Systems and Methods for Modular Floor Installation

Abstract

Connectors for joining adjacent modular floor covering units. The connectors include a base or film and one or more attachment members. As an exemplary use of a connector to install tiles, a first tile is placed on the floor and a connector is positioned so that an attachment member faces upward and attaches to the first tile. One or more other tiles are then positioned adjacent the first tile so that the same or other attachment members of the connector attach to the adjacent tiles. In certain embodiments, an attachment member comprises projections that form a mechanical connection with the undersides of the tiles. For example, a connector may comprise a plastic unit with raised ridges that interact with corresponding indentations on the undersides of the tiles. A connector can also or alternatively form a connection with tiles and/or the underlying floor surface by having a high coefficient of friction.

1 . A connector for joining floor covering tiles, the connector comprising:
 a base; and   an attachment structure on the base, the attachment structure comprising one or more projections,   wherein, when the connector is positioned on an underlying surface with the attachment structure of the connector facing upwards, the attachment structure forms mechanical connections with undersides of two or more of the floor covering tiles to prevent relative movement of the two or more floor covering tiles when subjected to ordinary foot traffic, rolling traffic, and stresses applied during cleaning and maintenance.   
     
     
         2 . The connector of  claim 1  wherein the one or more projections each have a relatively sharp point for interacting with the undersides of the two or more floor covering tiles. 
     
     
         3 . The connector of  claim 2  wherein the one or more projections further comprise smaller, downward projecting points that further secure the two or more floor covering tiles by resisting vertical displacement. 
     
     
         4 . The connector of  claim 1  wherein the one or more projections of the connector comprise raised ridges that are received in corresponding indentations on the undersides of the two or more floor covering tiles. 
     
     
         5 . The connector of  claim 1  wherein the connector is configured to span adjacent edges of at least some of the two or more floor covering tiles without abutting other similar connectors. 
     
     
         6 . The connector of  claim 1  wherein the base is relatively stiff so that a connector positioned partly in contact with an underside of a floor covering tile will project beyond an edge of the floor covering tile in roughly the same plane as the underside of the floor covering tile without significantly curl or droop down from the underside of the tile. 
     
     
         7 . The connector of  claim 1  wherein a bottom surface of the connector opposite the attachment structure is adapted such that when the connector is positioned on the underlying surface the connectors does not adhere to or form a connection with the underlying surface. 
     
     
         8 . A connector for joining floor covering tiles, the connector comprising:
 a base; and   an attachment structure on the base, the attachment structure having a high coefficient of friction,   wherein, when the connector is positioned on an underlying surface with the attachment structure of the connector facing upwards, friction between the connector and the undersides of the two or more floor covering tiles sufficient to prevent relative movement of the two or more floor covering tiles when subjected to ordinary foot traffic, rolling traffic, and stresses applied during cleaning and maintenance.   
     
     
         9 . The connector of  claim 8  wherein a bottom surface of the connector opposite the attachment structure also has a high coefficient of friction. 
     
     
         10 . The connector of  claim 8  wherein the connector is a part of a sheet configured for use underlying floor covering tiles, wherein the sheet comprises a layer that is a barrier to moisture. 
     
     
         11 . An installation of floor covering tiles, the installation comprising:
 floor covering tiles positioned adjacent to one another above a floor; and   one or more connectors connecting the floor covering tiles to one another, each connector comprising a base and an attachment structure on the base;   wherein the one or more connectors are positioned above the floor, wherein an attachment structure of each connector faces upwards and forms a mechanical connection with undersides of two or more of the floor covering tiles, preventing relative movement of the two or more floor covering tiles when subjected to ordinary foot traffic, rolling traffic, and stresses applied during cleaning and maintenance.   
     
     
         12 . The installation of floor covering tiles of  claim 11  wherein:
 the attachment structure comprises one or more projections;   the undersides of the two or more floor covering tiles are relatively soft; and   each of the one or more projections has a sharp edge for impressing into the undersides of the two or more floor covering tiles to form a connection.   
     
     
         13 . The installation of floor covering tiles of  claim 11  wherein the one or more connectors are one or more sheets providing at least some areas having a high coefficient of friction. 
     
     
         14 . The installation of floor coverings of  claim 13  wherein undersides of the sheets comprise a high coefficient of friction preventing movement of the sheet with respect to the floor. 
     
     
         15 . The installation of floor covering tiles of  claim 13  wherein the one or more sheets are positioned to at least partially overlap one another on the floor and provide a moisture barrier or cushion pad over the entire floor. 
     
     
         16 . The installation of floor covering tiles of  claim 11  wherein:
 each floor covering tile comprises a surface area and each connector comprises a surface area, wherein the surface area of a connector is no more than approximately 5% of the surface area of a floor covering tile; and   adjacent edges formed by adjacent floor covering tiles in the installation comprise a total length and wherein the connectors in the floor covering installation span up to approximately 10% of the total length of the adjacent floor covering tiles.   
     
     
         17 . The installation of floor covering tiles of  claim 11  wherein the film has a thickness between approximately 0.0005 and 0.015 inches, inclusive and the film comprises a material selected from the group consisting of: polyolefin, a polyamide, a polyester, and a polyethylene terephthalate polyester. 
     
     
         18 . The installation of floor covering tiles of  claim 11  wherein the film has a tensile strength between 165 and 210 MPa in at least one direction and between 160 and 270 MPa in at least one other direction. 
     
     
         19 . An installation of floor covering tiles, the installation comprising:
 floor covering tiles positioned adjacent to one another above a floor; and   one or more connectors between the floor covering tiles and the floor connecting the floor covering tiles to one another, each connector comprising a base and an attachment structure comprising a raised boundary between two or more of the floor covering tiles and projecting to a height sufficient to prevent relative movement of the two or more floor covering tiles when subjected to ordinary foot traffic, rolling traffic, and stresses applied during cleaning and maintenance.   
     
     
         20 . The installation of floor covering tiles of  claim 19  wherein the floor covering tiles are carpet tiles each having a backing and tufts tufted into the backing forming a carpet surface above the floor, wherein the raised boundary does not project higher than the backing of the carpet tiles. 
     
     
         21 . The installation of floor covering tiles of  claim 19  wherein the raised boundary is sufficiently narrow that any separation between adjacent tiles is unnoticeable to a casual observer viewing the installation from above. 
     
     
         22 . A floor covering installation comprising:
 a plurality of cushion modules, each having an underside, a topside, and edges, that are positioned on a flooring surface; and   connectors positioned to span adjacent edges of at least some of the adjacent cushion modules to secure the modules to one another, wherein the connectors are positioned to adhere to or form a mechanical connection with adjacent cushion modules, wherein each connector comprises a base that is relatively stiff so that a connector positioned partly in contact with a side of a cushion module will project beyond an edge of the cushion module in roughly the same plane as the side of the cushion module without significantly curl or droop down.