WO2021130658A1

WO2021130658A1 - Surface covering samples

Info

Publication number: WO2021130658A1
Application number: PCT/IB2020/062293
Authority: WO
Inventors: Blake Gordon
Original assignee: Inv Performance Surfaces, Llc
Priority date: 2019-12-23
Filing date: 2020-12-21
Publication date: 2021-07-01
Also published as: WO2021130658A9

Abstract

Various embodiments related to an apparatus for simulating a surface covering. The apparatus can comprise any one or combination of a first substrate, a color layer and a coating. The first substrate can have a first major surface and an opposing second major surface. The color layer can be applied to the first major surface and can have a first amount of light reflectivity. The coating can be selectively applied to or with a plurality of portions of the color layer. The coating can have a second amount of light reflectivity that differs from the first amount of light reflectivity. The coating can be in registration with the color layer and can be applied corresponding to a texture of the surface covering.

Description

SURFACE COVERING SAMPLES

FIELD

[0001] Disclosed herein are methods, apparatuses, and systems that generally relate to surface covering samples, more particularly, these methods, apparatuses and systems relate to surface covering samples that are configured to simulate the appearance of a surface covering.

BACKGROUND

[0002] In the flooring industry, a prospective buyer must rely on either online digital (photographical) representation of installed flooring in simulated shop-like environments or small (e.g., 4 inch by 4 inch) samples that comprise actual specimens of the product. Small samples of hardwood, laminate, engineered flooring, luxury vinyl tiles (LVTs), luxury vinyl planks (LVPs), etc. are available. Similarly, other industries such as those for cabinets, counter-tops, wall-coverings and carpeting tend to rely on small samples that comprise actual specimens of the product.

[0003] However, to the prospective buyer these samples or simulation may not of be of much help beyond just providing a basic color/shade information. The small hand-held samples are not effective in terms of giving the prospective buyer a “real feel” or “look” in the actual in-home/installed setting. There remains some uncertainty between the prospective buyer's choosing a flooring product based on these samples and how the actual flooring appears upon installation. This puts the prospective buyer in a very uncomfortable situation when making costly decisions of selecting from a wide variety of surface covering products.

[0004] In some cases, independent flooring contractors/installers carry stacks of selected products during their residential visits for show-n-tell. Carrying these large samples is cumbersome and still leaves buyers concerned and nervous about making costly decisions based on these one-of-a-kind specimens. SUMMARY

[0005] The present application recognizes solutions to some of the difficulties faced by the prospective buyer in determining the “real feel” or “look” in the actual in-home/installed setting. As discussed previously, there currently is no convenient and easy way for the buyer to fully appreciate and visualize the product aesthetics, look and feel until after the floor has been installed in the real setting.

The present inventor has recognized there is a need in various surface covering products industries (e.g., flooring, cabinets, counter- tops, wall-coverings, carpeting, etc.) and has designed and engineered large surface covering samples that are light weight, durable, cost-effective, portable for the ease of shipment/handling/transport to meet this need. Additionally, the samples disclosed are constructed to be adequately sized to give prospective buyers a real feel of what such surface covering may look like when installed in a real in-home environment. Thus, the instant application provides solutions to the challenges noted above by providing a more representative sampling option to put the prospective buyer at ease during the selection process. Furthermore, the present application provides a practical solution that is easy to implement and cost-effective to both the prospective buyer and the seller.

[0006] The manufacturing discussed herein can include applying an agent, such as a colorant and/or coating, as desired according to a control plan to at least a first substrate. The first substrate can have an elongate length and/or width in one or more directions relative to others. The elongate dimension is also referred to as a longitudinal length or longitudinal width herein. The substrate can also be configured as a sheet or web having a first major surface spaced apart from a second major surface by a thickness. This thickness can be orders of magnitude less than the length and/or width of the first major surface or the second major surface. The first substrate can comprise a non-surface covering material(s) according to some examples. The first substrate can be, for example, paper, paper composite, polymer or other material(s). The first substrate can be any material that can be printed on according to some examples. [0007] According to some examples, at least a second substrate can be utilized. The second substrate can comprise a non-surface covering material, for example. The second substrate can comprise a corrugated paper, foam board, polymer material, paper composite, etc. According to some examples, the second substrate can comprise a backing for the first substrate and can be laminated or otherwise coupled thereto.

[0008] The agent disclosed herein can include any liquid or paste chemical

(e.g., additive, coating, colorant, pre- treatment, post-treatment, luster modifier, or a combination thereof, etc.). Thus, the agent can comprise a liquid, a gel, or a gas having fluid-like properties. The colorant (sometimes referred as “color” or “color layer” herein) can include a variety of hues and densities. The colorant can include at least one color selected from the group cyan, magenta, yellow, and black (e.g., CYMK) and optionally can include one or more spot colors such as purple or orange. The colorant can be an ink, a dye, a pigment, or a combination thereof. Herein, when “ink” is referred to, a dye, ink, pigment, or combination thereof, can alternatively be used. A clear colorant (e.g., clear ink) can be used, for example, to adjust the density of the color. Non-limiting examples of the type of inks that can be used include digital inks, acid dye inks, disperse dye inks, reactive dye inks, sublimation inks, and pigment inks. The colorant can include a base carrier, such as a medium in which a dye or pigment is dispersed or dissolved. Depending on the base carrier used, the colorant can be water-based (aqueous), solvent-based, or oil- based. The colorant can also include a surfactant, a humectant, a viscosity modifier, a binder resin, a pH modifier, and other functional chemical, or a combination thereof, as needed.

