Flooring system and method

Abstract

A flooring system for use in a residential environment. The flooring system includes a subfloor adapted to support the mass of a user and modular surface covering elements for disposition in edge to edge covering arrangement across at least a portion of the subfloor. The modular surface covering elements include a pile fabric face with an arrangement of yarns projecting outwardly defining a pile layer for contact by a user. At least one layer of cushioning material is disposed in contacting relation at a position below the pile fabric face.

What is claimed is:  
     
         1 . A flooring system for use in a residential environment comprising: 
 a subfloor adapted to support the mass of a user; and    a plurality of modular surface covering elements including a plurality of edges, wherein the modular surface covering elements are adapted to be disposed in edge to edge covering arrangement across at least a portion of the subfloor, the modular surface covering elements comprising a pile fabric face including a primary base and a plurality of yarns projecting outwardly from the primary base defining a pile layer for contact by a user, the modular surface covering elements further comprising at least one layer of cushioning material secured in substantially fixed positional relation relative to the pile fabric face at a position below the pile fabric face and wherein the pile layer has a standard pile density in the range of about 500 to about 4,200 ounces per cubic yard and wherein the plurality of yarns projecting outwardly from the primary base have an average extended length above the primary base in the range of about 0.25 to about 1 inch.    
     
     
         2 . The invention as recited in  claim 1 , wherein the modular surface covering elements are of substantially elongate geometry suitable for packaging in roll form.  
     
     
         3 . The invention as recited in  claim 1 , wherein the modular surface covering elements comprise discrete tile structures adapted for manual placement across the subfloor by a user.  
     
     
         4 . The invention as recited in  claim 1 , wherein the modular surface covering elements are substantially quadrilateral in geometry.  
     
     
         5 . The invention as recited in  claim 4 , wherein the modular surface covering elements are substantially square.  
     
     
         6 . The invention as recited in  claim 4 , wherein the modular surface covering elements are substantially rectangular.  
     
     
         7 . The invention as recited in  claim 1 , wherein the modular surface covering elements have a first edge including two outwardly projecting chevrons, a second edge in opposing relation to the first edge including two inwardly projecting chevrons in substantial alignment with the outwardly projecting chevrons on the first edge, and two substantially straight lateral edges extending between the first edge and the second edge.  
     
     
         8 . The invention as recited in  claim 1 , wherein the modular surface covering elements comprise an elongate construction including two substantially straight lateral sides extending between a single outwardly projecting chevron and a single inwardly projecting chevron, wherein the inwardly projecting chevron is disposed in substantial alignment with the outwardly projecting chevron.  
     
     
         9 . The invention as recited in  claim 1 , wherein the modular surface covering elements have a first edge having at least three outwardly projecting chevrons, a second edge in opposing relation to the first edge including a number of inwardly projecting chevrons each in substantial alignment with one of the outwardly projecting chevrons, and two substantially straight lateral edges extending between the first edge and the second edge.  
     
     
         10 . The invention as recited in  claim 1 , wherein the modular surface covering elements have a first edge including an outwardly projecting chevron, a second edge in opposing relation to the first edge including an inwardly projecting chevron in substantial alignment with the outwardly projecting chevron on the first edge, and two lateral edges extending between the first edge and the second edge wherein a first one of said two lateral edges includes an outwardly projecting chevron and wherein the other of said two lateral edges includes an inwardly projecting chevron in substantial alignment with the outwardly projecting chevron on said first one of said two lateral edges.  
     
     
         11 . The invention as recited in  claim 1 , wherein the modular surface covering elements have a first edge including an outwardly projecting curved lobe, a second edge in opposing relation to the first edge including an inwardly projecting curved depression in substantial alignment with the outwardly projecting curved lobe on the first edge, and two lateral edges extending between the first edge and the second edge wherein a first one of said two lateral edges includes an outwardly projecting curved lobe and wherein the other of said two lateral edges includes an inwardly projecting curved lobe in substantial alignment with the outwardly projecting curved lobe on said first one of said two lateral edges.  
     
     
         12 . The invention as recited in  claim 1 , wherein the modular surface covering elements have a substantially triangular geometry.  
     
     
         13 . The invention as recited in  claim 1 , wherein the modular surface covering elements have a substantially diamond shaped geometry.  
     
     
         14 . The invention as recited in  claim 1 , wherein the modular surface covering elements have a substantially equilateral polygonal geometry.  
     
     
         15 . The invention as recited in  claim 1 , wherein the modular surface covering elements have a substantially hexagonal geometry.  
     
     
         16 . The invention as recited in  claim 1 , wherein the pile layer has a standard pile density in the range of about 1500 to about 3500 ounces per cubic yard.  
     
     
         17 . The invention as recited in  claim 16 , wherein the plurality of yarns projecting outwardly from the primary base have an average extended length above the primary base in the range of about 0.3 to about 0.9 inches.  
     
     
         18 . The invention as recited in  claim 16 , wherein the plurality of yarns projecting outwardly from the primary base have an average extended length above the primary base in the range of about 0.4 to about 0.8 inches.  
     
     
         19 . The invention as recited in  claim 16 , wherein the plurality of yarns projecting outwardly from the primary base have an average extended length above the primary base in the range of about 0.5 to about 0.7 inches.  
     
