Patent Publication Number: US-2006003141-A1

Title: Floor covering having a removable decorative inlay

Description:
FIELD OF THE INVENTION  
      This invention relates to a covering for a floor, in which the covering has a removable decorative inlay. The decorative inlay has a looped underside for attachment to a field of hooks. The inlay itself is composed of a plurality of decorative pieces which are attached to a carrier sheet which is itself secured by a hook and loop attachment system to an underlying anchor sheet or other floor or floor covering containing a field of hooks. The decorative pieces may be attached to the carrier sheet by a hook and loop attachment system.  
     BACKGROUND OF THE INVENTION  
      Over the past several years, attempts have been made at incorporating hook and loop (e.g., Velcro (™)) technology into floor coverings, particularly carpeting. There are several advantages to the use of such technology. It is environmentally friendly, permitting connection of flooring components in situ without the use of glues that release volatile organics. Hook and loop technology provides a robust connection, but one that is at the same time releasable, presenting advantages during installation and permitting replacement of damaged pieces, etc.  
      An example of the use of hook and loop technology in the field of carpets is described in U.S. Pat. No. 4,822,658, which issued to Pacione on Apr. 14, 1989. The specification of this patent shows a carpet having loops across its underside for attachment along its edges by means of hooked strips secured to a floor to be covered by the carpet.  
      Hook and loop attachment systems, in respect of flooring, provide an opportunity for creation of carpet units from multiple pieces to create interesting designs.  
      More recently, use of anchor sheets to cover, more or less, an entire area to be carpeted has been described in U.S. Pat. No. 6,306,477, which issued to Pacione on Oct. 23, 2001. Such an anchor sheet is described in a more detailed way in international patent application No. PCT/CA 00/00681, that was published under WO 00/74544 on Dec. 14, 2000, and names Pacione as the inventor. Each of these cases describes a final carpet construction in which multiple carpet pieces are attached across the surface of an underlayment made up of multiple anchor sheets. The present invention relates to this sort of arrangement.  
     SUMMARY OF THE INVENTION  
      In accordance with one broad aspect of the invention there is provided a floor covering having: (i) a carrier sheet having a first and second side, the first side being substantially covered in loops for attachment to a field of hooks covering a floor; (ii) a decorative inlay attached to the second side of the carrier sheet, the decorative inlay having a visually distinct design; and (iii) at least one fill piece attached to the second side of the carrier sheet, to fill the remaining exposed surface of the second side around the decorative inlay.  
      According to an embodiment of the invention, the carrier sheet may be of a size and shape that, when placed onto the field of hooks with the decorative inlay and fill piece attached thereto, permits it to integrate with at least one decorative piece covering the remaining field of hooks, without the need for substantial cutting or trimming of the decorative piece.  
      Conveniently, the at least one fill piece may have an appearance that permits it to visually integrate with the at least one decorative piece when the carrier sheet is placed onto the field of hooks and the remaining field of hooks is covered by the at least one decorative piece.  
      According to another embodiment of the invention, the fill piece is at least one of the same colour, shape and material as the decorative piece.  
      According to a further embodiment of the invention, the carrier sheet is of a size and shape that, when placed onto the field of hooks, fits within an opening defined by at least one decorative piece covering the remaining field of hooks, without the need for substantial cutting or trimming of the decorative piece. The carrier sheet may be of a uniform geometric shape, including a rectangular shape. The decorative inlay may also be made of at least four distinct pieces.  
      According to an embodiment of the invention, the second side of the carrier sheet is substantially covered in hooks and the decorative inlay has a side substantially covered in loops for detachable attachment to the second side of the carrier sheet. Furthermore, the second side of the carrier sheet may be substantially covered in hooks and the at least one fill piece has a side substantially covered in loops for detachable attachment to the second side of the carrier sheet.  
      In an embodiment, the decorative inlay is made from at least one of the materials selected from the group consisting of wood, ceramic, stone, carpet, rubber, plastic, vinyl, linoleum and metal. Furthermore, at least one fill piece may be made from at least one of the materials selected from the group consisting of wood, ceramic, stone, carpet, rubber, plastic, vinyl, linoleum and metal.  
