Abstract:
The present invention relates to a new type of floating carpet for covering any size surface, including entire rooms, by interlocking carpet covered bases on which resides a layer of carpet where each portion of the multiple tiles forming the carpet is a flat plastic base with side interlocking mechanisms made of male and mating female connectors to allow for the rapid design and installation of a modular layer of carpeting over existing surfaces, and more specifically multiple rectangular tiles each with a polymeric base on which is attached a piece of carpet for quick interlocking of side locking mechanisms on the polymeric base to secure adjacent carpet tiles into a carpet over a surface.

Description:
REFERENCE TO RELATED APPLICATION 
     The present patent application claims priority from and the benefit of U.S. Provisional Patent Application No. 61/715,027, filed Oct. 17, 2012, entitled CARPET TILING SYSTEM &amp; METHOD OF INSTALLATION, which prior application is hereby incorporated herein by reference. 
    
    
     FIELD OF THE INVENTION 
     The present invention relates to a new type of floating carpet comprising multiple tiles with interlocking mechanisms to allow for the rapid design and installation of a modular layer of carpeting over existing surfaces, and more specifically multiple rectangular tiles each with a polymeric base on which is attached a piece of carpet for quick interlocking of side locking mechanisms on the polymeric base to secure adjacent carpet tiles into a carpet over a surface. 
     BACKGROUND 
     Historically, carpets are used mostly to help with multiple improvements in living and working areas. Carpets can be used indoors, outdoors, or even in vehicles. Red carpets are laid down at movie premieres to help an event cloak itself with a touch of luxury; sidewalks can be covered by carpets to protect the feet of transition athletes in a triathlon running barefoot from a swim area to a bicycle area. But the large majority of carpet is used for covering floors of different living and working quarters of individuals. While generally what is described herein is the use of carpet in the context of a house, a room, or an office, what is contemplated is the use of the new concepts broadly to any known situation where carpets are currently used. 
     Houses and workplaces greatly benefit from carpeting. Adding a carpet allows for a very drastic change and refreshment of the overall look and feel of any room. A good example of this dramatic shift is how the area where management works in manufacturing plants will be covered in carpeting. 
     There are multiple sizes and types of carpets in existence. Carpeting applies equally to larger and smaller areas alike. In the case of smaller areas, the term rug is often used. Rugs have historically been used to cover only a small portion or a strip of an area with carpet. One advantage of having small surface rugs is the capacity to design elaborate pieces of art made of silk or other noble materials, or to cut the carpets in shapes and designs desirable in a room. 
     Removable carpets are generally rolled into a tube for storage, removal, and cleaning. These removable rugs and carpets can slip as individuals move upon them unless they are secured down with some type of clips or nails. Even smaller carpets are often extremely difficult to clean and wash. Over time, odors collect in rugs until they must be retired. Large carpets to cover a long distance, like red carpets at a movie premiere, must be thin or they may be too heavy to lift by individuals. One other problem of rugs and carpet strips is creation of hazards and interface problems between two adjacent rugs or carpets. For example, someone wearing a high heel shoe may trip if the heel strikes the ground between two adjacent carpets at a joint interface. What is needed is a new method and system of carpeting that is modular, can be easily applied and removed at any situation, that does not create any tripping hazard. 
     One solution to limit the tripping hazards between rugs or patches of carpet is to cover an entire room by a single large carpet. In this case, there is also no completely finished surface below a room-size carpet. Large room-size carpets are installed by specialists, using long rolls cut to size. Disadvantages of using room-size carpets include the inability to remove them for cleaning and the need to manage odors and humidity. For example, if a dog has an accident, the urine will be drawn into the carpet and will have to be dealt with. 
     Vacuum cleaners, while capable to collecting dust and some debris accumulating in the upper portion of a carpet, may not be able to dislodge particles trapped below the surface. With time, these permanent carpets will also be damaged in a single area where an accident occurred or where excessive wear is anticipated. 
     What is needed is a new type of carpeting solution that is easy to clean and easy to install, and offers the advantages of both of these carpeting solutions while having none of the drawbacks. 
