Abstract:
An anchor sheet subfloor that includes a laminate having an upper layer of relatively thin flexible rigid sheet material and a bottom layer of a relatively resilient cushioning material. The upper sheet layer can be formed of a plastic or polymer material. In one arrangement, the sheet can be cut and fit within the boundaries of a room and the sheet has sufficient rigidity and mass to remain without distortion or buckling within the room by free floating on the existing floor without substantial attachment to the floor. It can be possible for a sheet to be cut and fit on site to fit the contours of a room to form by itself or in combination wit other anchor sheets a free floating smooth subfloor on which can be overlaid decorative covering pieces.

Description:
RELATED APPLICATION 
     This is a continuation in part of application Ser. No. 08/684,004 filed Jul. 19, 1996, now abandoned and application No. 08/850,726 filed May 2, 1997. 
    
    
     INTRODUCTION TO THE INVENTION 
     This invention relates to the installation of decorative coverings. It has been shown in the present inventor&#39;s first patent U.S. Pat. No. 4,822,658 that carpets having a looped backing can be conveniently installed on a floor by the use of complementary hooked tape. One of the primary ways disclosed in that patent is attaching the tape to the floor at the perimeter and seams (hereinafter “perimeter and seam” installation). The present inventor has also developed an anchor sheet which is described in U.S. patent application Ser. No. 08/685,004 filed Jul. 19, 1996 and continuation-in-part application Ser. No. 08/850,726 filed May 2, 1997 (the specifications of which are herein incorporated by reference). Rather thin attaching the carpet directly to a hooked tape attached to the floor, an intermediate thin flexible relatively rigid anchor sheet is provided which gives rigidity and integrity and mass to the overlying pieces of carpet covering. The anchor sheet can be covered in hooks. The carpet has an underlying looped backing for attachment to the hooks. The carpet can be in pieces which overlap the anchor sheet pieces to provide rigidity and strength to the total unit. 
     The perimeter and seam method and the anchor sheet structure and method can both be used and will both work. However in some circumstances it may be advisable to use a combination of both methods in which a form of anchor sheet provides a stable framework into which either a cushion or a covering material or both can be inserted either attached to the floor by a hook and loop attachment method or as a “free float” within the framework. In these circumstances, the anchor sheet can be a support for a covering unit attached to the anchor sheet by hook and loop as shown in the earlier related cases. Carpet within the framework can then be installed with hook and loop or in a conventional manner, i.e., without hook and loop, by glue down or even by free floating. 
     In some circumstances the hook tape of a perimeter and scam installation can be the “framework” within which an anchor sheet installation can be made. In this case the anchor sheet may float within the framework created by hook tape attached to a floor. Additional methods of attaching a tape framework and a tape framework construction are disclosed as well as other methods of installing an anchor sheet as a framework, including the use of a form or jig. 
     BACKGROUND OF THE INVENTION 
     The need for flexibility in installing floor coverings is well known. Most floor coverings must be cut and fit on site and therefore must be flexible to provide for different physical limitations In addition subflooring and supporting substrates differ widely in both quality and type, even in new construction In old construction existing flooring may reman and present problems. 
     The background to the invention is substantially shown in the present inventor&#39;s prior issued patents U.S. Pat. No. 4,822,658 (Apr. 18, 1989, Pacione); U.S. Pat. No. 5,191,692 (Mar. 9, 1993, Pacione); U.S. Pat. No. 5,382,462 (Jan. 17, 1995, Pacione); and U.S. Pat. No. 5,479,755 (Jan. 2, 1996, Pacione). In addition attempts to make structural semi-permanent flooring and wall material incorporating a hook surface is also disclosed in the present inventor&#39;s earlier anchor board system U.S. Pat. No. 5,060,443 (Oct. 29, 1991, Pacione); U.S. Pat. No. 5,259,163 (Nov. Pat. No. 9, 1993, Pacione); and U.S. Pat. No. 5,144,786 (Sep. 8, 1992, Pacione). 
     SUMMARY OF THE INVENTION 
     A thin rigid but flexible anchor sheet has advantages to stabilize the overlying carpet to provide a relatively rigid subfloor for installation of an overlying carpet. When a resilient backing of cushioning material is attached to or supplied under such anchor sheet, the anchor sheet provides a novel subfloor which has significant advantages over existing underpads. 
     We have described the anchor sheet as both “flexible” and “rigid”. It is flexible in the sense that over a reasonable length it can bend and in most circumstances can even be rolled with a radius of curvature for example of perhaps 1 or 4 inches unlike for example plywood. It is rigid in the sense that if held at one end it can support itself for instance over a distance of 12-24 inches without drooping unlike a cloth or fabric tape. 