      According to a yet further embodiment of the invention, the carrier sheet, having the decorative inlay and at least one fill piece attached thereto, may be of a size and shape that it fits within an exposed area of the field of hooks revealed by the removal of at least one decorative piece covering the field of hooks without the need to cut or trim any remaining decorative piece that covers the field of hooks. The carrier sheet, having the decorative inlay and at least one fill piece attached thereto, may be of a size and shape that it does not require cutting or trimming to fit within an exposed area of the field of hooks revealed by the removal of at least one decorative piece covering the field of hooks.  
      According to an embodiment of the invention, the carrier sheet has a thickness of from 0.1 mm to 2 mm (not including the hooks or loops thereof).  
      According to another aspect of the invention, there is provided: (i) a carrier sheet having a first and second side, the first side being substantially covered in loops for attachment to a field of hooks covering a floor; (ii) a decorative inlay attached to the second side of the carrier sheet, the decorative inlay having a visually distinct design; and (iii) at least one fill piece attached to the second side of the carrier sheet, to fill some but not all of the remaining exposed surface of the second side around the decorative inlay. Furthermore, at least one fill piece may be of a size and shape that, when the carrier sheet is placed onto the field of hooks, permits it to integrate with at least one decorative piece covering the remaining exposed surface of the carrier sheet, without the need for substantial trimming of the decorative piece.  
      According to a yet further aspect of the invention, there is provided: (i) a rectangular carrier sheet having a first and second side, the first side being substantially covered in loops for attachment to a field of hooks covering a floor, and the second side being substantially covered in hooks; (ii) a decorative inlay made of at least four pieces of carpet and covered in loops on one side attached to the second side of the carrier sheet, the decorative inlay having a visually distinct design; and (iii) at least one fill piece made of carpet attached to the second side of the carrier sheet, to fill the remaining exposed surface of the second side around the decorative inlay; and (iv) wherein the carrier sheet, having the decorative inlay and fill piece pre-assembled thereto, when placed onto the field of hooks, integrates with decorative carpet pieces covering the remaining field of hooks, without the need for substantial trimming of the decorative pieces.  
      According to another broad aspect of the invention, there is provided a method of creating a floor covering as follows:  
      (i) laying a field of hooks on a floor;  
      (ii) assembling at least one decorative inlay having a non-decorative side substantially covered in loops onto a hooked surface of a carrier sheet;  
      (iii) filling in the remaining exposed surface of the second side of the carrier sheet around the decorative inlay with at least one fill piece attached to the second side of the carrier sheet;  
      (iii) detachably attaching a looped surface of the carrier sheet onto the field of hooks; and  
      (iv) attaching at least one decorative piece having a bottom side substantially covered in loops onto the field of hooks surrounding the carrier sheet, the at least one fill piece and decorative piece together creating an integrated field or background for the decorative inlay without the need to trim the decorative piece.  
      According to another broad aspect of the invention, there is provided a method of creating a floor covering as follows:  
      (i) laying a field of hooks on a floor;  
      (ii) attaching at least one decorative piece having a bottom side substantially covered in loops onto the field of hooks to define an area of uncovered hooks;  
      (iii) assembling at least one decorative inlay having a non-decorative side substantially covered in loops onto a hooked surface of a carrier sheet, the carrier sheet being substantially similar in size and shape to the area of uncovered hooks;  
      (iv) filling in the remaining exposed surface of the second side of the carrier sheet around the decorative inlay with at least one fill piece attached to the second side of the carrier sheet; and  
      (v) detachably attaching the carrier sheet onto the area of uncovered hooks, the at least one fill piece and decorative piece together creating a field or background for the decorative inlay.  
      In one preferred embodiment, the first set of decorative pieces are carpet pieces, and the second set of decorative pieces are also carpet pieces. The first set in additional aspects of the invention, usually comprises groupings of carpet pieces, often in intricate patterns, to create coats of arms, pictures, ornamental medallions, and any other intricate and complicated form of design.  
      In a preferred embodiment, the invention is suited for complicated designs which can be pre-installed on a carrier sheet in a factory or other location, transported to a site to be installed as a design element into a field of hooks at a flooring site.  
      In other aspects of the invention, the design could be carpet, ceramic, stone, metal, wood, or other suitable material, which can be installed onto the carrier sheet using a hook and loop attachment system or permanently installed on, or bonded to, the carrier sheet so that such a design can be inset into a larger field of carpet or other material that has been installed on the field of hooks.  
      In another aspect of the invention, the pieces (for instance carpet) installed on the carrier sheet, can be the same height as the pieces in the surrounding “fill” and are installed directly onto the field of hooks. In this way, the decorative inlay will be very slightly raised above the surface of the surrounding carpet materials.  