[0009] The coating can include at least one of a film or a cured agent. The coating (sometimes referred to as a gloss) discussed herein can include spot gloss or spot glossing. These terms as used herein, denote a technique (e.g., printing, rolling, spraying, lithography, etc.) whereby the coating is applied to chosen areas (or spots) of a surface of at least the first substrate. Other areas of the surface of the at least the first substrate can have relatively less coating or can be uncoated. Such spatial application of the coating may have the effect of highlighting and drawing attention to that part of the surface. This spot gloss technique may also provide the additional visual stimulus of simulating a varied texture (sometimes called topography herein) or achieving varied texture on the first substrate. Depending on the extent of spot glossing and/or finishing, the substantially planar surface of at least the first substrate may visually appear to have a three-dimensional texture but can remain substantially planar. Alternatively, the spot glossing may achieve a three- dimensional texture. It should be noted that the term “gloss” as used here is not limited to a particular reflectance percentage or gloss number. Thus, the term gloss or coating, unless otherwise specified can be a full gloss (e.g., 85% to 100% reflectance percentage), a gloss (e.g., 60% to 84% reflectance percentage), a semi gloss (e.g., 20% to 59% reflectance percentage), a low sheen (5% to 19% reflectance percentage) and a flat or matte (0.1% to 4% reflectance percentage). It should also be noted that the amount/type/reflectance percentage of the coating can be varied within the chosen spot gloss areas and across the first major surface of the first substrate as will be further discussed herein.

[0010] Although the colorant and the coating are described separately in some cases herein, it should be recognized that these can be combined together and/or applied simultaneously according to some examples.

[0011] The term “surface covering” includes floor coverings, cabinet covering, counter-tops, wall-coverings, carpeting, etc.

[0012] The term “topography” or “texture” or variations thereof refer to a level change in the surface covering along the display surface (sometimes called a major surface) thereof. Topography or texture can be an area or feature that is relatively raised/elevated or lowered/depressed in height relative to an average height along the display surface of the surface covering. Examples of topography include joints and seams of the surface covering such as a grout line, chamfering and other features for tongue and groove connection, etc. Topography/texture as used herein, however, is not limited to joints and seams and can include any relatively raised or relative lowered features such as a knot, grain, etc.

[0013] The term “registered” or variations thereof means alignment and/or synchronization of the coating and/or the color of the sample with one another and/or with corresponding topography of the actual surface covering in order to simulate the texture of the surface covering.

[0014] Various embodiments utilize an ink jet device for applying agent such as the colorant and/or coating to at least the first substrate. However, other devices are contemplated. The inkjet device can comprise a printer configured as an applicator (e.g., having print-heads with nozzles, valves, etc.) as known in the art. According to some examples, the device further includes a conveyor, for example. For colorant application, the printer can include flowing individual streams of cyan, magenta, yellow, and black colorant to an intermediate component or directly to the first substrate.

[0015] The present disclosure contemplates a platform with various modules that can be used throughout these steps in the manufacturing process. One or more controllers can be used to aggregate information to prepare one or more control plans (e.g., art files, design masks, etc.) for processing the surface covering sample(s) through the manufacturing process. Criteria, such as upcoming deadlines, order volume, order complexity, order similarity, planned/available manufacturing systems, agent type(s), agent availability, color profiles, agent profiles etc., may be used to filter and organize the available orders for more efficient manufacture. The control plan may include a set of instructions for operating one or more systems/devices within the manufacturing process to ultimately form the desired finished sample. In such a regard, some embodiments contemplate one or more controllers that can generate and provide the control plan to various devices/sy stems for performing efficient manufacturing of the sample.

BRIEF DESCRIPTION OF THE FIGURES [0016] Reference will now be made to the accompanying drawings, which are not necessarily drawn to scale, and wherein:

[0017] FIG. 1 is a block diagram of an example manufacturing process to fabricate a sample in accordance with an example of the present application. [0018] FIGS. 2A-2B are further block diagrams of other examples of a manufacturing process to fabricate the sample in accordance with an example of the present application.

[0019] FIG. 3A shows a perspective view of a surface covering in accordance with an example of the present application.

[0020] FIG. 3B shows a design mask simulating an appearance and/or texture of the surface covering of FIG. 3 A.

[0021] FIG. 3C shows a block diagram of a further method of manufacturing the sample in accordance with an example of the present application.

[0022] FIGS. 4A and 4B show actual surface covering product along with samples configured to simulate the appearance and/or texture of the floor samples in accordance with an example of the present application.

[0023] FIG. 5A shows a sample configured to simulate the appearance and/or texture of the surface covering of FIG. 3 A with the sample shown in a stacked position in accordance with an example of the present application.

[0024] FIG. 5B shows the sample of FIG. 5 A being unfolded from the stacked position or folded to the stacked position using one or more articulating joints in accordance with an example of the present application.

[0025] FIG. 5C shows the sample of FIGS. 5 A and 5B in a display position in accordance with an example of the present application.

DETAILED DESCRIPTION

[0026] Reference will now be made to certain embodiments (sometimes referred to as “example” or “examples” herein) of the disclosed subject matter, examples of which are illustrated in part in the accompanying drawings. While the disclosed subject matter is described in conjunction with the enumerated claims, it will be understood that the exemplified subject matter is not intended to limit the claims to the disclosed subject matter.