     SUMMARY 
     The present invention relates to a new type of floating carpet for covering any size surface, including entire rooms, by interlocking carpet covered bases on which resides a layer of carpet where each portion of the multiple tiles forming the carpet is a flat plastic base with side interlocking mechanisms made of male and mating female connectors to allow for the rapid design and installation of a modular layer of carpeting over existing surfaces, and more specifically multiple rectangular tiles each with a polymeric base on which is attached a piece of carpet for quick interlocking of side locking mechanisms on the polymeric base to secure adjacent carpet tiles into a carpet over a surface. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       Certain embodiments are shown in the drawings. However, it is understood that the present disclosure is not limited to the arrangements and instrumentality shown in the attached drawings. 
         FIG. 1  a picture of two adjacent carpet tiles on a laminated wood floor according to an embodiment of the present disclosure. 
         FIG. 2  is a picture of a user sliding in a carpet tile on a portion of floor according to an embodiment of the present disclosure. 
         FIG. 3  is an isometric partial view of a corner of a carpet tile base according to an embodiment of the present disclosure. 
         FIG. 4  is a bottom view of the carpet tile shown at  FIG. 3  according to an embodiment of the present disclosure. 
         FIG. 5  is a top view of the carpet tile shown at  FIG. 3  according to an embodiment of the present disclosure. 
         FIG. 6  is a detail of one of the V shaped notches located around the carpet tile shown at  FIG. 3 . 
         FIG. 7  is a side view of the carpet tile shown at  FIG. 3  according to an embodiment of the present disclosure. 
         FIG. 8  is a different top view of the carpet tile without cutting lines according to another embodiment. 
         FIG. 9  is a picture of a semi-round edge block illustrating a female connector. 
         FIG. 10  is a picture of a semi-round edge block illustrating a male connector. 
         FIG. 11  is an illustration showing the different steps of installing carpet using the carpet tiles. 
     
    
    
     DETAILED DESCRIPTION 
     Carpets, laminated floors, gym flooring, and other types of surfacing are often needed on surfaces to help improve or change the functionality of a location. In some cases, a room or surface is already covered with a first type of covering and what is needed is the capacity to place a floating second covering on top of the first type of covering. This invention relates to the installation of a second covering such as carpet in the current preferred embodiment over a first covering such as laminated wood in the current preferred embodiment. While one type of secondary covering is shown over a first type of first covering, what is disclosed is a system and method of installation that can be applied to any surface, even over a flat surface without covering like grass, ground, or cement. 
       FIG. 1  shows a flat horizontal surface  100  such as a floor covered by laminated wood or any other known surface upon which two or more adjacent carpet tiles  1  and  2  are placed. While the use of the carpet tiles  1  and  2  are shown on a flat horizontal surface, one of ordinary skill in the art will know that any flat surface can be used and covered by the tiles  1  and  2 , including walls or even ceilings. 
       FIG. 1  shows generally the elements of a system  200  for covering a flat horizontal surface  100  where a plurality of tiles, here shown by two tiles  1  and  2 , are aligned at their side edges so the different male and female connectors as explained in greater detail below can interlock.  FIG. 2  shows how, in one embodiment, a user  10  can use his or her hands to slide a tile  1  into position to rest upon adjacent tiles  2  and  3 . In the example shown, locks described hereinafter are made in a V shape and slide into the adjacent tiles. One of ordinary skill in the art of interlocking tiles will understand that in some cases or models, the tiles may be secured permanently to each other using one-way locking tabs, glue, bolts, or screws if the system  200  is used to cover a flat horizontal surface permanently. In other cases or models, the system  200  can be used for a short period of time or may require the frequent replacement of some of the tiles to compensate for wear. In these models or cases, the connection between adjacent tiles can be temporary. 
       FIGS. 1 and 2  also do not show the use of an underlying carpet, a foam, or other underlying layer between the tiles  1 ,  2 , and  3  and the flat horizontal surface  100 . One of ordinary skill in the art in the covering of surfaces knows that small foam or other layers can be used to attenuate sound, correct floor irregularities, and help protect and prepare the surface  100  upon which the system  200  can be placed. 
     In the primary embodiment shown in the figures, one single geometry of flat square tile can be used to cover a surface. One of ordinary skill in the art knows that in the art of covering a surface with tiles, two or more different shape tiles can be used in tandem to create different effects and shapes. For example, a user wanting to cover a surface with floor tiles can create different edges, shapes, or a mosaic of different colors by alternating the shapes, sizes, and colors of the tiles selected. One of ordinary skill in the art will recognize that while one square and single color carpeted tile is shown, what is contemplated is the use of this technology on any type of tiling system currently in use on ordinary tiles. 