      In another aspect of the invention, the inlay can be of a thinner or thicker or the same material than the surrounding “fill”, thereby creating other design possibilities.  
      Related to the invention(s) disclosed herein are invention(s) in the following U.S. provisional patent applications: 
      U.S. Provisional Patent Application 60/443,576 entitled “Carpet tile, installation, and methods of manufacture and installation thereof”, filed Jan. 30, 2003 and incorporated herein by reference;     U.S. Provisional Patent Application 60/443,561 entitled “System and methods of manufacturing hook-plates”, and filed Jan. 30, 2003 and incorporated herein by reference;     U.S. Provisional Patent Application 60/443,564 entitled “Improved anchor sheet”, and filed Jan. 30, 2003 and incorporated herein by reference;     U.S. Provisional Patent Application 60/443,565 entitled “Ultrasonic welding of resilient layers to plates”, and filed Jan. 30, 2003; and     U.S. Provisional Patent Application 60/443,563 entitled “Anchor sheet positioning and connection system”, and filed Jan. 30, 2003.   

    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
      Particular embodiments of the invention are described below with reference to the accompanying drawings, in which:  
       FIG. 1  shows a prior art floor tile that includes multiple carpet pieces attached to a carrier sheet;  
       FIG. 2  shows an installation of a decorative inlay of the present invention attached to a field of hooks created by an anchor sheet subfloor;  
       FIG. 3  shows an installation in which the decorative inlay of  FIG. 2  has carpet pieces as surrounding “fill” attached to the carrier sheet;  
       FIG. 3A  shows an installation in which the carrier sheet is larger than the decorative inlay and “fill” carpet pieces;  
       FIG. 4  shows a cross-section of the installation of  FIG. 3  taken along line  4 - 4  of  FIG. 3 ;  
       FIG. 5  is a sectional type view of a preferred carpet construction for use with the present invention;  
       FIG. 6  is a sectional type view of a preferred carrier sheet for use with the present invention;  
       FIG. 7  is a sectional type view of a preferred anchor sheet for use with a carrier sheet. 
    
    
     DETAILED DESCRIPTION OF EMBODIMENTS OF THE INVENTION  
      Turning to the drawings,  FIG. 1  shows prior art carpet tiles  10 ,  12 . This drawing is based on FIG. 29 contained in the specification of U.S. Pat. No. 6,298,624, which issued on Oct. 9, 2001 and FIG. 1 of Patent Co-operation Treaty Application No. PCT/CA2004/000123 which was filed Jan. 29, 2004, both by the inventor named herein, and both are incorporated herein by reference. Each tile includes multiple carpet pieces  14 ,  16 ,  18  which are assembled onto carrier sheet  20 , having loops  22  on its underside, to create a unit for installation onto piece  24 . This creates a module as shown in  FIG. 1B , that can be used and installed in an overlapping fashion with other modules as shown in the &#39;624 Patent.  
      One aspect of the present invention is shown in  FIGS. 2, 3 , and  4 . A carpet installation  26  is shown. It includes a decorative inlay  28  in one preferred embodiment carpet installation. The inlay is made up of carpet pieces  30  attached to a carrier sheet  32 . The decorative inlay  28  is formed from one or more carpet pieces  30  and carrier sheet  32  is attached to a field of hooks  33  created by anchor sheets  36 . In the figures, the hooks are generally shown as larger than they would be in an actual installation. Also, for illustrative purposes, fewer hooks are shown than would actually be used.  
      One or more carpet pieces  35  provide a “fill” or background to the decorative inlay  28  and are also installed onto the hooks of carrier sheet  32  that are not covered by decorative inlay  28 . One or more carpet pieces  34  are used to cover the remainder of the floor area around carrier sheet  32  and are installed directly onto the hooks of anchor sheets  36 . Carrier sheet  32  is preferably relatively thin in relation to the thickness of carpet pieces  30 ,  34  and  35 . For example, carrier sheet  32  preferably has a thickness that falls in the range from 0.1 mm to 2 mm, not including the hooks or loops thereof Carpet pieces  35  are typically in the range of thickness from about 3/16 of an inch to 2 inches, but could conceivably be thicker or thinner.  
