Abstract:
A flooring system including a modular frame surrounding modular floor covering units. Frame members attach easily to one another, providing stability to the flooring system and ease of installation.

Description:
RELATED APPLICATION DATA  
       [0001]     This application is a continuation-in-part of U.S. application Ser. No. 10/381,025, which is a U.S. National Phase application of International Application No. PCT/US01/29313, filed Sep. 19, 2001, incorporated by reference herein. 
     
    
     FIELD OF INVENTION  
       [0002]     The invention generally relates to the field of carpet and floor covering, specifically to the area of self contained flooring systems.  
       BACKGROUND OF THE INVENTION  
       [0003]     Floor covering has included a vast array of materials such as ceramic tile, wood, carpet, carpet tile and other materials. Equally as numerous have been the methods for installing and securing flooring, either permanently or temporarily, to subfloors. Traditionally, among other approaches, flooring systems have used surrounding walls as a method of containing and securing the flooring material. However, this method provides very little flexibility to the installer of the flooring system. Using existing walls as lateral support for flooring materials requires that the installer invest substantial time and labor to fit the flooring materials to the existing subfloor. Accordingly, a need exists for a method or system that allows floor tiles to be contained and laterally supported by a means other than the existing walls of the structure.  
       SUMMARY OF THE INVENTION  
       [0004]     This invention is a self contained kit or a group of components from which a purchaser can assemble an area floor covering. In one embodiment, a four-sided modular frame surrounds modular units of carpet or carpet tile bounded by the frame, which also provides transition from the carpet to the floor on which the assembly lies. Frame members may be attached to the modular units and to one another. The frame members may be made of plastic, wood, metal, ceramic, marble, or other suitable materials.  
         [0005]     One feature of this invention is a system having components salable through retail outlets for producing an area floor covering.  
         [0006]     Another feature of this invention is a system and method for containing replaceable wear surfaces without reliance on interior walls of a room for lateral support.  
         [0007]     Yet another feature of this invention is an efficient method of installing replaceable wear surfaces in any room with a minimal investment of time and labor.  
         [0008]     Another feature of this invention is an area floor covering having an exterior frame that is stable and easy to assemble.  
         [0009]     An aspect of this invention provides an area floor covering, comprising a plurality of replaceable wear surfaces having edges, and a plurality of connectable edge segments adapted to bound the plurality of replaceable wear surfaces when connected and comprising a flap having attachment material for attaching one of the replaceable wear surfaces.  
         [0010]     Another aspect of this invention provides a framing system for an area floor covering, the framing system comprising a plurality of connectable frame segments, each segment comprising: a flap comprising adhesive for attaching a replaceable wear surface; an aperture adapted to receive a connector; and a connector retainer.  
         [0011]     Another aspect of this invention provides an area floor covering comprising a plurality of carpet tiles and a frame adapted to bound the plurality of carpet tiles, the frame comprising: at least one connector; at least two edge segments, each segment comprising a flap comprising adhesive for attaching a replaceable wear surface, and an aperture adapted to receive the connector; and at least one a connector retainer. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0012]      FIG. 1  is a top plan view of an area rug of this invention.  
         [0013]      FIG. 2  is a side elevation view of the rug of  FIG. 1 .  
         [0014]      FIG. 3  is a cross-sectional view of a segment and replaceable wear surface of this invention.  
         [0015]      FIG. 4  is a perspective view of a portion of the exterior frame of  FIG. 1 .  
         [0016]      FIG. 5  is an end view in cross-section of a segment of  FIG. 1 .  
         [0017]      FIG. 6  is a plan view of the bottom of the connection between two segments, without a retainer.  
         [0018]      FIG. 7  is a perspective view of a collaboration of pieces for forming an area rug.  
     