       FIG. 3  is an isometric illustration of a portion of a flat square horizontal interlocking tray  150  showing with greater detail a portion of the underside  30  of the tray  150 . Since the system  200  must be able to be adapted to any shape and size of room to be covered, what is contemplated is the need to cut and trim down any single tile to fit in place. To help guide and direct the cut of the tiles to precise dimensions, as shown, the underside  30  of a plate or horizontal interlocking tray  150  can include different guides  31 , ridges or other weaknesses, such as for example saw guides or snap-off guides, to help with the installation. In another embodiment, a user can purchase square tiles of a fixed dimension (e.g., 12″×12″) along with a handful of partial tiles (e.g., 12″×6″) to help limit the need to cut and trim down a tile to the right dimension. 
     What is shown at  FIG. 3  is a portion of a horizontal interlocking tray  150  including two sides, each having an outer horizontal edge  51 . The portion shown of one edge  51   a  has a male connector  52  shown in a V shape while the portion shown of the second edge  51   b  has a female connector  53 . The area defined within the outer edges  51  is a flat plate  150  with an underside  30  for laying down on a flat surface  100  as shown at  FIGS. 1 and 2 , and an upper side opposite to the underside  30 . 
     In the design as shown guides and ridges  31  can be made at regular intervals in the tile underside  30  to help with any potential cut or change in any dimension. As shown, these ridges  31  are made in two dimensions but what is contemplated is the use of these ridges in any direction. One of ordinary skill in the art will understand that in cases where the horizontal interlocking tray  150  is made of polymer or other types of material having inherent flexibility, these ridges  31  can be made as ribs using ribbing techniques to help reinforce the horizontal interlocking tray  150  and limit the thickness of the horizontal interlocking tray  150 . As shown, rounded corners  55  can also be included to help adjacent tiles interlock. Another useful feature are small areas for placing support feet  56  where the mold is attached. 
     Each of the four sides of a tray  150  as shown at  FIGS. 4 and 5  includes an outer horizontal edge  51  on the four sides each with two V shaped male connectors  52  and two V shaped female connectors  53 . As shown, each of the four sides of the tiles  1 ,  2 , and  3  is designed to mate and interlock with an adjacent tiles  1 ,  2 , and  3  as shown at  FIGS. 1 and 2  in such a way that the two male connectors  52  from a first tile will slide into the two adjacent female connectors  53  of the second tile. What is shown is the use of four V shaped male-female connectors but what is contemplated is the use of any number of connectors or any type of connector to help connect adjacent carpet tiles including locks, slips, screws, little clips, etc. 
     In one embodiment as shown at  FIG. 3 , each male connector  52  includes a centering lug  60 , a tab  61 , and a snap lock piece  62 . These features as either the male or female part of one possible connector  52 ,  53  are shown more clearly on a snap-on side piece  80 , also called trims, as illustrated on  FIGS. 9 and 10 . 
       FIG. 7  shows a side view of a section of the base plate  150  (also described as a horizontal interlocking tray) of a tile with an end male connector  52  on the outer edge  51 . As shown, the tray  150  includes both an upper side  54  and a lower side  30 . 
       FIG. 8  shows how the upper side  54  or the upper portion of the base plate of the tile can be made with a small ridge  57  to help glue or attach a square of carpet, or secure an intermediate layer to the upper side  54  of the tray  150 . Once again, while one configuration is shown, what is contemplated is the use of any possible configuration or system to help attach carpet to the upper portion of the base plate. 
     As shown at  FIG. 1 , a textured carpet  35  is attached to the upper side  55  of horizontal interlocking tray  150  for securing the carpet  35  to the flat interlocking tray  150 . In this case, the male connector  52  and the female connector  53  located on the outer horizontal edge  51  are designed to interlock each with a different adjacent carpet tile laid down on the flat surface. 
       FIGS. 9 and 10  show two different portions of a trim  80  designed to be clipped to the side of the tiles in places where a transition must be made between the carpet area and the floor surface  100  on which the tiles  1  and  2  are placed. The male  52  and female  53  connectors on these trims  80  are easier to see without all of the additional features and ribs of the tiles  1  and  2 . 
     In this embodiment, an opening  90  is made to form the female connector  53  as shown at  FIG. 9 . The male connector  52  including all of its features is slowly slid into the opening  90  until the tab  61  and the lock piece  62  slide into place. The bottom opening  91  allows the use of a tool or screwdriver to push the lock piece  62  away from the small bar  93  to allow the male connector  52  to slide back out. 