      Carrier sheet  32  is preferably rectangular in shape. Carpet pieces  35  are positioned, and cut, if necessary, to fill the area of carrier sheet  32  that is not covered by decorative inlay  28  (for illustrative purposes, not all pieces  34  and  35  are shown installed in  FIG. 3 ). If decorative inlay  28  substantially covers carrier sheet  32 , then carpet pieces  35  are not required. Carrier sheet  32  may then be placed on a field of hooks provided by anchor sheets  36 . The remaining exposed hooks of anchor sheets  36  may be covered by carpet pieces  34 . Since carrier sheet  32  is preferably rectangular, rectangular carpet pieces  34  may be positioned adjacent carpet pieces  35 , without the need to cut or trim carpet pieces  34  to fit. While carrier sheet  32  is shown in  FIG. 2  aligned with edges of anchor sheets  36 , carrier sheet  32  may be placed anywhere on the field of hooks created by anchor sheets  36 .  
      Alternatively, carpet pieces  34  may be placed onto anchor sheets  36  and positioned to leave an exposed area of anchor sheets  36  for placement of carrier sheet  32 . In the present embodiment, carpet pieces  34  are rectangular and may be positioned to define a rectangular exposed area without the need to cut or trim the carpet pieces  34  bounding the exposed area. Carrier sheet  32  may then be placed onto the exposed anchor sheets  36  to substantially fill the exposed area.  
      While carpet pieces  34  are typically rectangular, they may have some other shape such as triangular (not shown). A single piece of carpet  34  having an opening or rebate formed therein may also be used. If triangular carpet pieces  34  are used, then various non-rectangular exposed areas may be defined (e.g., hexagonal), without the need to cut or trim carpet pieces  34 . If triangular carpet pieces  34  are used, then carrier sheet  32  is preferably the same shape as the area exposed, e.g., hexagonal. Carpet pieces  35  are trimmed accordingly to fit the shape of carrier sheet  32  and decorative inlay  28 . Alternatively, if carpet pieces  35  are a complementary size and shape to carpet pieces  34 , then carpet pieces  35  will usually only need to be trimmed to lie adjacent decorative inlay  28 . For example, if carpet pieces  35  are triangular, then they may be positioned to match the hexagonal boundary of the carrier sheet  32 , without the need to trim them at the boundary.  
      Carrier sheets  32  having decorative inlays  28  and “fill in” or “fill” carpet pieces  35  may conveniently be cut and pre-assembled at a central location, such as a factory, and then installed as a single unit where a floor covering is being installed. This can reduce the amount of cutting and trimming required at the job site to install the decorative inlay because the shape of the carrier sheet  32  is configured to match the area exposed by carpet pieces  34 . (As noted, the carrier sheet may alternatively be installed first with the remainder of the floor being filled in by carpet pieces  34  afterward.) As a result, there may be a reduced need for specialized cutting equipment and skilled installers at the installation site.  
      In an alternative embodiment, shown in  FIG. 3A , the carrier sheet may be bigger than the combined decorative inlay  28  and carpet pieces  35  (for illustrative purposes, not all pieces  34  and  35  are shown installed in  FIG. 3A ). In this embodiment, decorative inlay  28  and carpet pieces  35  are arranged in a similar manner to that described above. As before, the carrier sheet is placed onto the field hooks provided by anchor sheets  36 . Carpet pieces  34  are then placed onto the remaining exposed area of carrier sheet  32  adjacent carpet pieces  35  and the remainder of the exposed hooks  33  of anchor sheets  36  (carpet pieces  34  may alternatively be placed onto the anchor sheets  36  and then on to the exposed carrier sheet  32 ). If the carrier sheet is installed in this manner, then the particular shape of the carrier sheet is less important, as long as carpet pieces  35  are assembled to permit the installation of carpet pieces  34  in the manner described above. Due to the thickness of carrier sheet  32 , this embodiment may not be as visually pleasing as other embodiments. This is because it might be noticeable that carpet pieces  34  are not at a uniform level in the area adjacent the edge of carrier sheet  32 .  