     
         20 . The invention as recited in  claim 16 , wherein the plurality of yarns projecting outwardly from the primary base have an average extended length above the primary base of about 0.6 inches.  
     
     
         21 . The invention as recited in  claim 1 , wherein the pile layer has a standard pile density in the range of about 2000 to about 3000 ounces per cubic yard.  
     
     
         22 . The invention as recited in  claim 21 , wherein the plurality of yarns projecting outwardly from the primary base have an average extended length above the primary base in the range of about 0.3 to about 0.9 inches.  
     
     
         23 . The invention as recited in  claim 21 , wherein the plurality of yarns projecting outwardly from the primary base have an average extended length above the primary base in the range of about 0.4 to about 0.8 inches.  
     
     
         24 . The invention as recited in  claim 21 , wherein the plurality of yarns projecting outwardly from the primary base have an average extended length above the primary base in the range of about 0.5 to about 0.7 inches.  
     
     
         25 . The invention as recited in  claim 21 , wherein the plurality of yarns projecting outwardly from the primary base have an average extended length above the primary base of about 0.6 inches.  
     
     
         26 . The invention as recited in  claim 1 , wherein the average cumulative gap length between edges of adjacent modular surface covering elements is less than 0.05 centimeters.  
     
     
         27 . The invention as recited in  claim 1 , wherein the modular surface covering elements are characterized by an average cumulative tuft overhang along all edges in the range of about 2.6 mm to about 5.4 mm as measured according to the procedure set forth in comparative example 14.  
     
     
         28 . The invention as recited in  claim 1 , wherein the modular surface covering elements are characterized by an average seamability index of not greater than about 4 when measured according to the procedure set forth in comparative example 13.  
     
     
         29 . The invention as recited in  claim 1 , wherein the modular surface covering elements are characterized by an average seamability index of not greater than about 3 when measured according to the procedure set forth in comparative example 13.  
     
     
         30 . The invention as recited in  claim 1 , wherein the modular surface covering elements are cut from below the pile fabric face.  
     
     
         31 . A flooring system for use in a residential environment comprising: 
 a subfloor adapted to support the mass of a user; and    a plurality of modular surface covering elements including a plurality of edges, wherein the modular surface covering elements are adapted to be disposed in edge to edge covering arrangement across at least a portion of the subfloor, the modular surface covering elements comprising a pile fabric face including a primary base and a plurality of yarns projecting outwardly from the primary base defining a pile layer for contact by a user, the modular surface covering elements further comprising at least one layer of cushioning material secured in substantially fixed positional relation relative to the pile fabric face at a position below the pile fabric face and a layer of stabilizing material disposed at a position between the cushioning material and the pile fabric face, wherein the pile layer has a standard pile density in the range of about 1500 to about 4,200 ounces per cubic yard and wherein the plurality of yarns projecting outwardly from the primary base have an average extended length above the primary base in the range of about 0.25 to about 1 inch.    
     
     
         32 . The invention according to  claim 31 , wherein the stabilizing material comprises glass.  
     
     
         33 . The invention as recited in  claim 32 , wherein the stabilizing material comprises a sheet of nonwoven glass.  
     
     
         34 . A flooring system for use in a residential environment comprising: 
 a subfloor adapted to support the mass of a user; and    a plurality of modular surface covering elements including a plurality of edges, wherein the modular surface covering elements are adapted to be disposed in edge to edge covering arrangement across at least a portion of the subfloor, the modular surface covering elements comprising a pile fabric face including a primary base and a plurality of yarns projecting outwardly from the primary base defining a pile layer for contact by a user, the modular surface covering elements further comprising at least one layer of cushioning material secured in substantially fixed positional relation relative to the pile fabric face at a position below the pile fabric face and a load distributing layer disposed at a position between the cushioning material and the pile fabric face, wherein the pile layer has a standard pile density in the range of about 1500 to about 4,200 ounces per cubic yard and wherein the plurality of yarns projecting outwardly from the primary base have an average extended length above the primary base in the range of about 0.25 to about 1 inch.    
     
     
         35 . The invention as recited in  claim 34 , wherein the load distributing layer comprises a resilient polymeric adhesive.  
     
     
         36 . The invention as recited in  claim 35 , wherein said resilient polymeric adhesive is a hot melt adhesive.  
     
     
         37 . A flooring system for use in a residential environment comprising: 
 a subfloor adapted to support the mass of a user; and    a plurality of modular surface covering elements including a plurality of edges, wherein the modular surface covering elements are adapted to be disposed in edge to edge covering arrangement across at least a portion of the subfloor, the modular surface covering elements comprising a pile fabric face including a primary base and a plurality of yarns projecting outwardly from the primary base defining a pile layer for contact by a user, the modular surface covering elements further comprising at least one layer of cushioning material secured in substantially fixed positional relation relative to the pile fabric face at a position below the pile fabric face and a load distribution layer comprising a tie coat material and a layer of stabilizing material disposed at a position between the cushioning material and the pile fabric face, wherein the pile layer has a standard pile density in the range of about 1500 to about 4,200 ounces per cubic yard and wherein the plurality of yarns projecting outwardly from the primary base have an average extended length above the primary base in the range of about 0.25 to about 1 inch.    
     
     
         38 . The invention as recited in  claim 37 , wherein the tie coat material is a resilient hot melt adhesive.  
     
     
         39 . The invention as recited in  claim 38 , wherein the stabilizing material is glass.