[0027] Corrugated sheet manufacturing is described herein as an example of one method of making the surface covering samples. It should be recognized that other manufacturing processes such as those for creating samples with foam board backing, polymer sheet samples, etc. are also contemplated. In some such corrugated manufacturing, a corrugator is used to glue together layers of board web with a flute medium positioned in between. Depending on the desired characteristics of the corrugate board web, different layers/arrangements can be combined. Once formed, the sample can comprise a corrugate board web (e.g., with top/display layer comprising the first substrate discussed herein, flute medium, and bottom layer) that may then be cut into appropriate sample structures, and later scored to form the stacked/shippable form of the sample (that is then unfolded to the display position and otherwise manipulated, such as by the prospective customer). Although the following description can discuss examples of “corrugators”, some example embodiments of the present invention contemplate the term “corrugator” to mean a board-making device, such as a high-speed laminator.

[0028] FIG. 1 illustrates an example manufacturing process 10 to form one or more samples, according to an embodiment of the present invention. The manufacturing process 10 can include a number of phases that result in a finished sample product that has a look that simulates that of a surface covering a potential customer is considering for purchase. The process 10 may include one or more controllers 12 (also referred to modules herein) and can include various phases or steps including ordering 14, plan/design 16, print 18, coat 20, board making/cut 22 and finishing 24.

[0029] Modules described can include one or more dedicated controllers, memory, software and/or communication devices sufficient for implementation and interaction.

[0030] The one or more controllers 12 may be used to control one or more of the various phases (e.g., various systems/devices therein) of the manufacturing process 10. In some embodiments, less or more phases or different orders of phases are contemplated. The one or more controllers 12 may be configured to control operation such as of corrugator, one or more printers, etc. during the phases illustrated. Likewise, the controller 12 may be used with the ordering 14 phase and/or during the plan/design 16 phase, such as described herein. In some embodiments, the controller 12 may comprise any number of controllers at any of the various phases of the manufacturing process 10.

[0031] The controller 12 may comprise one or more suitable electronic device(s)/server(s) capable of executing described functionality via hardware and/or software control. In some embodiments, the controller 12 may include one or more user interfaces, such as for displaying information and/or accepting instructions in the form of an input. The controller 12 can be, but is not limited to, a microprocessor, microcomputer, a minicomputer, an optical computer, a board computer, a complex instruction set computer, an ASIC (application specific integrated circuit), a reduced instruction set computer, an analog computer, a digital computer, a molecular computer, a quantum computer, a cellular computer, a solid- state computer, a single-board computer, a buffered computer, a computer network, a desktop computer, a laptop computer, a personal digital assistant (PDA) or a hybrid of any of the foregoing.

[0032] The controller 12 can include one or more processors coupled to a memory device. The controller 12 may optionally be connected to one or more input/output (I/O) controllers or data interface devices (not shown). The memory may be any suitable form of memory such as an EPROM (Erasable Programmable Read Only Memory) chip, a flash memory chip, a disk drive, or the like. As such, the memory may store various data, protocols, instructions, computer program code, operational parameters, etc. In this regard, controller may include operation control methods embodied in application code. These methods are embodied in computer instructions written to be executed by one or more processors, typically in the form of software. The software can be encoded in any suitable language, including, but not limited to, machine language, assembly language, and any combination or derivative of at least one of the foregoing. Additionally, an operator can use an existing software application such as a spreadsheet or database and correlate various cells with the variables enumerated in the algorithms. Furthermore, the software can be independent of other software or dependent upon other software, such as in the form of integrated software. In this regard, in some embodiments, the controller 12 may be configured to execute computer program code instructions to perform aspects of various embodiments of the present invention described herein.

[0033] In brief, and as will be further elaborated upon further subsequently, the customer may supply an order that includes one or more surface coverings of interest for purchase/review. This can be referred to as an input specification during the ordering phase 14. In some embodiments, the customer may input such an order through a web interface. The web interface may enable the customer to easily input the input specification of the order electronically, such as by selecting surface covering(s) of interest via SKU or other reference. The web interface may also enable the potential customer to handling payment, provide feedback (including to request dimensions, etc.) and the like.

[0034] The web interface may also directly interact with and provide information for automated processes useful in the remainder of the manufacturing process 10. For example, the information from the web interface may be fed directly into the controller 12 and can be utilized accordingly. The information from the web interface can be used to form a control plan (e.g., image file, art file, design mask, process plan, etc.) for a planned run of the sample.

[0035] As shown in FIG. 1, the manufacturing process 10 with instructions from the controller 12 can organize the process plan, art file, design mask, etc. in the plan/design phase 14. If an art file has not been generated for a prospective surface covering yet, an image file can be obtained from imaging the prospective surface covering. The plan/design phase 14 can include logistical criteria such as allocation of orders to particular corrugators and/or printers based upon capacity, capability, production sequencing (e.g., aggregating orders) and the like. This can be based upon criteria like orders sharing same or similar characteristics such as same or similar color, design, coating, can be fabricated together, for example.