     As the male connector  52  is pushed in the opening slit  90  of the female connector  53 , it is centered by the centering lug  60  until the snap lock  62  passes the small bar  93  and then is capable of snapping in position. One advantage of the snap lock mechanism and an opening  90  on the female connector  53  is the capacity to unlock two adjacent tiles  1  and  2  by using a screwdriver or other hand tool to push up the snap lock  62  away and pull the male connector  52  out of the female connector  53 . The tab  61  is also used as a slightly rigid and deforming body that will bend slightly as the snap lock  62  slides over the small bar  93 .  FIG. 6  shows with greater detail the tab  61  with the centering lug  60  and the snap lock  62 . 
     In one embodiment, the top side  54  of a tray  150  may be first covered with a padding layer which is then covered with a carpet layer. In one embodiment the interlocking tray has a thickness of 3/16 of an inch and the padding layer has a thickness of ⅜ of an inch. As will be clear to one of skill in the art, a variety of thicknesses of tray, padding, and carpet may be used. What is contemplated is the use of any padding and carpet known in the art. In another embodiment, the underside  54  includes a marking to indicate a preferred orientation of the tile  1  as part of a fully assembled carpet made of a plurality of tiles  1 ,  2 , and  3 . The marking (not shown) can be an arrow indicating the grain of a textured carpet. 
     In addition to a simple carpet tile  1 ,  2 , and  3 , each tile can be part of a removable carpet  200  also described as a system for covering a floor or a surface  100 . This removable carpet  200  can include a plurality of carpet tiles  1 ,  2 , and  3  above. Each tile  1 ,  2 , and  3  has at least a trim  80  with at least a mating male connector  52  for the female connector  53  of one of the other carpet tiles  1 ,  2 , or  3 , and a mating female connector  53  for the male connector  52  of one of the other carpet tiles  1 ,  2 , or  3 . 
       FIG. 11  shows a method of what is contemplated using a series of tiles (e.g., tiles  1 ,  2 , and  3  shown in  FIGS. 1 and 2 ) which are shown as squares but that can be of any shape that can be interlocked together to cover a surface. A user will obtain a series of carpet tiles. In one embodiment the carpet will be pre-attached on the base of the tile, while in another embodiment, the base tile will be sold independently and a user will in a first step have to cut the carpet in the right sections and attach the carpet to the base tile using an adhesive or any other mode to attach used in this art. 
       FIG. 11  shows the tiles as already found with carpet on the upper side. First, in step  202 , the room is measured to determine the number of tiles to install. Next, in step  204 , tiles are attached or snapped together to cover the desired area. Finally, in step  206 , tiles are trimmed if necessary. To trim a tile, the user then can flip the carpet tile upside down, use the carpet thickness as protective distance and using a tool such as a short knife blade with a blade that is shorter than the thickness of the carpet to cut along lines made in the bottom surface of the base tile. 
     In an embodiment, semi-round edges or other rim boards commonly used in the industry are used to help create finished edges to the carpet tiles. For example, a design can include an internal opening area such as a dance floor where each edge is covered by a trim or edge piece. In an embodiment, these rim boards are produced to have male  52  and female  53  connectors so as to interconnect with the outer female  53  and male  52  connectors, respectively, on the tiles. In other words, each of the rim board would have at least a mating male connector for the female connector of one of the carpet tiles, and a mating female connector for the male connector of one of the carpet tiles. 
     The system for use of carpet tiles is aesthetically pleasing and can create a wall-to-wall carpet. Alternatively, a portion of room may be covered. One main advantage of using a carpet tile is that the room in which the carpet is installed does not need to be emptied of furniture. Once the old existing carpet is removed or any other type of floor is found, the furniture can be displaced to one end of the room as the tiles are assembled. Once in the middle of the room, the furniture can be lifted and placed on the partly completed carpet, allowing for completion of the work. 
     In order to cut a tile to any needed dimension to fit a room, what is contemplated is a hand tool such as a utility knife with a sharp blade. The carpet tiles can be installed over plywood, concrete, vinyl, hardwood, tile or any surface. In a preferred embodiment, the surface is one that is structurally sound, clean, dry, and smooth. In a preferred embodiment, if concrete is used for the surface it is fully cured and dry before installation of the tiles. In one embodiment, the surface is a subfloor with a with a variation of no more than ⅛ inches in 6 feet. 
