. 8-14, the pile of the carpet layer 14 is loop pile with the loops arranged in the same orientation within each carpet section 40, 42, 44, 46, but the loops have a non-uniform arrangement (e.g., are not in straight rows). The loops of the carpet sections 40 and 44 have the loops oriented so that the fibers are disposed in the direction across the width of the carpet plank 10 (in the direction from side edge 20 to side edge 22). Therefore, the ends of the loops for carpet section 40 are visible in FIGS. 13 and 14 and the sides of the loops for carpet section 40 are visible in FIG. 12. The loops of the carpet sections 42 and 46 have the loops oriented so that the fibers are disposed in the direction along the length of the carpet plank 10 (in the direction from end 32 to end 36). Therefore, the ends of the loops for carpet section 46 are visible in FIG. 11 and the sides of the loops for carpet sections 42 and 46 are visible in FIGS. 13 and 14.
In the embodiment of FIGS. 15-21, the pile of the carpet layer 14 is tufted pile. The tufts within each carpet section 40, 42, 44, 46 may be slightly oriented in one direction (e.g., have a directional component). In this embodiment, when one carpet section is rotated 90 degrees with respect to an adjacent carpet section, the two carpet sections may have subtle differences in visual appearance.
Referring to FIG. 22 and to FIG. 23, which is a partially exploded version of FIG. 22, illustrated a group of carpet planks 10 arranged in rows 50 to form a floor covering assembly 52. In one embodiment, each carpet plank 10 is six inches by 36 inches and the constituent carpet sections 40, 42, 44, 46 for each carpet plank 10 respectively are a six inch by six inch square (e.g., a square as wide and long as the width of the carpet plank 10), a six inch by twelve inch rectangle (e.g., a rectangle as wide as the carpet plank 10 and twice as long as the carpet plank 10 is wide), another six inch by twelve inch rectangle (e.g., a rectangle as wide as the carpet plank 10 and twice as long as the carpet plank 10 is wide), and a six by six inch square (e.g., a square as wide and long as the width of the carpet plank 10). Therefore, the first and fourth carpet sections 40 and 46 are the same size as each other and the second and third carpet sections 42 and 44 are the same size as each other. It will be appreciated that other dimensions are possible.
Within the floor covering assembly 52, there are two types of carpet planks 10, referred to as type A and type B and denoted by reference numerals 10A and 10B. In one embodiment, the carpet sections for the type A carpet planks 10A are arranged as a mirror image of the carpet sections for the type B carpet planks 10B. That is, when the side edges 20 having the first joining element 24 (e.g., a male joining element) all face in the same direction for each carpet plank 10A and 10B and the side edges 22 having the second joining element 26 (e.g., the female joining element) all face in the opposite direction for each carpet plank 10A and 10B, then the carpet sections 40 and 44 of the type A carpet plank 10A will have the same pattern as the carpet sections 42 and 46 of the type B carpet plank 10B and the carpet sections 42 and 46 of the type A carpet plank 10A will have the same pattern as the carpet sections 40 and 44 of the type B carpet plank 10B. The first joining element 24 for each carpet plank 10 locks into the second joining element 26 of one or more carpet planks 10 from an adjacent row of carpet planks 10.
Four exemplary carpet plank rows 50A, 50B, 50C and 50D are illustrated. In each row 50, the type A carpet planks 10A are alternated with the type B carpet planks. Also, the carpet planks 10A and 10B in each row are offset with the carpet planks 10A and 10B in adjacent rows so that carpet sections from carpet planks 10 in a first row (e.g., row 50A or row 50C) of a pair of adjacent rows align with commonly patterned carpet sections from carpet planks 10 in the second row (e.g., row 50B paired with row 50A or row 50D paired with row 50C) of the pair of rows. In the illustrated example, the square carpet section 46 from a type B carpet plank 10B in the first row 50A joins with the square carpet section 40 from an adjacent type A carpet plank 10A in the first row 50A and with rectangular carpet section 42 of an offset type B carpet plank 10B in the second row 50B to form a square carpet area 54A with a first carpet pattern. Also, the rectangular carpet section 42 from the type A carpet plank 10A joins with the rectangular carpet section 44 of the type B carpet plank 10B in the second row 50B to form a square carpet area 54B with a second carpet pattern. Similarly, the rectangular carpet section 44 from the type A carpet plank 10A in the first row 50A joins with the square carpet section 46 of the B carpet plank in the second row 50B and with the square carpet section 40 of an adjacent type A carpet plank 10A in the second row 50B to form a square carpet area 54C with the first carpet pattern. Next, the square carpet section 46 from the type A carpet plank 10A in the first row 50A joins with the square carpet section 40 from an adjacent type B carpet plank 10B in the first row 50A and with the rectangular carpet section 42 of an offset type A carpet plank 10A in the second row 50B to form a square carpet area 54D with the second carpet pattern. Next, the rectangular carpet section 42 from the type B carpet plank 10B joins with the rectangular carpet section 44 of the type A carpet plank 10A in the second row 50B to form a square carpet area 54E with the first carpet pattern. The rectangular carpet section 44 from the type B carpet plank 10B in the first row 50A joins with the square carpet section 46 of the type A carpet plank in the second row 50B and with the square carpet section 40 of an adjacent type B carpet plank 10B in the second row 50B to form a square carpet area 54F with the second carpet pattern.