     It is not commonly appreciated that an underpad, while it provides resiliency, can lead to degradation in the overlying decorative textile surface. This is because the resiliency allows for the carpet to deform when walked upon or when furniture or other items are placed on the carpet. This deformation can, if it is not properly supported from below, result in crushing and eventual deterioration of the carpet structure. 
     The anchor sheet of this invention has a relatively rigid yet flexible thin sheet material, preferably a plastic or of a polymer material such as a polyester, polycarbonate, polypropylene or even a graphite or other advanced polymer material overlying a resilient cushion. This structure provides a surprising amount of resiliency and cushioning to the carpet. However because the overlying anchor sheet is relatively rigid, the carpet fibres are protected from crushing and therefore the life of the carpet is significantly extended while still appearing to have a sufficient degree of resiliency. 
     In order to provide the proper degree of resilience in the hooks and the proper degree of rigidity to the sheet, the hooks and sheets may need to be made from, for example, different plastic materials by lamination or coextrusion. 
     To the inventor&#39;s knowledge no person, until disclosed in this and the earlier related applications, has had the relatively unconventional idea of covering a resilient material with a thin flexible relatively rigid sheet material. 
     Thus the invention comprises in, one aspect, an anchor sheet subfloor comprising a laminate having an upper layer of a relatively thin and flexible rigid sheet material and a bottom layer of a relatively resilient cushioning material. 
     While not as pronounced, the advantages of a relatively rigid but flexible anchor sheet to create a smooth subfloor and to tie overlying carpet pieces together into a stable mass can to some extent be achieved even without a resilient undercushioning. Thus the invention comprises in another aspect a relatively thin flexible rigid sheet material preferably of plastic or polymer which can be cut and fit on site to fit the contours of a room or other area to be covered to form by itself or in combination with other anchor sheets a free floating smooth subfloor on which can be laid decorative covering pieces. 
     In another aspect the invention comprises a carpet and subfloor comprising a first layer of relatively resilient cushioning material overlaying the floor. A second layer of a thin flexible rigid polymer material overlaying the first layer and hooks covering at least a portion of the top surface of the second layer and a carpet having an undersurface covered in loops and detachably attached to the hooks covering the second layer to form a coherent stable carpet structure. 
     In another aspect, the subfloor and structure created by the first resilient layer and the second layer of anchor sheet, can be covered across its surface by perimeter and seam hooked tape so as to allow for installation of a carpet on the subfloor in accordance with the method described in U.S. Pat. No. 4,822,658. In this case the subfloor is actually not attached to the floor directly but is normally “floating” but this may be sufficient, in many installations, to stabilize the carpet. 
     As previously described, in some circumstances, the anchor sheet can act as g framework for either a carpet or an underpad or both, Thus, in another aspect, the invention covers an anchor sheet, carpet and an underpad combination for installing a carpet or underpad onto a floor comprising an anchor sheet installed along the perimeter of an area to be covered, describing and bounding that area, hook tape attached to the sheet along the perimeter of the upper face of the anchor sheet and a resilient underpad of a height matching the height of the anchor sheet sized to fit within the area bounded by the anchor sheet. A carpet having an underside covered in loops can then be overlaid. The anchor sheet perimeter and the resilient underpad may be either free floating or installed in a conventional manner within the anchor sheet framework. 
     A more complex anchor sheet framework can also be formed consisting of modular covering units made as disclosed in related application Ser. No. 08/850,726. Thus in another aspect the invention comprises a modular framework for carpet installation comprising a plurality of covering modules having decorative coverings attached to a thin flexible rigid anchor sheet so as to leave exposed overlapping areas of anchor sheet or covering for detachable attachment and interlocking relationship to an adjoining module as disclosed in related application Ser. No. 08/850,726. In this aspect of the invention, the modules are then detachably interlocked to define and enclose an area. Carpet or underpad or carpet and underpad depending upon the height of the framework created, is then cut and fit within the area defined by the covering modules, 
     As previously mentioned, an anchor sheet subfloor can also be installed within a perimeter bounded by hooked tape, in effect creating a hooked tape framework. In this aspect of the invention, a perimeter of hooked tape is attached to the floor. The tape may be of a form disclosed in, for instance, U.S. Pat. No. 5,382,462 or having a tape with a cushioned backing or a tape with a foundation sheet as disclosed in the present application. 
     In this aspect of the invention, a thin rind flexible anchor sheet having an upper surface having a plurality of hooks in which the anchor sheet or anchor sheet and cushion is substantially the same height as the tape can then be cut and fit within the area bounded by the hooked tape to provide for a surface underlayment over which a carpet or other decorative covering having a looped backing can be installed. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     Embodiments of the invention will now be described, reference being had to the accompanying drawings, wherein: 
     FIG. 1 shows covering modules and a jig for installation. 