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0019]      FIG. 1  illustrates an area rug flooring system  10  of this invention. The flooring system  10  includes an exterior base  12  and multiple replaceable wear surfaces  14 . The replaceable wear surfaces  14  maybe carpet tiles or hard surface modules composed of materials such as, but not limited to hardwoods or ceramics.  
         [0020]     In one embodiment, exterior frame  12  includes multiple segments  16  sized to receive replaceable wear surfaces  14 . The segments  16  typically are joined at a 90° angle to form a square or rectangular base  12  around the area rug  10 . Alternatively, segments  16  may be joined at other angles to form various shapes to suit the needs of the layout of the desired design. In the embodiment shown, the segments  16  include linear sides  18  and corners  20 . Corners  20  and linear sides  18  are joined to form a rectangular exterior frame  12 . However, the exterior frame  12  may be comprised of any number of segments  16  in any number of shapes, including triangular, circular, and any shape in between. The replaceable wear surfaces  14  may be assembled in various combinations and patterns to suit the needs and tastes of the consumer.  
         [0021]      FIG. 2  is a side elevation view of the system  10 . The exterior frame  12  can be constructed of a variety of materials including plastics, wood, rubber, metals, ceramics, marble and other resilient and workable materials. Extruded plastic or aluminum profiles are particularly desirable for use as exterior frame  12 .  
         [0022]      FIG. 3  is a cross-sectional view showing a replaceable wear surface  14  disposed within the exterior frame  12 . The segment  16  can have a thickness equal to or approximately equal to the thickness of the replaceable wear surface  14 . However, segment  16  could also have a thickness less than or more than the thickness of replaceable wear surface  14 .  
         [0023]     As shown in  FIG. 3 , frame  12  includes an exterior surface  17 , which may be formed from a hard plastic, and a flap  19 , which may be formed from a soft plastic. Exterior surface  17  also includes contact surface  21 , which may be formed from soft plastic, which provides non-skid properties to the frame member. Segments  16  and corners  20  may be co-extruded during manufacture. Upper surface  23  of flap  19  includes an adhesive  25 , which adheres to a replaceable wear surface  14 . Adhesive  25  may be a peel and stick adhesive, or any other adhesive suitable for attaching a replaceable wear surface. Segments  16  are sized to correspond to the size of a modular carpet tile, or may be designed in any suitable size or shape.  
         [0024]     Segments  16  may be joined in a number of ways including adhesives, snap fittings, sonic welding, splines, nails, screws, or other means of attachment. In one embodiment, as shown in  FIGS. 5 and 6 , the segments  16  include an aperture on the underside of the segment  16  and spaced from an end of the segment  16 . The aperture is adapted to receive end  28  of a connector  30 . A second end  28  of a connector  30  is received in an aperture in a second segment  16 . Tensioner  32  extends between ends  28  of connector  30  and is received in channel  34  on the underside of the segment. Retainer  36  having recess  38  snaps in place over connector  30 , securing the position of the components. Lip  40  of retainer  36  joins with ridge  42  of segment  16  and the opposite edge  44  of retainer  36  fits over protrusion  46  of segment  16  so that retainer  36  locks in place over each channel  34  of each segment  16 . Retainer  36  thus provides torsional stability to the union of the two segments  16 . In this manner, connector  30  and retainer  36  join two segments  16 .  
         [0025]     The components of flooring system  10  may be sold unassembled so that the purchaser may assemble the exterior base  12  by joining segments  16  and corners  20  and positioning replaceable wear surfaces  14  within exterior base  12  in an arrangement chosen by the purchaser.  
         [0026]     The system described above can be marketed and sold as a kit.  FIG. 7  illustrates various components that may be included in various quantities. For instance, the system can be contained within a container, such as a pasteboard or other box. Alternatively, the system can be sold as individual components so that a consumer can select the pieces, such as segments  16 , and replaceable wear surfaces  14 . Further, the segments may by offered in various thickness, lengths, colors and designs. The replaceable wear surfaces  14  may also be offered in various sizes, colors and designs.  
         [0027]     An advantage of this invention is that it provides systems and methods for installing free lay replaceable wear surfaces with a minimal investment of time and labor.  
         [0028]     Another advantage of this invention is that it provides systems and methods for containing many types of hard and soft replaceable wear surfaces without the need for lateral support or containment typically provided by interior wall surfaces.  
         [0029]     Yet another advantage of this invention is that it provides systems and methods for a flooring structure where the surface may be easily replaced.  
         [0030]     Still another advantage of this invention is that modules of the replaceable wear surface may be assembled in multiple configurations in order to obtain multiple designs with the same components.  
         [0031]     An additional advantage of this invention is that the rug may be installed in oddly shaped rooms with a minimal investment of time and labor.  
         [0032]     While various 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.