      Anchor sheets  36  may initially be installed with carpet pieces  34  or other decorative covering attached to substantially the entire field of hooks provided by anchor sheets  36 . One or more carpet pieces  34  may be subsequently removed to reveal hooks  33  of the anchor sheets. This may be done to permit the addition of a decorative feature or inlay in place of the removed covering. Carrier sheet  32  may be cut or trimmed or otherwise configured to have a size and shape that corresponds to the exposed area of the field of hooks revealed by the removal of carpet piece  34 . This reduces or eliminates the need to cut or trim any of the remaining decorative piece or pieces  34  that cover the field of hooks. With decorative inlay  28  and at least one fill piece  35  attached to carrier sheet  32 , the exposed area may be conveniently covered by placing similarly shaped carrier sheet  32  thereon. If carpet pieces  34  are geometrically shaped, then the removal thereof will reveal a geometrically shaped exposed area of anchor sheet hooks  33 . Carrier sheet  32  is accordingly configured to a similar same size and shape as the exposed area to permit convenient placement therein. As a result, attached decorative inlay  28  and fill pieces  35 , which together substantially cover a surface of carrier sheet  32 , may replace the removed carpet piece or pieces  34 .  
      Accordingly, in at least one embodiment, the design or decorative inlay  28  (with the fill pieces  35 , if needed) when combined with carrier sheet  32  conveniently fits into the regular geometric shape created from the regular geometric patterns of the carpet tiles  34 .  
      In many embodiments carpet pieces  30 ,  34  and  35  can be made to have the same construction as each other, or of a different construction from each other. For example, if carpet pieces  30 ,  34 , and  35  have the same thicknesses and weight, and carpet pieces  34  and  35  are the same color and shape, then decorative inlay  28  may appear to be an integral part of the overall carpet, and carpet pieces  34  and  35  may appear to be somewhat visually indistinguishable. Because carrier sheet  32  is of a relatively low profile in relation to the thickness of the carpet, the decorative inlay  28  and carpet  35  will only be very slightly raised above the surrounding carpet  34 . This possible height differential preferably is not sufficient to create an impediment to walking.  
      In an alternative embodiment, carpet piece  34  can be made to have a different thickness than carpet pieces  30  and  35 . For example, carpet pieces  34  may be made to have a greater thickness than carpet pieces  30  and  35 . The increased thickness of carpet pieces  34  may be made to correspond to the thickness of carrier sheet  32 . This may be done to accommodate for the thickness added by carrier sheet  32  so that the decorative inlay  30  is at the same height as the “field” created by carpet pieces  34  and  35 . Alternatively, two or more of carpet pieces  30 ,  34 , and  35  may have different thicknesses, shapes and/or colours to create various visual effects, such as making decorative inlay  28  appear sunken or raised in relation to carpet pieces  34  and  35 .  
      In a further alternative embodiment, one or more of carpet pieces  30 ,  34 , and  35  can be made of some other suitable material, such as stone, ceramic, marble, or even metal. In a preferred form, the pieces are provided with a loop backing and the carrier sheet has a top side covered in hooks.  
      Further alternatively, the decorative pieces can be permanently attached to the carrier sheet. Since the carrier sheet will have loops on the back for detachable attachment to the underlying field of hooks, the permanent attachment of pieces  30  and/or  35  to carrier sheet  32  is not of concern, as presumably the decorative inlay operates as a stand alone separate unit that can be moved, transported and reinserted in another background or field as desired.  
      In a preferred embodiment, the carpet, for example carpet  30 , is constructed in accordance with the carpet construction shown in the above-detailed application entitled “Carpet Tile, Installation, and Methods of Manufacture.” As shown in  FIG. 5 , typically, such carpet is a laminate made up of an upper first layer  40  and a lower second layer  42 . The first layer  40  of the carpet includes a nonwoven primary backing  44  into which is needle pile yarn  46 . Second layer  42  includes secondary backing  48  to which are attached lower loops  50 . The layers are secured to each other by hot melt adhesive  52 .  
      Again, typically the primary backing  44  is a nonwoven fabric. Pile yarn  46  is tufted into primary backing  44 .  
      One preferred secondary layer  42  is a tricot knit, supplied by Guilford Mills, Inc. of Greensboro, N.C. Typically, such a tricot knit forms a dense substrate which provides for loops  50  on the underside of the secondary backing  48 , which tricot precludes most, if not all, bleeding of hot melt  52  into the loops. Excessive bleeding, of course, is to be avoided as this could interfere with the function of the loops as fasteners.  
      First and second layers  40 ,  42  are attached to each other by hot melt layer  52  which also encapsulates tufts  53 . One particular adhesive used is an ethylene-vinyl acetate-based adhesive known as XP-025 provided by Barrier-Bac, Inc. of Calhoun, Ga. The adhesive is substantially free of filler, organic and inorganic. The overall weight of the carpet of the present invention is approximately 80-100 oz per square yard. It will thus be appreciated that it is possible, according to the invention, to have a carpet, and carpet tile, with a relatively lightweight secondary backing. Such a backing lacks a stabilizing layer and, as is explained below, is relatively free of filler. Such a carpet or carpet tile has little or no inherent dimensional stability of its own in relation to externally applied physical forces, such as stretching forces, forces exerted in use by rolling machinery, furniture movement, etc.  
