Floor underlayment
An easy-to-install flooring underlayment 10 with improved tear resistance and tensile properties is disclosed. The flooring underlayment 10 has a first layer 12 and a second layer 14 with a plurality of cell-like openings 20. A plurality of the cell-like openings 20 have a surface opening or a cross-sectional area (A) of at least 2.5 mm2. Both the first and second layers 12, 14 may be made of polymeric materials, and the second layer 14 may be in contact with the first layer 12, connected to the first layer 12, integral with the first layer 12, or embedded in the first layer 12.
Not Applicable.
FEDERALLY SPONSORED RESEARCH OR DEVELOPMENTNot Applicable.
TECHNICAL FIELDThe invention relates generally to a floor underlayment, and more particularly to a floor underlayment that reduces tearing, has improved tensile properties and is easy to install.
BACKGROUND OF THE INVENTIONFloor underlayment systems are well known in the art. Floor underlayments are generally used to make the floor more resilient and slightly cushioned, to even out minor irregularities, and to dampen sound. While floor underlayment systems according to the prior art provide a number of advantageous features, they nevertheless have certain limitations. The present invention seeks to overcome certain of these limitations and other drawbacks of the prior art, and to provide new features not heretofore available.
SUMMARY OF THE INVENTIONThe present invention generally provides a flooring underlayment. One embodiment of the flooring underlayment comprises a first layer and a second layer. The first layer is generally a substrate having a first surface and a second surface. The second layer is generally a netting having a plurality of cell-like openings.
According to another embodiment, the first layer and the second layer may be formed of polymeric materials.
According to another embodiment, the second layer may be in contact with the first layer, connected to the first layer, integral with the first layer or embedded in the first layer.
According to another embodiment, cell-like openings of the second layer are arranged in a matrix.
According to yet another embodiment, a plurality of the cell-like openings have a surface opening or a cross-sectional area of at least 2.5 mm2.
Other features and advantages of the invention will be apparent from the following examples in the specification taken in conjunction with the following drawings.
BRIEF DESCRIPTION OF THE DRAWINGSTo understand the present invention, it will now be described by way of example, with reference to the accompanying drawings in which:
While this invention is susceptible of embodiments in many different forms, and will herein be described in detail, preferred embodiments of the invention are disclosed with the understanding that the present disclosure is to be considered as exemplifications of the principles of the invention and are not intended to limit the broad aspects of the invention to the embodiments illustrated.
Referring now in detail to the FIGS., and initially to
As shown in
In a preferred embodiment, both the first layer 12 and the second layer 14 are formed of polymeric materials. As explained above, the first layer 12 is typically made of a foam, as shown in
Further, in a preferred embodiment, the first layer 12 is an integral material. Further, in a most preferred embodiment, the first layer 12 is a homogeneous layer. As such, it has substantially common properties throughout, as opposed to certain recycled materials which are comprised of various heterogeneous materials composed of dissimilar elements.
As explained above, and shown in the FIGS., the netting of the second layer 14 of the underlayment 10 has a plurality of openings 20. In the examples shown in
While the size of the openings 20 can vary, in a preferred embodiment, a plurality of the openings 20 of the second layer 14 have a surface opening or a cross-sectional opening area A of at least 2.5 mm2, which corresponds to approximately a 1/16 inch square opening 20, but more preferably at least 10 mm2, which corresponds to approximately a ⅛ inch square opening 20, and most preferably at least 40 mm2, which corresponds to approximately a ¼ inch square opening 20, and moreover, the cross-sectional opening area A can be much larger than 40 mm2. For example, in the embodiment shown in
Similar to the first layer 12 being formed in various embodiments of a first polymeric material, the second layer 14 is formed of a second polymeric material in various embodiments. Such a polymeric material for the second layer 14 may include a rubber-based or a nylon-based polymer, high-density or low-density polyethylene, polystyrene, linear low density polyethylene, or any other suitable polymer or co-polymers of the above. If the second layer 14 is a rubber-based polymer, and the second layer 14 is on either the first surface 16 or the second surface 18 of the first layer 12, the flooring underlayment 10 may stay in place better due to the increased coefficient of friction provided by the rubber of the second layer 14. Further, the polymeric material for the second layer 14 may be a thermoplastic, which means that it becomes soft when heated and hard when cooled, such as polystyrene or polyethylene. In a preferred embodiment, the second layer 14 is made of a low density polyethylene netting. As explained in detail below, this allows the second layer 14 to be heat laminated to the first layer 12. Like the first layer 12, the second layer 14 can also be formed of non-polymeric materials.