In this manner, the carpet sections from adjacent carpet planks 10 come together to form squares (e.g., twelve inch by twelve inch areas using the above described exemplary dimensions) of alternating commonly patterned carpeted floor covering areas (e.g., carpet areas 54B, 54D and 54F of the second pattern interleaved with carpet areas 54A, 54C and 54E of the first pattern). Then, a pair of rows (e.g., rows 50C and 50D) is offset with an adjacent pair of rows (e.g., rows 50A and 50B) to form a checkerboard pattern in the floor covering assembly 52 using the first and second carpet area 54 patterns.
The carpet planks 10 in the embodiments shown in FIGS. 1-23 have carpet layers 14 with carpet pile that has an orientation and where adjacent carpet sections 40, 42, 44, 46 are rotated 90 degrees with respect to each other. As indicated, other types of patterns and/or differences between carpet sections 40, 42, 44, 46 are possible.
For example, FIG. 24 shows a type A carpet plank 10A that has a carpet layer 14 with carpet pile that has an orientation and where adjacent carpet sections 40, 42, 44, 46 are rotated 180 degrees with respect to each other. FIG. 25 shows a corresponding type B carpet plank 10B that may be used with the type A carpet plank 10A of FIG. 24 to form a floor covering assembly 52 similar to that of FIG. 22.
As another example, FIGS. 26 and 27 respectively show a type A carpet plank 10A and a corresponding type B carpet plank 10B where the pattern for each carpet section is a color or design in the carpet layer for each carpet section. These carpet planks 10A and 10B also may be used to form a floor covering assembly 52 similar to that of FIG. 22.
Turning to FIGS. 28-30, another embodiment for the carpet planks 10 is illustrated. In this embodiment, there is a type A carpet plank 10A′ and a type B carpet plank 10B′ that each have three carpet sections 40′, 42′, 44′ instead of the four carpet sections of the previous embodiments. But, similar to the earlier embodiments, the carpet pattern for each carpet section 40′, 42′, 44′ differs from an adjacent carpet section 40′, 42′, 44′. In the illustrated embodiment, the first carpet section 40′ and the third carpet section 44′ each have the same carpet pattern and the second carpet section 42′ has a different carpet pattern, such as a carpet pile orientation rotated 90 degrees or 180 degrees from a carpet pile orientation of the first and third carpet sections 40′ and 44′, or a different color or design than the color or design of the first and third carpet sections 40′ and 44′.
In one embodiment, the carpet sections of the type B carpet plank 10B′ has an inverse of carpet patterns relative to the carpet patters of the carpet sections of the type A carpet plank 10A′. In this embodiment, the carpet sections 40′ and 44′ of the type A carpet plank 10A′ have the same pattern as the carpet section 42′ of the corresponding type B carpet plank 10B′. Similarly, the carpet section 42′ of the type A carpet plank 10A′ has the same pattern as the carpet sections 40′ and 44′ of the corresponding type B carpet plank 10B′.
In one embodiment, the carpet planks 10A′ and 10B′ each are six inch by 36 inch rectangles, in which the first and third carpet sections 40′ and 44′ each are six inch by nine inch rectangles (e.g., rectangles as wide as the width of the carpet plank 10 and 1.5 times as long as the carpet plank 10 is wide) and the middle second carpet section 42′ is a six inch by eighteen inch rectangle (e.g., a rectangle as wide as the width of the carpet plank 10 and four times as long as the carpet plank 10 is wide). Therefore, the first and third carpet sections 40′ and 44′ are the same size as each other. It will be appreciated that other dimensions are possible.
The carpet planks 10A′ and 10B′ may be arranged to form a floor covering assembly 52′ that has a checkerboard arrangement. In one embodiment, a first row 50A′ and a third row 50C′ each have aligned type A carpet planks 10A′. In between the first row 50A′ and the third row 50C′ is a second row 50B′ having type B carpet planks 10B′ that are offset by 50 percent of the length of the carpet planks 10′. In this manner, the third carpet section 44′ of a type A carpet plank 10A′ in the first row 50A′ combines with each of: a first carpet section 40′ of an adjacent type A carpet plank 10A′ in the first row 50A; a second carpet section 42′ of an offset type B carpet plank 10B′ in the second row 50B; another third carpet section 44′ of a type A carpet plank 10A′ in the third row 50C; and another first carpet section 40′ of an adjacent type A carpet plank 10A′ in the third row 50C′. The result is a carpet area 54A′ having a first pattern. Similarly, a second carpet section 42′ of a type A carpet plank 10A′ in the first row 50A′ combines with each of: a third carpet section 44′ of a type B carpet plank 10B′ in the second row 50B; a first carpet section 44′ of an adjacent type B carpet plank 10B′ in the second row 50B; and a second carpet section 42′ of a type A carpet plank 10A′ in the third row 50C′. The result is a carpet area 54B′ having a second pattern adjacent the carpet area 54A′ having the first pattern.
In this manner, the carpet sections from groups of carpet planks 10′ come together to form squares (e.g., eighteen inch by eighteen inch areas using the above described exemplary dimensions) of alternating commonly patterned carpeted floor covering areas (e.g., carpet areas 54A′ of the first pattern interleaved with carpet areas 54B′ of the second pattern). Then, a group of three rows (e.g., rows 54D′, 54E′ and 54F′) are offset with an adjacent group of three rows (e.g., rows 54A′, 54B′ and 54C′) to form a checkerboard pattern in the floor covering assembly 52′ using the first and second carpet area 54′ patterns.
Although certain embodiments have been shown and described, it is understood that equivalents and modifications falling within the scope of the appended claims will occur to others who are skilled in the art upon the reading and understanding of this specification.