[0036] The controller 12 can be configured to generate and verify instructions for the corrugator and/or printer (or other devices) utilized in the manufacturing process 10. The instructions can be based upon the design mask (discussed subsequently) and can form of a part of the control plan associated with the sample (or plurality of samples). In this regard, each order (or plurality of orders) may correspond to at least one design for a surface covering. However, a production run can include several orders and/or several designs, such as one for each respective different surface covering. For example, the control plan, as part of the plan/design 16 phase can include a set of first level instructions for forming or gathering an image file based upon one or more images of the selected surface covering. Additionally, in some embodiments, the control plan may have a second or more levels of order instructions, such as to generate or select an art file from the corresponding image file, generate or select a design mask from the art file, control manufacturing, layout, design, etc. according to one or more of these files and/or masks. In some cases, the control plan may be generated such that different orders from different potential customers are positioned or planned to run one after the other (or together) in a longitudinal direction of the web comprising the first substrate to minimize waste, take advantage of similar or same design, similar or same coating, similar or same colorant, similar or same post-processing, etc.

[0037] The control plan can include (in addition to instructions), specification, databases, etc. for enabling control and/or operation of various systems/devices of the manufacturing process 10. For example, one set of instructions may comprise the design mask corresponding to the input specification. Ultimately, in some embodiments, the plan instructions (and other instructions) can form a full set of order instructions that can be used during the manufacturing process 10 to form the desired sample(s).

[0038] The manufacturing process 10 can include the print 18 phase and the coat phase 20. These can be a single phase according to some embodiments. These can utilize one or more devices such as one or more inkjet printers as discussed previously to apply colorant and coating to the first substrate according to the design mask and other instructions of the control plan. Digital print processes can be used, providing for enhanced image quality. According to one example, the inkjet printer can have a plurality of digital print-heads, which are used for a colorant application, one or more of the plurality of print-heads can be used in sequence to apply primary colors/inks, for example, cyan (C), magenta (M), yellow (Y), black (K), and the like. Another agent such as clear ink, coating etc. can also optionally be applied. [0039] Each print-head of the plurality of print-heads, and indeed each nozzle of the plurality of nozzles of each print-head, can be programmed or controlled via the controller 12 to apply agent (e.g., to color, to coat, etc.) independent of other nozzles or heads to provide a selectable amount, type (e.g., color, coat, etc.) and pattern. Agent can be applied along a longitudinal length and/or longitudinal width of the first substrate from one or more of the nozzles spaced therefrom or via an intermediate component.

[0040] During the print 18 phase and/or coat 20 phase, the controller 12 can direct the printer to select desired agent(s) and to print one or more features, designs, patterns, colors, coatings etc. derived from the design mask at specific areas/locations on a first major surface of the first substrate. In some embodiments, the controller 12 may utilize topographical information of the control plan to determine where on the first major surface of the first substrate to print the features, designs, patterns, colors, coatings etc. as further described herein. In some embodiments, the controller 12 may utilize topographical information of the control plan to determine within an area on the first major surface of the first substrate how to vary colors and/or coating such as to provide a contrast to simulate texture of the surface covering as further described herein. In some embodiments, the controller 12 may provide the control plan to the one or more printers for operation thereof to cause the one or more printers to print the desired features, designs, patterns, colors, coatings etc. at an appropriate area/position and in a registered manner on the first major surface of the first substrate (e.g., within each designated area having an alignment/synchronization in color and coating) — thereby forming the sample with the desired visual effect to simulate the floor covering.

[0041] The manufacturing process 10 can include a board making and cut 22 phase using the corrugator as previously described. The corrugator and other devices can operate according to the control plan. This phase can include corrugating or other processing to add the second substrate coupled to the first substrate. This second substrate can comprise one or more layers and can comprise a rigid material so as to provide a backing for the first substrate. During this phase, samples may additionally be separated from one another. For example, the web may be divided by being cut into appropriate sample structures, and later scored to form the stacked/shippable form of the sample (that is then unfolded to the display position and otherwise manipulated, such as by the prospective customer).

[0042] The finishing phase 24 can include post-processing treatment such as folding each sample into a stacked/shippable position, order aggregation, packaging of the samples, etc.

[0043] FIG. 2A shows an exemplary method 100 of forming a sample to simulate a surface covering. The method 100 can include imaging 102 a major surface of the surface covering. This can be performed using one or more digital cameras, for example. The camera can be positioned appropriately and configured to capture not only the color appearance of the major surface of the surface covering but also the texture of the major surface of the surface covering. To this end, the camera may utilize filtering (e.g., contrast, etc.) techniques known in the art to better identify the texture. According to some examples, the camera (or several cameras) can be utilized at different positions relative to the first major surface of the surface covering to capture the texture.

[0044] From the imaging, the method 100 can generate 104 an art (image) file that can be saved and utilized for manufacture in order to fabricate the sample to simulate the surface covering. It should be noted that after imaging of a particular type or brand of surface covering has been performed, the art file can be saved for future reference such that further imagining of that particular brand or type of surface covering need not be performed again. Thus, in some cases the method 100 need only reference or otherwise obtain the art file without the need of generating an image file. The method 100 based upon the art file can generate 106 (reference or otherwise obtain) a design mask. The design mask will be discussed in further detail in FIGS. 3A-3C.

[0045] The method 100 can apply 108 colorant and coating to the first substrate according to the design mask to simulate the appearance including at least the texture of the first major surface of the surface covering. According to another example, the coating can be applied with a variation in reflective intensity to simulate the texture of the surface covering. As discussed previously, the applying of the colorant and coating can be simultaneously or sequential in nature.

[0046] FIG. 2B shows a method 100A that obtains 106A a design mask.