     FIG. 2 shows the covering modules and jig in the process of installation to a floor. 
     FIG. 3 shows the next step in installation of the covering module and jig. 
     FIG. 4 shows the finished covering module framework. 
     FIG. 5 shows the covering module framework at the commencement of the installation of an inserted cushion or carpet. 
     FIG. 6 shows the completed covering. 
     FIG. 7 shows the anchor sheet perimeter arrangement. 
     FIG. 7A shows another form of anchor sheet perimeter arrangement similar to that shown in FIG.  7 . 
     FIG. 8 shows another form of anchor sheet perimeter arrangement in which the anchor sheet carries a decorative covering which contains a border pattern. 
     FIG. 8A shows a completed anchor sheet perimeter arrangement. 
     FIG. 9 shows a form of anchor sheet upon which is installed a perimeter and seam hook and loop tape arrangement. 
     FIG. 10 shows a form of tape suitable for use in a perimeter arrangement. 
     FIG. 11 shows a cross-section of a perimeter arrangement having a hooked tape bounding an area of anchor sheet and an overlying decorative covering. 
     FIG. 12 shows an arrangement of anchor sheet providing a border. 
     FIG. 13 shows another border arrangement with anchor sheet and cushion. 
    
    
     DESCRIPTION OF PREFERRED EMBODIMENTS 
     In FIG. 1 is shown a variety of covering modules  2  and  4 . These are similar to the type of covering modules disclosed in related case Ser. No. 08/850,726. In the case of covering module  2  there is an anchor sheet  6  larger than the decorative covering piece  8 . In the case of covering module  4  there is a decorative covering piece  10  which overlaps the anchor sheet  12 . 
     Normally the anchor sheet areas would be substantially covered in hooks  14  as shown in only representative detail. The overlapping pieces  10  will have on their undersurface loops (not shown) for attachment to the exposed hooks  14  of anchor sheet, for instance,  6 . 
     A jig or pattern  16  is also shown in FIG.  1 . Its use will become apparent. 
     The jig at  16  has corners for instance  18  and  19  which serve to locate the corresponding comers of decorative covering piece  8  at each of the four corners of the jig. Thus the covering modules are separated and appropriately spaced in the desired location. Covering module  4  cam then be inserted along the sides of the jig abutting the jig as shown. Loops on the undersurface of covering piece  10  (not shown) will enable the covering piece to be installed in detachable attachment in a manner shown in related case Ser. No. 08/850,726 preferably by the use of a smooth slip cover as disclosed in related U.S. patent application Ser. No. 08/850,726. The slip cover can be a hard smooth piece temporarily insert. It can then be removed and the covering modules will form a framework as shown in FIG. 3, in which pieces  4  and pieces  2  have combined to create a structure. Jig  16  is then removed as shown in FIG. 4 so that the anchor sheet framework now lies upon and circumscribes an area of floor  21  and also an area of hooked anchor sheet  20  which is at a different level than the surface of decorative covering  22 . 
     As shown in FIG. 5 a decorative covering unit  24  can be inserted into the framework  26 . The unit may be carpet having a looped backing (not shown) in which case the carpet would be detachably attached to hooks  28  in the area shown. Normally the complete area would be covered in hooks but only representative samples are shown. 
     If desired the floor area  21  could be made level with the hooked area  28  by the use of an anchor sheet of suitable thickness, also covered with hooks or smooth, or by the installation of a pad. The area of floor  21  could be left empty because of the low profile of the hooked area  20 . 
     FIG. 6 shows the unfinished subunit which is ready to be attached by hooks  30  to other adjoining anchor sheet units or covering modules. 
     In FIG. 7 is shown another form of anchor sheet perimeter installation in which an anchor sheet  32  is formed having a thin rigid flexible covering  34  preferably formed of a plastic or polymer material as described in related application Ser. No. 08/850,726 preferably of a polypropylene, polycarbonate or polyester material and laminated and bonded thereto is a resilient cushion  36  of polyurehane foam or other similar carpet underpad material. Similar anchor sheet units  32 A and  32 B are placed on the floor in abutting relation and the units may be joined together by a pressure sensitive adhesive hooked tape  38  overlying the seams of the anchor sheets or by plain single-sided pressure sensitive tape. Additional hooked tape  40  is added to the perimeter of the anchor sheet installation to provide for a regular perimeter and seam installation as shown in U,S. Pat. No. 4,922,659. It would be convenient if the tape covering joins  41  line up with carpet seams but if they do not, additional tape can be installed on the anchor sheet  32  to provide for at least seam coverage. 
     Of course if plain tape is used, then hooked tape will normally have to be installed at the carpet seams. Such tape is normally covered prior to installation. Full coverage could also be provided either by adding more hooked tape or by providing anchor sheet  32  with a flexible sheet pre-manufactured with a complete hook covering. 