Claims

1. A rectangular carpet plank comprising:

a baseplate having a first side edge opposed from a second side edge; and

a carpet layer attached to a top surface of the baseplate, the carpet layer being divided into carpet sections, wherein:

each carpet section extends from the first side edge to the second side edge;

each carpet section having a carpet pattern; and

adjacent carpet sections having different carpet patterns.

2. The carpet plank of claim 1, further comprising:

a first joining element located along the first side edge of the baseplate; and

a second joining element located along the second side edge of the baseplate, the first joining element and the second joining element being complementary in shape.

3. The carpet plank of claim 2, wherein the first joining element extends along the entirety of the first side edge of the baseplate and the second joining element extends along the entirety of the second side edge of the baseplate.

4. The carpet plank of claim 2, wherein the first joining element is a male joining element and the second joining element is a female joining element.

5. The carpet plank of claim 4, wherein the male joining element is a tongue and the female joining element is a complementary groove.

6. The carpet plank of claim 2, wherein the joining elements are integrally formed with the baseplate.

7. The carpet plank of claim 2, the carpet plank further comprising:

a third joining element located along a first end edge of the baseplate; and

a fourth joining element located along a second end edge of the baseplate, the third joining element and fourth joining element being complementary in shape.

8. The carpet plank of claim 7, wherein the third joining element extends along the entirety of the first end edge of the baseplate and a fourth joining element extends along the entirety of the second end edge of the baseplate.

9. The carpet plank of claim 1, the carpet pattern of each carpet section being a color of the carpet.

10. The carpet plank of claim 1, wherein each carpet section has a pile and the carpet pattern of each carpet section being an orientation of the pile.

11. The carpet plank of claim 10, wherein the pile is loop pile.

12. The carpet plank of claim 10, wherein the pile is cut pile or tufted pile.

13. The carpet plank of claim 10, wherein the pile of one carpet section is rotated 90 degrees with respect to an adjacent carpet section.

14. The carpet plank of claim 10, wherein the pile of one carpet section is rotated 180 degrees with respect to an adjacent carpet section.

15. The carpet plank of claim 1, wherein the carpet plank is 6 inches by 36 inches.

16. The carpet plank of claim 1, the carpet layer having a first carpet section at a first end of the baseplate, a second carpet section adjacent the first carpet section, a third carpet section adjacent the second carpet section, and a fourth carpet section adjacent the third carpet section and at a second end of the baseplate opposed to the first end of the baseplate.

17. The carpet plank of claim 16, the first and third carpet sections having the same carpet pattern and the second and fourth carpet sections having the same carpet pattern.

18. The carpet plank of claim 16, the first and fourth carpet sections being squares and the second and fourth carpet sections being rectangles that are twice as long as the first and fourth carpet sections.

19. The carpet plank of claim 1, the carpet layer having a first carpet section at a first end of the baseplate, a second carpet section adjacent the first carpet section, and a third carpet section adjacent the second carpet section and at a second end of the baseplate opposed to the first end of the baseplate.