The method 100A can print 108A colorant on a major surface of first substrate according to the design mask. The method 100A can apply 110A the coating according to the design mask and in a registered manner with the colorant. This can provide for a variation in color corresponding with a variation in gloss, for example. Put another way, the registration can provide a contrast in the color and/or in gloss to simulate the appearance and/or texture of the surface covering. According to some examples of the method 100A, the gloss can be applied with a variation in reflective intensity to simulate at least one of an appearance or texture of the surface covering.

[0047] The design mask can include appearance characteristics of the surface covering (e.g., color, texture, color quality, gloss, luster, glitter, pattern (e.g, linear extending seams/joints/edges, linear extending simulated seams/joints/edges, chamfering, etc.) features (e.g., knots, etc.) for feedback in controlling and/or operating various components utilized in the systems and methods discussed herein. The design mask can further include appearance characteristics for the sample simulating the surface covering including a pattern, coloration and gloss to simulate texture among other criteria.

[0048] FIG. 3A shows a surface covering 200 comprising a floor covering that is itself design to simulate a natural wood floor. The surface covering 200 can include a first major surface 202 and edges 204. The first major surface 202 can have a plurality of textured features 206 including simulated joints 208 and other features 210 such as actual or simulated wood grain.

[0049] Sections of the surface covering 200 can be joined together at the edges 204 when installed. The first major surface 202 comprises the display surface of the surface covering 200. The simulated joints 208 can comprise areas or lines of linear extent that can be elevated or depressed relative to an average height/topography of the first major surface 202. The other features 210 can comprise areas that are relatively depressed or relatively elevated relative to the average height/topography of the first major surface 202.

[0050] FIG. 3B shows an example of a design mask 212 corresponding to the surface covering 200. The design mask 212 has a plurality of layers 214 according to the example of FIG. 3B. However, a plurality of layers is not necessary in all embodiments and are shown in FIG. 3B for exemplary purposes. [0051] The design mask 212 of FIG. 3B is shown both in a combined design 216 state and an exploded state with the plurality of layers 214. The combined design 216 state can include colorant and gloss with the colorant and/or gloss registered with one another and the colorant and/or gloss having a contrast across, along and in various areas of a first major surface 218 that simulates the topography and coloration of the first major surface 202 of the surface covering 200 of FIG. 3 A. The design mask 212 and resulting sample can be configured to have a 1 : 1 ratio correspondence with the surface covering 200 according to some examples. Put another way, features of the design mask 212 and sample that simulate the textured features 206, for example, can have a 1 : 1 geometric correspondence to such textured features 206.

[0052] The plurality of layers 214 can include at least one layer comprising a color layer 220 configured to simulate a color of the first major surface 202 of the surface covering 200 of FIG. 3 A. The color layer 220 can be a printed layer or can be fabricated by another technique as previously discussed. One or more of the plurality of layers 214 can be coat layers including an un-coated or matte layer 222 (e.g., with less than 19% reflectivity), a semi-gloss layer 224 (e.g., with a 20% to about 59% reflectivity) and a gloss layer 226 (60% and above reflectivity). The un coated or matte layer 222 can correspond to relatively depressed areas of the first major surface 202 of FIG. 3 A such as the simulated joints 208. The gloss layer 226 can correspond to relatively elevated topography of the first major surface 202 of FIG. 3 A.

[0053] As shown in FIG. 3B, the color layer 220 can be configured such that the first amount of light reflectivity remains substantially the same along a pathway extending in a linear direction of the first major surface and the coating (resulting from one or more coating layers such as the un-coated or matte layer 222) of the pathway can be configured such that the second amount of light reflectivity remains substantially the same along the pathway. This can give the appearance of a simulated joint for the design mask 212 and the sample corresponding to one of the simulated joints 208 of FIG. 3 A. Furthermore, the color layer 220 can be configured such that the first amount of light reflectivity can remain substantially the same for a second pathway extending parallel with and spaced from the pathway and the coating (resulting from one or more coating layers such as the semi-gloss layer 224) of the second pathway can be configured such that the second amount of light reflectivity remains substantially the same along the second pathway. Such arrangement can simulate an end, chamfer or other feature of the simulated joint of the design mask 212 and the sample corresponding to similar feature (e.g., the end, chamfer, or other feature) adjacent the one of the simulated joints 208 of FIG. 3 A. The coating can be selectively applied to differ the second amount of light reflectivity from the pathway to second pathway (e.g., the coating can change from - coated or matte layer 222 to the semi-gloss layer 224).

[0054] Further layers than the plurality of layers 214 are contemplated according to some examples. Furthermore, according to some examples, the plurality of layers 214 may not comprise coat or color layers but simply correspond to topography identified from the surface covering 200 that can be utilized for control instructions (e.g., areas to apply coating of a similar type/amount of gloss). Thus, according to other examples, a single layer with color and coating mixture being varied/contrasted along, across and in certain areas of the first substrate is also contemplated.

[0055] FIG. 3C shows a method 300 according to one embodiment. The method 300 can be utilized to create the design mask and also to fabricate the sample. As discussed, the method 300 can optionally include imaging techniques such as filtering 302 to determine topography and color information of the surface covering. The method 300 can identify 304A features having a same topography as corresponding with the areas identified for various layers, types of color, types of coating, etc. in FIG. 3B. Additionally, or alternatively, the method 300 can identify or determine 304B linear features (e.g., simulated joints 208) and/or other patterns from the surface covering imaging. Based upon criteria 302A and/or 302B, the method 300 can register 306 the coating with the colorant according to the topography and the other criteria (e.g., the identified features, edges, and/or pattern). Such registration can be performed to provide a 1 : 1 geometric correspondence between features of the sample and those of the surface covering. The method 300 can then apply 308 the colorant and the coating according to the registration.

