Note: Descriptions are shown in the official language in which they were submitted.
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MODULAR FLOORING SYSTEMS AND METHODS
FIELD OF THE INVENTION
This invention relates in general to the field of carpet and other floor
covering,
and in particular to modular flooring systems and methods.
BACKGROUND OF THE INVENTION
Traditional floor covering includes carpet, tile, vinyl or other materials
that
cover a floor or sub-floor. Purchasing, installing and maintaining floor
covering
requires a major investment in time, labor and material costs. Over time, use
wears out
a floor covering. In some instances, the existing floor covering is perfectly
usable, yet a
user wishes to change the appearance of the entire floor covering or perhaps
just a
section of it because they are no longer satisfied with the color, design or
other
attributes of their carpet or floor covering. However, due to the investment
in the floor
covering, users may experience reluctance in replacing unworn carpet.
Replacing only a portion of the floor covering or only the wear surfaces would
solve this problem. Yet currently, changing patterns and colors requires
complete or
substantial replacement of the existing floor covering. Blending old and new
floor
covering patterns and colors may prove difficult.
Additionally, renovations to floor covering in offices and other spaces
requires
removal of existing floor covering andlor placement of the new floor covering
on top of
the existing floor covering. Height concerns arise when a new floor covering
is placed
on top of an existing one. Further, maintaining an overall level floor becomes
a
concern when a new floor covering is placed over one that is worn.
Therefore, a need exists for modular flooring systems and methods that is
modular and interchangeable.
SUMMARY OF THE INVENTION
This invention includes a modular flooring device including a baseplate, and a
frame member attached to the baseplate and having a first arm and a second anm
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integrally attached to the first arm. The device is configured to support a
replaceable
wearing surface disposed within a recess formed between a lip of the upper
portion of
the frame and the baseplate.
An alternative embodiment of this invention is a self contouring modular
flooring device, including a first baseplate having a frame member attached to
the
baseplate and having a first arm and a second arm integrally attached to the
first arm
forming substantially a right angle, and a second baseplate movably attached
to the first
baseplate. Another embodiment is a self contouring flooring device that
includes a
flexible baseplate and a frame member integrally attached to the flexible
baseplate and
having a first arm and a second arm attached to the first arm foaming
substantially a
right angle whereby the flexible baseplate contours to an underlying floor.
Still another embodiment of this invention is a replaceable wear surface
modular flooring, including at least one base module having a baseplate, floor
grid
members having a first arm and a second arm, each of which is formed as an
open
channel and attached on adjacent edges of the baseplate, and a trim member
having a
decorative upper surface engaging the floor grid members.
In yet another alternative embodiment of this invention is a method for
providing a wear surface modular flooring structure that includes creating a
floor
covering structure by placing at least one baseplate on a floor surface, and
inserting a
wear surface on the baseplate.
Another embodiment of the invention is a method for providing a wear surface
modular flooring structure that includes inserting at least one floor module
having a
removable trim member positioned over a channel, and placing a wear surface on
the
floor module. Power header or cables and/or communications headers or cables
may be
placed in the channels with branches from these headers running in the
channels
providing for use in a middle region of the flooring structure.
Objects of this invention include:
To provide systems and methods for a flooring structure that is modular and
interchangeable.
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To provide systems and methods for a flooring structure that replaces certain
raised floor systems that utilizes more slab to slab distance.
To provide systems and methods for a flooring structure that provides many
design options.
To provide systems and methods for a flooring structure that utilizes
sustainable
materials.
To provide systems and methods for a flooring structure that presents no
height
concerns.
To provide systems and methods for a flooring structure that facilitates
efficient
and economic renovation of poor office or other spaces.
To provide systems and methods for a flooring structure that permits extended
product life by replacement of only the wear surfaces.
To provide systems and methods for a flooring structure that enables recycle
materials to be used and avoids recycling problems.
As the following description and accompanying drawings make clear, these and
other objects are achieved by this invention.
BRIEF DESCRIPTION OF THE DRAWINGS
Fig. 1 shows a perspective view of a free-lay support module of the modular
flooring system of this invention.
Fig. 2 shows a perspective view of a plurality of the free-lay support modules
of
Fig. 1 including a replaceable wear surface and positioned together as a
flooring
surface.
Fig. 3 shows a perspective view of an alternative embodiment of the free-lay
support module with trim members.
Fig. 4 shows a perspective view of a plurality of the free-lay support modules
of
Fig. 3 including a replaceable wear surface and positioned together as a
flooring
surface.
Fig. 5 shows an exploded cross-sectional view of a free-lay support module
having a wearable surface, trim member, grid member and an underlay.