      The carpet laminate can eventually be cut into tiles at some convenient point. This enables a decorative inlay to be created from numerous carpet pieces. Such pieces installed on a carrier sheet in a factory or other location, can have a complicated pattern, but, as they exist as a self-contained unit on the carrier sheet, can be transported to a site, and installed separately. They can also be removed when a change is desired.  
      With the carpet described above, combined with a field of hooks, it is possible to make a carpet tile of any shape and size to order. Even small carpet tiles, e.g., 2″×2″ can be easily incorporated into carpet installation. The carpet laminate can be cut through the back or the front by, for example, an ultrasonic cutting cutter on a plotting table. The cutter can be controlled by software to make any form of pattern or design.  
      Carrier sheet  32  is illustrated separately in  FIG. 6 . Carrier sheet may include upper layer  54  and lower layer  56 . Upper layer  54 , manufactured of polypropylene, includes base sheet  58  and hooks  60  across the upper side of the sheet. The whole carrier sheet is designed to carry individual pieces of carpet to form a decorative inlay surrounded by fill carpet  35  to permit convenient integration of the decorative inlay and carpet  34  of a carpet installation. Generally speaking, it is desired to have the profile of carrier sheet  32  to be as thin as possible, so as not to raise the decorative inlay and fill carpet  35  above the surrounding carpet  34 , other than, perhaps, a small amount without impairing the ability of a person or persons to walk over the decorative inlay  28  and carpet  35 .  
      One particular carrier sheet of the invention includes two extruded sheets of polypropylene, which are secured together by a hot melt, typically EVA hot melt. Other materials may be used for the carrier sheet including other plastics or polymers. The thickness of each two extruded sheets (not taking into account hooks and loops) is about 0.3 mm, and the bonding layer is about 0.1 mm. There are alternatives to these sheets commercially available, and, as mentioned, the carrier sheet may be as thin as 0.1 mm. Thicker carrier sheets may be used, but will likely be more noticeable when installed by raising the level of any attached pieces (e.g., carpet or decorative inlay). This may be desirable in some installations. Lower layer  56  of the carrier sheet provides the carrier sheet with loops  62  across the underside of the sheet. Layer  56  can have the same tricot construction of second layer  42  of carpet  36  described above. Layers  54  and  56  are secured to each other by EVA hot melt  64 .  
      Anchor sheet  36  is illustrated separately in  FIG. 7 . The preferred embodiment is manufactured in accordance with the description provided in the above-detailed applications entitled “System and methods of Manufacturing hook-plates” and “Improved anchor sheet”. The thickness of anchor sheet A is about ⅛ inches, and the thickness of the anchor sheet at  66  is about 1/16 inches. The corner of the anchor sheet includes a counter sunk area attachment, for attaching, if desired, to other anchor sheets, or to an underlying floor, as described in WO 0/74544 published Dec. 14, 2000. The anchor sheet  36  includes a cushion  68  of thickness that can be either approximately ¼ inches, or ⅜ inches depending on the desired resiliency and the amount of surface traffic. The hooks  72  of the top surface layer  70  will have a density that may range from 160-1200 hooks/square inch, with a preferred density of approximately 230 hooks/square inch.  
      The preferred material for the top surface layer  70  is polypropylene and the cushion  68  is polyethylene. In a preferred embodiment, the cushion  68  is made from linear load density polyethylene with a density of approximately 30 kg/m 3 .  
      With the floor covering having a decorative inlay formed by an additional carrier sheet, complicated decorative inlays can be pre-made and installed into a surrounding field or background.  
      Such decorative inlays can be moved or replaced to change the look of a floor immediately and inserted and removed to provide features such as a family crest, cartoon character, team crest, or any other preferred design. Decorative inlays can easily be sold as a unit for insertion into a surrounding field of hooks and can appeal to particular categories of consumers, children, sports fans, music lovers, or virtually any category where a specific design can be incorporated into a carpet or other decorative inlay as desired.  
      The invention disclosed in this preferred embodiment is just one aspect of the invention which is intended to be defined by the claims which follow.