Flooring system and methods

Abstract

A flooring system for use in a residential environment. The flooring system includes a subfloor adapted to support the mass of a user and modular surface covering elements for disposition in edge to edge covering arrangement across at least a portion of the subfloor. The modular surface covering elements include a pile fabric face with an arrangement of yarns projecting outwardly defining a pile layer for contact by a user. At least one layer of cushioning material is disposed in contacting relation at a position below the pile fabric face.

1 . A flooring system for use in a residential environment comprising: 
 a plurality of modular surface covering elements including a plurality of edges, wherein the modular surface covering elements are configured for disposition in edge to edge covering arrangement across at least a portion of a subfloor, the modular surface covering elements comprising a pile fabric face including a primary base and a plurality of yarns projecting outwardly from the primary base defining a pile layer for contact by a user, the modular surface covering elements further comprising at least one layer of cushioning material secured in substantially fixed positional relation relative to the pile fabric face at a position below the pile fabric face and wherein the pile layer has a standard pile density in the range of about 500 to about 4,200 ounces per cubic yard and wherein the plurality of yarns projecting outwardly from the primary base have an average extended length above the primary base in the range of about 0.25 to about 1 inch, wherein each of the modular surface covering elements in the flooring system are of substantially identical geometry and have a first edge including two outwardly projecting chevrons, a second edge in opposing relation to the first edge including two inwardly projecting chevrons in substantial alignment with the outwardly projecting chevrons on the first edge, and two substantially straight lateral edges extending between the first edge and the second edge such that the inwardly projecting chevrons of any one of the modular surface covering elements in the flooring system are mateable in interlocking relation in one configuration of the modular surface covering elements with both of the outwardly projecting chevrons of an abutting modular surface covering element in the flooring system and in another configuration of the modular surface covering elements with one of the outwardly projecting chevrons of an abutting modular surface covering element in the flooring system.    
   
   
       2 . The invention as recited in  claim 1 , wherein at least one of said modular surface covering elements has a friction enhancing coating on the bottom thereof.  
   
   
       3 . The invention as recited in  claim 1 , wherein said layer of cushioning material includes at least one layer of rebond foam.  
   
   
       4 . The invention as recited in  claim 1 , wherein said layer of cushioning material includes at least one layer of virgin, filled, polyurethane foam.  
   
   
       5 . A flooring system for use in a residential environment comprising: 
 a plurality of modular surface covering elements including a plurality of edges, wherein the modular surface covering elements are configured for disposition in edge to edge covering arrangement across at least a portion of a subfloor, the modular surface covering elements comprising a pile fabric face including a primary base and a plurality of yarns projecting outwardly from the primary base defining a pile layer for contact by a user, the modular surface covering elements further comprising at least one layer of cushioning material secured in substantially fixed positional relation relative to the pile fabric face at a position below the pile fabric face and wherein the pile layer has a standard pile density in the range of about 500 to about 4,200 ounces per cubic yard and wherein the plurality of yarns projecting outwardly from the primary base have an average extended length above the primary base in the range of about 0.25 to about 1 inch, wherein each of the modular surface covering elements in the flooring system are of substantially identical geometry and have a first edge having at least three outwardly projecting chevrons, a second edge in opposing relation to the first edge including at least three inwardly projecting chevrons each in substantial alignment with one of the outwardly projecting chevrons, and two substantially straight lateral edges extending between the first edge and the second edge such that the inwardly projecting chevrons of any one of the modular surface covering elements in the flooring system are mateable in interlocking relation in one configuration of the modular surface covering elements with all three of the outwardly projecting chevrons of an abutting modular surface covering element in the flooring system, and in another configuration of the modular surface covering elements with two of the outwardly projecting chevrons of one abutting modular surface covering element and with one of the outwardly projecting chevrons of a second abutting modular surface covering element in the flooring system.    
   
   
       6 . The invention as recited in  claim 5 , wherein at least one of said modular surface covering elements has a friction enhancing coating on the bottom thereof.  
   
   
       7 . The invention as recited in  claim 5 , wherein said layer of cushioning material includes at least one layer of rebond foam.  
   
   
       8 . The invention as recited in  claim 5 , wherein said layer of cushioning material includes at least one layer of virgin, filled, polyurethane foam.