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Fig. 6 shows a cross-sectional view of the free-lay support module of Fig. 5
having a passageway for a communications system.
Fig. 7 shows a cross-sectional view of an alternative embodiment of the trim
member and channel of Fig. 6 where the trim member and channel have mating
teeth.
Fig. 8 shows a cross-sectional view of an alternative embodiment of the trim
members of the modular flooring system of Fig. 6.
Fig. 9 shows a cross-sectional view of an alternative embodiment of the
modular flooring system of Fig. 8 where the flooring system is without an
underlay.
Fig. 10 shows a top plan schematic view of a flooring made from the flooring
structures of Figs. 6 - 9.
DETAILED DESCRIPTION OF THE INVENTION
The attached drawing Figs. 1 - 10 depict alternative embodiments of a new
modular flooring system utilizing a base and a framing member or members.
Replaceable wear surfaces, such as modular carpet, carpet-like or other
flooring
components, are placed on the base and held in position by the framing
members.
In a first alternative embodiment of this invention shown in Fig. 1, a free-
lay
support module 10 that is generally square or rectangular includes a baseplate
12 and a
frame member 14 having a first arm 16 and a second arm 18 integrally formed
and
meeting at an angle. In one embodiment, the frame member is structured to
resemble a
"horizontal" arm 16 and a "vertical" arm 18 in a plane parallel to the
baseplate 12 with
the two arms meeting to form a right angle. The cross-sectional shape of frame
14 is a
wedge that is widest on the top 20 of frame 14 and narrows in the region of
attachment
22 to base 12. This shape allows the top 20 of frame 14 partially to overlie
replaceable
wear surface modules 24 that may be carpet, carpet tile, vinyl flooring, wood
flooring,
wood parquet flooring or a variety of other materials.
As will be appreciated by reference to Figure 2, a plurality of free-lay
support
modules 10 may be positioned on a floor or subfloor surface in "rows" and
"columns,"
with the result that wear surface modules 24 will be entirely surrounded by
arms 16 and
18 of frame members 14, thereby providing an attractive and versatile flooring
with
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replaceable wear surfaces, which flooring may be quickly installed. Friction
between
the wear surface modules 24 and top 20 of the frame 14 permit the plurality of
free-lay
support modules 10 to remain locked into position when a downward force is
exerted
on the support module 10; such as a user walking on the flooring surface.
In a second, self contouring embodiment of the free-lay support module
flooring described above and depicted in Figs. l and 2, base 12 may be made in
two
pieces divided along a diagonal suggested by broken line 26 in Fig. 1. The two
triangular halves of base 12 are then hinged together in any of a variety of
appropriate
manners, including the use of conventional metal strap or other hinges,
bridging fabric
affixed with glue or otherwise to each half of base 12. The modules may rest
on small
pads of feet for self leveling that is particularly useful for the hinged
environment. The
corner of one triangle remote from the hinge line 26 and all three corners of
the other
triangle may rest on the small pads of feet (not shown). The thus-provided
ability of
base 12 to articulate modestly along the hinge line indicated by broken line
26,
combined with the described pads, will permit base 12 to conform to modest
irregularities in a floor or subfloor of the type that are frequently
encountered in
concrete subfloors in office and light industrial buildings. This will permit
the
replaceable wear surface flooring system depicted in Figs. 1 and 2 to be self
leveling.
As an alternative means for providing a self contouring flooring, base 12
depicted in Fig. 1 can be a flexible material so that it naturally "drapes" or
contours
itself to the underlying subfloor.
Yet another embodiment of this invention is depicted in Figs. 3 through 9.
Fig.
3 shows a replaceable wear surface modular flooring structure 30 that is
provided
utilizing floor grid members 32 that have a first arm 34 and a second arm 36,
each of
which are in the form of an open U-shaped channel 37. A trim member 38 has a
decorative upper surface 40 and any of a variety of cross-sectional shapes
with
downward facing members 42 that engage grid members 32 to provide a decorative
and
protective cap on the top of such grid members. The trim member 38, in
particular the
downward facing members 42, may contain teeth or detents that releasably
engage as
co-pending teeth or detents on the grid members 32.
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Although the channels 36 depicted in Fig. 3 are shown as unitary members of a
single right angle structure, parallel channels 36 in a particular flooring
structure 31
could run the entire length or width of the room, as shown in Fig. 4. In this
figure, the
flooring structure 30 includes transverse channels equal in length to the side
of a single
module filling in between the parallel, longer channels. A wear surface 48 and
an
optional underlay or backing structure 50 fitting within the flooring
structure 30 are
shown in Fig. 4. The wear surface 48 and the backing structure 50 are
positioned flush
against an interior 33 of the floor grid member.