[0056] FIGS. 4A and 4B show images including a sample 400 with a corresponding floor covering 402 having a first major surface 404 the sample 400 simulates. The sample 400 can comprise a first substrate 406 having a first major surface 408. The first major surface 408 can have a colorant and coating comprising a spot glossing applied thereto. The spot glossing provides a sheen or luster to the sample 400, which to the human eye simulates the texture of the first major surface 404 of the floor covering 402.

[0057] As shown in FIGS. 4A and 4B, the sample 400 can comprise a sheet of paper product that can be configured to interface with and take a shape of a surface it is placed upon. Thus, the sample 400 can be substantially flat when placed on a substantially flat floor or other substantially flat surface.

[0058] FIG. 5 A shows an exemplary construction of a sample 500 configured to simulate an appearance and/or texture of the surface covering 200 of FIG. 3A. FIG. 5A shows the sample 500 including a first substrate 502 (top layer) and a second substrate 504. FIG. 5A further shows the sample 500 in a stacked position 506 with at least a first portion 508 positioned above (and folded over) at least a second portion 510. It should be noted that according to some examples, stacking or otherwise temporarily changing the configuration of the sample may not be needed. Furthermore, other arrangements such as rolling, etc. in alternative to stacking are contemplated.

[0059] The stacked position 506 can be configured to facilitate a more compact shape for shipping the sample 500. The stacked position 506 can be facilitated by one or more articulating joints 512 that can join at least the first portion 508 to the second portion 510 (and other portions shown). The joints 512 can comprise board game joints, for example, configured to articulate in a reversible manner. The joints 512 can comprise corrugated joints as known in the art according to some examples. In further examples, the joints 512 can comprise seams. In some examples, the sample 500 can utilize dedicated articulating features such as hinges rather than seams or joints.

[0060] FIG. 5B shows the sample 500 in an intermediate position being unfolded or folded in the fashion of a game board via the articulating joints 512. Thus, the sample 500 of FIG. 5B shows the first portion 508 being unfolded or folded relative to the second portion 510 and other portions that together comprise the sample 500.

[0061] FIG. 5C shows the sample 500 in a display position 513 with a substantially planar extend across all of the portions including the first portion 508 and the second portion 510 (and the further other portions 514 and 516 shown). To achieve such position the first portion 508 has been articulated relative to the second portion 510 via the articulating joint(s) 512 as shown in FIG. 5B. In the display position 513, the first portion 508 can be positioned adjacent the second portion 510 and adjacent the other portions 514 and 516. In the display position, the sample 500 can have a combined area of between 1.0 square feet and 36 square feet. However, other areas are contemplated. FIG. 5C additionally shows the articulating joints 512 with dashed lines. A cut edge of the sample 500 is indicated with a solid line 516. [0062] Throughout this document, values expressed in a range format should be interpreted in a flexible manner to include not only the numerical values explicitly recited as the limits of the range, but also to include all the individual numerical values or sub-ranges encompassed within that range as if each numerical value and sub-range is explicitly recited. For example, a range of “about 0.1% to about 5%” or “about 0.1% to 5%” should be interpreted to include not just about 0.1% to about 5%, but also the individual values (e.g., 1%, 2%, 3%, and 4%) and the sub-ranges (e.g., 0.1% to 0.5%, 1.1% to 2.2%, 3.3% to 4.4%) within the indicated range. The statement “about X to Y” has the same meaning as “about X to about Y,” unless indicated otherwise. Likewise, the statement “about X, Y, or about Z” has the same meaning as “about X, about Y, or about Z,” unless indicated otherwise.

[0063] The term “substantially” “about” “generally” should be interpreted as being within +/- 10 percent or +/- 10 degrees of a provided value, whichever is applicable.

[0064] In this document, the terms “a,” “an,” or “the” are used to include one or more than one unless the context clearly dictates otherwise. The term “or” is used to refer to a nonexclusive “or” unless otherwise indicated. The statement “at least one of A and B” has the same meaning as “A, B, or A and B.” In addition, it is to be understood that the phraseology or terminology employed herein, and not otherwise defined, is for description only and not of limitation. Any use of section headings is intended to aid reading of the document and is not to be interpreted as limiting; information that is relevant to a section heading may occur within or outside of that section.

[0065] In the methods described herein, the acts can be carried out in any order without departing from the principles of the subject matter, except when a temporal or operational sequence is explicitly recited. Furthermore, specified acts can be carried out concurrently unless explicit claim language recites that they be carried out separately. For example, a claimed act of doing X and a claimed act of doing Y can be conducted simultaneously within a single operation, and the resulting process will fall within the literal scope of the claimed process.

Claim Related Embodiments

[0100] The following embodiments are provided, the numbering of which is not to be construed as designating levels of importance:

[0101] Embodiment 1 can be an apparatus for simulating a surface covering.

The apparatus can comprise any one or combination of a first substrate, a color layer and a coating. The first substrate can have a first major surface and an opposing second major surface. The color layer can be applied to the first major surface and can have a first amount of light reflectivity. The coating can be selectively applied to or with a plurality of portions of the color layer. The coating can have a second amount of light reflectivity that differs from the first amount of light reflectivity.

The coating can be in registration with the color layer and can be applied corresponding to a texture of the surface covering.

