Abstract:
This invention relates to methods for manufacturing plates bonded to resilient layers, wherein the plate is made of a polypropylene and the resilient layer is made of a polyethylene. Ultrasonic welding used to bond the resilient layer to the plate. In some embodiments, a thin film is applied to a layer of the resilient layer before ultrasonic welding. While the film layer may be located adjacent the plate when welding, the film layer may also be advantageously located on the opposite of the resilient layer from the plate when welding. The film may also be applied to both sides of the resilient layer.
Abstract:
A method and apparatus for connecting anchor sheets to each other and/or to a floor is described. The approach involves using attachment pieces which fit into an area of reduced thickness of the anchor sheet which surround a cut away of the anchor sheet. In one embodiment, the attachment pieces are corner pieces which overlap areas of reduced thickness on a number of anchor sheets.
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 with other anchor sheets a free floating smooth subfloor on which can be overlaid decorative covering pieces. A method for installing the modular framework includes placing a jig of a pre-determined size in a location to be covered, locating covering modules in an interlocking relationship around the perimeter of the jig, removing the jig, and installing a decorative covering in the space formely occupied by the jig.
Abstract:
A covering module for installation on a subsurface and for attachment to additional modules to form a finished decorative surface is provided. The covering module comprises a decorative covering that is detachably or permanently attached to an anchor sheet. The covering module is configured so as to expose a joining region of the decorative covering and a joining region of the anchor sheet.
Abstract:
Attachment devices are described for attaching and locating overlapped anchor sheets while allowing for some relative movement as to expansion and contraction. Generally, the devices are a male/female connection on corresponding sheets and expansion openings or apertures surrounding either the male or female part to provide for areas of flexibility to provide for possible movement of either the male or female part.
Abstract:
A relatively thin flexible anchor sheet (21, 31) for installation under carpets or other decorative coverings and a covering module (19, 21) composed of a pre-attached decorative covering (19) and anchor sheet (21) which can be assembled by overlapping hook and loop attachment to an additional covering module (31, 29) to create a complete floor covering of carpet, tile, stone or other material and without attachment to a floor. Also a temporary hook covering (27) to prevent premature attachment of the hook and loop attachment is disclosed.
Abstract:
A method for installing a first surface covering element onto a surface is provided. The element has one half of a hook and loop attachment system, and the surface has the other of the hook and loop attachment system. The method may include the steps of: (i) placing the first element onto the surface so that at least some of the respective hooks and loops of the first element and surface engage; and (ii) applying a force to the first element to encourage tensioning in the loops; and (iii) securing the first element into place.
Abstract:
A system and method for manufacturing a substrate having a bed of hooks located therein, in particular a system or manufacturing a hook plate having hooks with enlarged shaped heads. The system can include the use of a heated generally flat coining plate, a resilient layer placed under the hook plate, and a forming sheet placed between the coining plate and the tops of stems to be coined.
Abstract:
An improved anchor sheet is described. The anchor sheet can be injection molded from polypropylene and can have a thickness of between 0.031 inches and 0.75. Such an anchor sheet can be molded with hooks and can have an attached resilient layer. Stems integral with the anchor sheet are used to form the hooks, and may be lmm high and 0.55 mm in diameter. The density of stems may be approximately 230 per square inch, or approximately 128,000 stems on a plate. An anchor sheet made in this way makes an excellent field of hooks when installed onto a supporting surface such as a floor. This field of hooks can take an overlying decorative covering such as pieces of loop backed carpet. When a resilient layer is attached, for example by ultrasonic welding, to the underside of the anchor sheet, between the anchor sheet and the floor, the anchor sheet can have the right degree of "give", so that a user can experience some cushioning effect from the resilient layer below the anchor sheet, but with some level of rigidity so that the load of walking is transmitted across a larger surface and does not "dig" into the resilient layer.
Abstract:
A system and method for manufacturing a substrate having a bed of hooks located therein, in particular a system or manufacturing a hook plate having hooks with enlarged shaped heads. The system can include the use of a heated generally flat coining plate, a resilient layer placed under the hook plate, and a forming sheet placed between the coining plate and the tops of stems to be coined.