20. The carpet plank of claim 19, the first and third carpet sections having the same carpet pattern and the second carpet section having a different carpet pattern then the first and third carpet sections.

21. The carpet plank of claim 19, the first and third carpet sections being rectangles and the second carpet section being a rectangle that is twice as long as the first and third carpet sections.

22. A system of carpet planks, comprising:

a first carpet plank of claim 1; and

a second carpet plank of claim 1, wherein the first and second carpet planks having the same lengths and widths; and

wherein the first and second carpet planks having an equal number of carpet sections, each section being the same in size as a corresponding carpet section of the other plank, and the corresponding carpet sections having different carpet patterns, the first carpet plank being a first carpet plank type and the second carpet plank being a second carpet plank type.

23. The system of claim 22, wherein carpet planks are arranged in a repeating pattern of rows including a first row and a second row, wherein:

the first row of carpet planks alternating between the first carpet plank type and the second carpet plank type;

the second row of carpet planks alternating between the first carpet plank type and the second carpet plank type; and

each carpet plank of the second row is offset with a corresponding carpet plank of the first carpet plank type of the first row and a corresponding carpet plank of the second carpet plank type of the first row so that carpet sections of the carpet planks from the first row align with carpet sections having the same carpet pattern of the carpet planks from the second row.

24. The system of claim 23, wherein aligned carpet sections of the same carpet pattern from the rows cooperate to form a square carpet area of the carpet pattern.

25. The system of claim 24, wherein the repeating pattern further includes a third row and a fourth row, wherein square carpet areas of the carpet pattern in the third and fourth rows are offset with the square carpet areas of the carpet pattern in the first and second rows to form a checkerboard pattern.

26. The system of claim 22, wherein carpet planks are arranged in a repeating pattern of rows including a first row, a second row, and a third row, wherein:

the first row comprises carpet planks of the first carpet plank type;

the second row comprises carpet planks of the second carpet plank type, wherein each carpet plank of the second row is offset with two corresponding carpet planks of the first row so that carpet sections of the carpet planks from the first row align with carpet sections having the same carpet pattern of the carpet planks from the second row; and

the third row comprises carpet planks of the first carpet plank type, wherein each carpet plank of the third row is offset with two corresponding carpet planks of the second row so that carpet sections of the carpet planks from the second row align with carpet sections having the same carpet pattern of the carpet planks from the third row.

27. The system of claim 26, wherein aligned carpet sections of the same carpet pattern from the three rows cooperate to form a square carpet area of the carpet pattern.

28. The system of claim 27, wherein the repeating pattern further includes a fourth row, a fifth row, and a sixth row, wherein square carpet areas of the carpet pattern in the fourth, fifth, and sixth rows are offset with the square carpet areas of carpet pattern in the first, second and third rows to form a checkerboard pattern.

29. A carpet plank comprising:

a rectangular baseplate having a top surface, a first side edge opposed from a second side edge, a first end edge extending between the side edges and a second end edge extending between the side edges and opposed from the first end edge, wherein the side edges are longer than the end edges;

a carpet layer attached to a top surface of the baseplate and having dimensions to cover the top surface;

a first joining element located along the first side edge of the baseplate; and

30. The carpet plank of claim 29, wherein the first joining element extends along the entirety of the first side edge of the baseplate and the second joining element extends along the entirety of the second side edge of the baseplate.

31. The carpet plank of claim 29, wherein the first joining element is a male joining element and the second joining element is a female joining element.

32. The carpet plank of claim 31, wherein the male joining element is a tongue and the female joining element is a complementary groove.

33. The carpet plank of claim 29, wherein the joining elements are integrally formed with the baseplate.

34. The carpet plank of claim 29, the carpet plank further comprising:

a third joining element located along a first end edge of the baseplate; and

35. The carpet plank of claim 34, wherein the third joining element extends along the entirety of the first end edge of the baseplate and a fourth joining element extends along the entirety of the second end edge of the baseplate.

36. The carpet plank of claim 29, wherein the carpet plank is 6 inches by 36 inches.

37. The carpet plank of claim 29, wherein the end edges of the baseplate are planar.

38. The carpet plank of claim 29, wherein the side edges are more than twice as long as the end edges.

39. A system of carpet planks, comprising:

a first carpet plank of claim 29; and

a second carpet plank of claim 29, wherein the first joining element of the first carpet plank is mated with the second joining element of the second carpet plank.

40. The system of carpet planks of claim 39, wherein the first end edge of the first carpet plank is longitudinally offset from the first end edge of the second carpet plank.