[0102] Embodiment 2 can be the apparatus of Embodiment 1, wherein the coating can be applied with a gradient such that the second amount of light reflectivity varies from a first location to a second location along the color layer. [0103] Embodiment 3 can be the apparatus of Embodiment 2, wherein the coating can be applied along an entirety of the color layer.

[0104] Embodiment 4 can be the apparatus of Embodiment 3, wherein the color layer can be applied along an entirety of the first major surface.

[0105] Embodiment 5 can be the apparatus of any one or any combination of

Embodiments 1-4, wherein the second amount of light reflectivity can be greater than the first amount of light reflectivity.

[0106] Embodiment 6 can be the apparatus of any one or any combination of

Embodiments 1-5, wherein the coating can include at least one of a film or a cured agent.

[0107] Embodiment 7 can be the apparatus of any one or any combination of

Embodiments 1-6, optionally further comprising a second substrate coupled to the second major surface and configured as a backing for the first substrate.

[0108] Embodiment 8 can be the apparatus of Embodiment 7, wherein the first substrate can comprise a paper and the second substrate can include one of a corrugated paper or a foam board.

[0109] Embodiment 9 can be the apparatus of Embodiment 8, wherein the second substrate can be configured to retain the first substrate such that the first major surface is substantially planar.

[0110] Embodiment 10 can be the apparatus of any one or any combination of Embodiments 7-9, wherein the second substrate can have one or more joints configured to allow at least a first portion of the apparatus to fold relative to a second portion of the apparatus. [0111] Embodiment 11 can be the apparatus of Embodiment 10, wherein the first portion can articulate relative to the second portion via the one or more joints to a display position and in the display position the first major surface can have an area of between 1.0 square feet and 36 square feet.

[0112] Embodiment 12 can be the apparatus of Embodiment 10, wherein the first portion can articulate relative to the second portion via the one or more joints to a stacked position where the at least the first portion is positioned above the second portion.

[0113] Embodiment 13 can be the apparatus of any one or combination of

Embodiments 1-12, wherein the color layer can be configured such that the first amount of light reflectivity remains substantially the same along a pathway extending in a linear direction of the first major surface and the coating of the pathway can be configured such that the second amount of light reflectivity remains substantially the same along the pathway.

[0114] Embodiment 14 can be the apparatus of Embodiment 13, wherein the color layer can be configured such that the first amount of light reflectivity remains substantially the same for a second pathway extending parallel with and spaced from the pathway and the coating of the second pathway can be configured such that the second amount of light reflectivity remains substantially the same along the second pathway, wherein the coating can be selectively applied to differ the second amount of light reflectivity from the pathway to second pathway.

[0115] Embodiment 15 can be the apparatus of any one or combination of

Embodiments 1-14, wherein the color layer and the coating can be arranged according to an image of the surface covering and can be configured to have a 1 : 1 geometric ratio with one or more features of the surface covering.

[0116] Embodiment 16 can be the apparatus of any one or combination of

Embodiments 1-14, wherein the coating can be applied to create a 1 : 1 geometric ratio between the texture of the surface covering and a simulated texture of the sample.

[0117] Embodiment 17 can be a system for simulating a surface covering.

The system can optionally include an apparatus and packaging for the apparatus. The apparatus can have two or more portions including at least a first portion and a second portion. The first portion and the second portion can be joined together at an articulating joint. The apparatus can be foldable via the articulating joint between a stacked arrangement and a display arrangement. In the display arrangement the two or more parts can be positioned adjacent one another to simulate the surface covering. Each of the first portion and the second portion can optionally include a substrate, a color layer and a coating. The substrate can have a first major surface and an opposing second major surface. The color layer can be applied to the first major surface and having a first amount of light reflectivity. The coating can be selectively applied to or with a plurality of portions of the color layer. The coating can have a second amount of light reflectivity that differs from the first amount of light reflectivity. The coating can be in registration with the color layer and can be applied according to a texture of the surface covering. The package can be configured to carry the apparatus in the stacked arrangement.

[0118] Embodiment 18 can be the system of Embodiment 17, optionally further comprising a second substrate coupled to the second major surface and configured as a backing for the first substrate.

[0119] Embodiment 19 can be the system of Embodiment 18, wherein the first substrate can comprise a paper and the second substrate can include one of a corrugated paper or a foam board.

[0120] Embodiment 20 can be the system of Embodiment 19, wherein the second substrate can be configured to retain the first substrate such that the first major surface is substantially planar.

[0121] Embodiment 21 can be the system of any one or any combination of

Embodiments 18-20, wherein the second substrate can have the articulating joint. [0122] Embodiment 22 can be the system of any one or combination of

Embodiments 17-21, wherein in the display arrangement the apparatus has a combined area of the first major surface between 1.0 square feet and 36 square feet. [0123] Embodiment 23 can be a method for forming a sample to simulate a surface covering. The method can optionally include imaging a major surface of the surface covering; generating an art file from the imaging; generating a design mask from the art file; printing a colorant on a major surface of a first substrate according to the design mask; and applying a gloss according to the design mask and in a registered manner with the colorant, wherein the gloss is applied with a variation in reflective intensity to simulate at least one of an appearance or texture of the surface covering.

[0124] Embodiment 24 can be the method of Embodiment 23, optionally further comprising forming a joint between a first portion of the sample and a second portion of the sample and articulating the sample along the joint to create a stacked arrangement of the first and second portions of the sample.

[0125] Embodiment 25 can be the method of any one or combination of

Embodiments 23-24, optionally further comprising one of corrugating or laminating a second substrate to the first substrate.