Fig. 5 shows an exploded cross-sectional view of the wearable surface 48, trim
member 38, grid member 32 and an underlay or backing structure 50 of the free-
lay
support module 30. As shown in Fig. 5, the trim member 38 attaches to the grid
member 32. In this embodiment, friction between the trim member 38 and the
grid
member 32 adheres the two pieces together.
As will be appreciated, in particular, by reference to Figs. 6, 8 and 9, the
above-
described construction provides intersecting channels through which cables and
wiring
44 may be run. Fig. 6 shows a cross-sectional view of the free-lay support
module 30
of Fig. 5 having a passageway or chase 61 for a communications cable system or
wiring
44. Such cables and wiring 44 may be easily accessed simply by removing
appropriate
portions of trim member 38.
Fig. 7 shows an alternative embodiment of a trim member 43 and a grid member
45. Teeth 47 on the trim member 43 mate with teeth 49 on the grid member 45.
This
arrangement provides an alternative locking mechanism for adhering the trim
member
43 to the grid member 45.
As will be appreciated, the top of trim in all embodiments may have a variety
of
shapes. Fig. 8 illustrates one such shape and shows a cross-sectional shape of
a
dovetail 46 clearly depicted in Fig. 8. Such a dovetail 46 shape provides
particularly
attractive and effective framing structure for modular flooring wear surfaces
48 that
may be carpet, carpet tile, fabric, vinyl flooring, wood and a wide variety of
other
materials. Each wear surface 48 may rest on top of a separate pad or backing
structure
50. This mufti-component construction permits portions of the flooring, such
as the
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wear surface 48, to be replaced without replacement of underlying layers that
contribute
to the under-foot and other characteristics of the flooring 31.
As will be appreciated by reference to Figs. 8 and 9, trim members 38 and 59
may engage base modules 60 directly by fitting rabbets 62 in the base module.
In this
instance, separate channels are not needed, and the trim strips 38 cooperate
with base
modules 60 to form cable chases 61.
The trim 38 can be produced from a wide variety of different materials,
including aluminum and other metals and relatively hard plastics such as
extruded
polyvinyl chloride, pultruded fiber reinforced plastics, polyethylene or a
"wood flour"
material. The strips can also be made of solid wood, plywood or other wood
veneer
structures.
Fig. 9 shows a cross- sectional view of an alternative embodiment of the
modular flooring system of Fig. 8 where the flooring system 30 is without an
underlay
or backing structure 50. Additionally, the trim member 59 has a underside with
a
varied shaped from the trim member 38 of Fig. 8.
Fig. 10 shows a top plan schematic view of flooring structure 31 of this
invention, having a power header or cable 52 running horizontally as indicated
at the
top of Fig. 10 and power or cable branches 54 running in the channels 32 to
locations
for use in the middle region of the floor. A power header 52 is a power
source,
preferably a cylindrically shaped insulated conductor having distribution
branches
connected thereto. A communications header or cable provides for distributing
telecommunications access throughout the flooring structure 31. The
communications
header or cable 56 may run horizontally at the bottom of Fig. 10, with
branches 58 that
run up to locations for use in the middle of the room. This avoids routing
power and
communications cables side-by-side.
In another embodiment of this invention, power, communications or other
cables can be permanently installed in flooring modules and interconnected
when the
modules are installed. Moreover, flooring modules could be manufactured with
built in
computer chips and sensors to provide a variety of functions such as
temperature or
load sensing.
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Among numerous other benefits of this invention, as will be readily
appreciated
by those skilled in the art, it is possible utilizing the components described
above to
provide an attractive and highly functional floor utilizing carpet or carpet
tile type
components that are not bonded to each other, thereby facilitating replacement
of soiled
or worn components without the need for replacement of all components in the
flooring
system. This fiu~kher facilitates recycling of the materials of the system,
because
dissimilar materials are not incorporated in the same structure.
An advantage of this invention is that it can utilize sustainable materials.
Another advantage is that this invention is modular and interchangeable.
Yet another advantage of this invention is that it can replace some raised
floor
systems that utilize more slab to slab distance.
Still another advantage of this invention is that it provides for many floor
covering design options.
Another advantage of this invention is that it presents no floor covering
height
concerns.
Yet another advantage of this invention is that it facilitates renovation of
poor
office or other spaces.
Another advantage of this invention is that it permits extended product life
by
replacement of only the wear surfaces.
Still another advantage of this invention is that it enables recycle materials
to be
used and avoids recycling problems.
While certain embodiments of this invention have been described above, these
descriptions are given for purposes of illustration and explanation.
Variations, changes,
modifications and departures from the systems and methods disclosed above may
be
adopted without departure from the spirit and scope of this invention.