     What is claimed is a method in accordance with the present invention for installing tiles. In a preferred embodiment, the subfloor is first cleared of any debris that would prevent the tiles from lying flat, for example by sweeping or vacuuming the surface. As will be clear to one of skill in the art, this is only necessary if debris are present on the subfloor. A location is determined to start the installation. In a preferred embodiment, installation begins in one corner of the room. The width and length of the room is measured to obtain the overall dimensions of the area to be covered. Based on these measurements, the number of tiles (including both complete and partial tiles) to be installed is determined. For example, the measured dimensions or a room can be a total of 5′2″×7′3″. The number of tiles necessary may be determined by rounding up to cover a surface larger than the measured surface. In the above example, the surface to cover before trimming would be 6′×8″, yielding a total of 48 tiles (6×8) if square tiles of 12″×12″ (1′×1′) are used. 
     In one embodiment, tiles of uniform shape, size, and color may be used. In an alternate embodiment, different types or styles of tiles are used and are placed in either a predetermined or random pattern. For example, two or more different colors of tiles may be used. Each color of tile may come in a separate box. During installation, these tiles of different colors may be mixed randomly to help generate the best degree of variations between the different elements. In a preferred embodiment, tiles from at least three boxes, each containing for example a different color of tile, are used. During installation, these different-colored tiles are mixed, either randomly or in a predetermined pattern. In a preferred embodiment, all of the tiles of each color come from the same dye lot to ensure matching colors. 
     The first tile to be installed is then placed flat on the ground. In a preferred embodiment, a marking on the bottom surface of each tile indicates the orientation in which each tile should be placed. For example, the marking could be an arrow. The marking could further indicate the grain of the texture of the carpet. In this example, the tiles would be installed with all of the arrows facing in the same direction. Doing so would orient the grain of the carpet on all of the tiles in a single direction. 
     A second tile is then placed flat on the ground next to the first, in the proper orientation. The two tiles are then interlocked by lining up the tabs and pressing the tiles together firmly until they lock. As will be clear to one of skill in the art, a tile may be connected to a group of two or more tiles that have already been interconnected together. Accordingly, the steps are repeated until each of the predetermined number of tiles has been installed. 
     Further, the method concludes with trimming the last row and/or column of tiles if necessary. Tiles may be trimmed during installation to cover only the desired area. Once the width of the room is calculated, if the width of the last row is less than a certain fraction of the full tile, the first row may be trimmed as well. In the above example where the room is 5′2″, then in theory the last row would be made of tiles of only 2″. In order to increase the thickness of the last row, the first row may be trimmed by 4″, reducing the first row from the full 12″ down to 8″. This will allow the last row to be 6″ in width (adding the 4″ removed from the first row to the 2″ left). 
     Additionally, in a preferred embodiment, a minimum of ¼″ of expansion space is left around the perimeter of the room. To install the last row of tiles around the perimeter of the area, the tiles are cut to the correct size leaving at least a ¼″ gap between the tile and the wall. The tile may be flexed slightly if necessary and the tile next to it lifted so the tabs can lock into place. If it is necessary to unlock carpet tile, a tool such as a small utility knife may be slid between two tiles and twisted until the tiles unlock. Alternatively, a user may use their hand to lift the tiles and push the tab upwards to unlock the tiles. 
     In an embodiment, the ¼″ expansion space is created between the tiles and the wall by cutting off the tabs on the outer edges of the tiles on the perimeter of the room. The tabs may be removed, for example, by scoring the tabs with tool such as a utility knife and snapping them off. In one embodiment, the tabs on the outer edges of the perimeter carpet tiles are cut from the bottom. In an embodiment, the tabs are created from a material (e.g., a type of plastic) which allows for the tiles to be snapped off after a score is made on the bottom along one of the notched lines using a tool such as a sharp utility knife. Once the base plate is separated, a cutting instrument like a knife is used to carefully cut through the pad and carpet. 
     It is understood that the preceding is merely a detailed description of some examples and embodiments of the present invention and that numerous changes to the disclosed embodiments can be made in accordance with the disclosure made herein without departing from the spirit or scope of the invention. The preceding description, therefore, is not meant to limit the scope of the invention but to provide sufficient disclosure to one of ordinary skill in the art to practice the invention without undue burden.