[0126] Embodiment 26 can be the method of any one or combination of

Embodiments 23-25, wherein colorant can be applied with a variation in color to simulate a color appearance of the surface covering.

[0127] Embodiment 27 provides a method, sample good, system or apparatus of any one or any combination of Embodiments 1-26 optionally configured such that all elements or options recited are available to use or select from.

Claims

CLAIMS What is claimed is:

1. An apparatus for simulating a surface covering, the apparatus comprising: a first substrate having a first major surface and an opposing second major surface; a color layer applied to the first major surface and having a first amount of light reflectivity; and a coating selectively applied to or with a plurality of portions of the color layer, wherein the coating has a second amount of light reflectivity, and wherein the second amount of light reflectivity differs from the first amount of light reflectivity, and wherein the coating is in registration with the color layer and is applied corresponding to a texture of the surface covering.

2. The apparatus of claim 1 , wherein the coating is applied with a gradient such that the second amount of light reflectivity varies from a first location to a second location along the color layer.

3. The apparatus of claim 2, wherein the coating is applied along an entirety of the color layer.

4. The apparatus of claim 3, wherein the color layer is applied along an entirety of the first major surface.

5. The apparatus of any one of claims 1-4, wherein the second amount of light reflectivity is greater than the first amount of light reflectivity.

6. The apparatus of any one claims 1-5, wherein the coating includes at least one of a film or a cured agent.

7. The apparatus of any one claims 1-6, further comprising a second substrate coupled to the second major surface and configured as a backing for the first substrate.

8. The apparatus of claim 7, wherein the first substrate comprises a paper and the second substrate includes one of a corrugated paper or a foam board.

9. The apparatus of claim 8, wherein the second substrate is configured to retain the first substrate such that the first major surface is substantially planar.

10. The apparatus of any one of claims 7-9, wherein the second substrate has one or more joints configured to allow at least a first portion of the apparatus to fold relative to a second portion of the apparatus.

11. The apparatus of claim 10, wherein the first portion articulates relative to the second portion via the one or more joints to a display position and in the display position the first major surface has an area of between 1.0 square feet and 36 square feet.

12. The apparatus of claim 10, wherein the first portion articulates relative to the second portion via the one or more joints to a stacked position where the at least the first portion is positioned above the second portion.

13. The apparatus of any one of claims 1-12, wherein the color layer is configured such that the first amount of light reflectivity remains substantially the same along a pathway extending in a linear direction of the first major surface and the coating of the pathway is configured such that the second amount of light reflectivity remains substantially the same along the pathway.

14. The apparatus of claim 13, wherein the color layer is configured such that the first amount of light reflectivity remains substantially the same for a second pathway extending parallel with and spaced from the pathway and the coating of the second pathway is configured such that the second amount of light reflectivity remains substantially the same along the second pathway, wherein the coating is selectively applied to differ the second amount of light reflectivity from the pathway to second pathway.

15. The apparatus of any one of claims 1-14, wherein the color layer and the coating are arranged according to an image of the surface covering and are configured to have a 1 : 1 geometric ratio with one or more features of the surface covering.

16. The apparatus of any one of claims 1-14, wherein the coating is applied to create a 1 : 1 ratio between the texture of the surface covering and a simulated texture of the sample.

17. A system for simulating a surface covering, the system comprising: an apparatus of two or more portions including at least a first portion and a second portion, wherein first portion and the second portion are joined together at an articulating joint, wherein the apparatus is foldable via the articulating joint between a stacked arrangement and an display arrangement, wherein in the display arrangement the two or more parts are positioned adjacent one another to simulate the surface covering, each of the first portion and the second portion comprising: a substrate having a first major surface and an opposing second major surface; a color layer applied to the first major surface and having a first amount of light reflectivity; and a coating selectively applied to or with a plurality of portions of the color layer, wherein the coating has a second amount of light reflectivity, and wherein the second amount of light reflectivity differs from the first amount of light reflectivity, and wherein the coating is in registration with the color layer and is applied according to a texture of the surface covering; and a package configured to carry the apparatus in the stacked arrangement.

18. The system of claim 17, further comprising a second substrate coupled to the second major surface and configured as a backing for the first substrate.

19. The system of claim 18, wherein the first substrate comprises a paper and the second substrate is one of a corrugated paper or a foam board.

20. The system of claim 19, wherein the second substrate is configured to retain the first substrate such that the first major surface is substantially planar.

21. The system of any one of claims 18-20, wherein the second substrate has the articulating joint.

22. The system of any one of claims 17-21, wherein in the display arrangement the first major surface of the apparatus has a combined area of between 1.0 square feet and 36 square feet.

23. A method for forming a sample to simulate a surface covering, the method comprising: imaging a major surface of the surface covering; generating an art file from the imaging; generating a design mask from the art file; applying a colorant on a major surface of a first substrate according to the design mask; and applying a gloss according to the design mask and in a registered manner with the colorant, wherein the gloss is applied with a variation in reflective intensity to simulate a texture of the surface covering.

24. The method of claim 23, further comprising: forming a joint between a first portion of the sample and a second portion of the sample; and articulating the sample along the joint to create a stacked arrangement of the first and second portions of the sample.

25. The method of any one of claims 23-24, further comprising one of corrugating or laminating a second substrate to the first substrate.

26. The method of any one of claims 23-25, wherein colorant is applied with a variation in color to simulate a color appearance of the surface covering.