     In FIG. 7A is shown an additional similar form of arrangement which combines a hooked tape  42  to be described later at the perimeter of the room, an underpad or anchor sheet with underpad  44 , an additional anchor sheet with underpad  46 , conventional underpads  48  and  50  and anchor sheets  52  and  54  with resilient cushioning and then tape  56 . Thus a complete resilient underlayment is created which is partly a framework made by tape  42  and anchor sheets  44 ,  46 ,  52  and  54  within which are contained conventional underpads  48  and  50 . A carpet can then be installed over top of this by perimeter and seam tape using tape  42  and  56  at the perimeter and tape  53  at the seams or by the use of an additional anchor sheet (not shown) to provide for decorative surface covering pieces. As shown in FIG. 8 an additional foundation sheet  58  of a similar material to the anchor sheet can have pre-attached permanently or detachably an anchor sheet  60  having a resilient undercushion  62 . The anchor sheet  60  could be one as shown in related application Ser. No. 08/850,726 having its upper surface substantially covered in hooks  64 , Decorative cover pieces, in this case carpet units  65 , can then be installed in any pattern over the anchor sheet. In the example given in FIG. 8 they are installed in a border pattern. When fully assembled as shown in FIG. 8A such a unit can create a framework within which carpet can be installed in a conventional way, or using hook and loop or perimeter and seam or in a small enough area free floated within the area bounded by the decorative border  66  as shown in FIG.  8 A. 
     FIG. 9 shows an arrangement similar to FIG. 7 in which there is an anchor sheet and resilient cushion framework  68  on either side of conventional carpet pads  70 . The conventional carpet pads may be free floating or attached to the floor in a conventional manner. Normally if the anchor sheets  68  are on the perimeter of the room and abut, for instance, wall  71  on one side and wall  72  on the other side, the whole structure can be “free floating” in the sense that it is not attached to the floor. Hook tape  74  can be installed at the perimeter. Suspended tape  76  at the seams provides a form of perimeter and seam installation over top of a conventional cushion or a partial anchor sheet and conventional cushion. The carpet or other decorative surface covering has loops on its undersurface at  80  (not shown) for detachable attachment to hooks  81  on pieces  74  and  76 . 
     FIG. 10 shows a form of hook tape that can be used to create a perimeter for the installation of a conventional underpad  87 . This tape has a foundation layer  8  to which is attached the tape  84  having a resilient cushion layer  86 . The tape is hook tape and contains across its surface resilient hooks  88 . It normally would be supplied with a tape covering  90 . The foundation sheet  82  allows for a lip or area so that the hook tape may be stapled or nailed through the sheet  82  or through tape  84  to the floor or it ran be installed using double-sided adhesive tape  92  or by hook and loop or by a conventional method. 
     Another form of tape  94  is also shown having foundation sheets  96  and  98  on both sides of the tape. The tape could be stapled to a floor and within the framework bounded by the tape could be inserted an appropriate underpad which could either be installed in a conventional manner or free floating between the tape gad an overlying anchor sheet or an anchor sheet having hooked covering (not shown) could also be installed within the area bounded by the tape. 
     In FIG. 11 is shown a cross-section of hooked tape  100  having cushion  102  attached to the floor. 
     If the tape is as shown in FIG. 10 it could have foundation sheet  82  for installation. Anchor sheet  104  with (as shown) or without an attached resilient cushion can then be inserted within the area bounded by hooked tape  100  and a decorative covering  106  having an undersurface covered in loops  107  could be installed across the area created by the hooked tape and anchor sheet. 
     FIG. 12 shows an arrangement in which an anchor sheet  108  is provided with hooks at least over the exposed area  110  shown and also under carpet pieces  112  and border pieces  114 ,  116  and  118 . Border pieces  114 ,  116  and  118  may be detachably attached to anchor sheet  108  in a pattern anchor sheet and  108  with such pieces could be sold as a preassembled unit. Such piece could be attached to a floor by pressure sensitive adhesive, with hook and loop or by nailing through sheet  108 . Carpet  112  having a loop backing and a pile surface  120  could then be installed and attached to hooks on anchor sheet  110 . 
     FIG. 13 shows another arrangement, in which anchor sheet  122 , has a resilient cushion  124  and a carpet covering piece  126  detachably attached to the anchor sheet. A conventional cushion  128  can abut the anchor sheet and cushion and a carpet  130  having a loop backing  132  can be installed over the anchor sheet  122  and cushion  128 . 
     It will be recognized that within the description of this present case and the related earlier pending cases many variations and permutations and combinations are possible of anchor sheet and tape with or without cushion and with or without installation directly to the floor all of which come within the spirit of the described invention as defined in the attached claims.