The order of the first and second layers 12,14 is not important. In
In addition to being connected to the first layer 12, the second layer 14 can also be integral with or embedded within the first layer 12. For example,
As shown in
Thus, the flooring underlayment 10 of the present invention provides several benefits and features not heretofore available. For example, the flooring underlayment 10 of the present invention has improved tear-resistance and tensile properties, resulting in faster, easier and less expensive installation of the underlayment 10.
Several alternative embodiments and examples have been described and illustrated herein. A person of ordinary skilled in the art would appreciate the features of the individual embodiments, and the possible combinations and variations of the components. A person of ordinary skill in the art would further appreciate that any of the embodiments could be provided in any combination with the other embodiments disclosed herein. Additionally, the terms “first” and “second” as used herein are intended for illustrative purposes only and do not limit the embodiments in any way. Further, the term “plurality” as used herein indicates any number greater than one, either disjunctively or conjunctively, as necessary, up to an infinite number.
It will be understood that the invention may be embodied in other specific forms without departing from the spirit or central characteristics thereof. The present examples and embodiments, therefore, are to be considered in all respects as illustrative and not restrictive, and the invention is not to be limited to the details given herein.
Claims
1. A flooring underlayment comprising:
- a homogeneous first layer, and a second layer in contact with the homogeneous first layer, the second layer having a plurality of cell-like openings having a surface opening of at least 2.5 mm2.
2. The flooring underlayment of claim 1, wherein the second layer is a netting.
3. The flooring underlayment of claim 1, wherein the openings are positioned about a matrix about the second layer.
4. The flooring underlayment of claim 1, wherein the openings are positioned randomly about the second layer.
5. The flooring underlayment of claim 1, wherein the openings have a surface opening of at least 10 mm2.
6. The flooring underlayment of claim 1, wherein the second layer is fixedly connected to a surface of the first layer.
7. The flooring underlayment of claim 6, wherein the second layer is connected to the first layer by a heat lamination process.
8. The flooring underlayment of claim 6, wherein the second layer is connected to the first layer by an adhesive.
9. The flooring underlayment of claim 1, wherein the second layer is embedded within the first layer.
10. The flooring underlayment of claim 1, wherein a portion of the second layer extends past an edge of the first layer.
11. The flooring underlayment of claim 1, wherein the first layer is formed of a first polymeric material.
12. The flooring underlayment of claim 11, wherein the first polymeric material is polyethylene foam.
13. The flooring underlayment of claim 11, wherein the first polymeric material is low-density polyethylene foam.
14. The flooring underlayment of claim 11, wherein the second layer is formed of a second polymeric material.
15. The flooring underlayment of claim 11, wherein the second layer is formed of a rubber-based material.
16. The flooring underlayment of claim 11, wherein the second layer is formed of a nylon-based material.
17. The flooring underlayment of claim 14, wherein the second polymeric material is a thermoplastic.
18. A flooring underlayment comprising:
- a substantially integral first polymeric layer; and,
- a second polymeric layer connected to the first polymeric layer, the second polymeric layer comprising a plurality of cell-like openings, wherein a plurality of the cell-like openings have a cross-sectional area of at least 2.5 mm2.
19. The flooring underlayment of claim 18, wherein the second polymeric layer is made of a netting.
20. The flooring underlayment of claim 18, wherein an outermost edge of the second polymeric layer extends past an outermost edge of the first polymeric layer.
21. The flooring underlayment of claim 18, wherein the first polymeric layer is formed of a polyethylene foam.
22. The flooring underlayment of claim 21, wherein the second polymeric layer is made of polyethylene.
23. The flooring underlayment of claim 18, wherein the second polymeric layer is heat laminated to the first polymeric layer.
24. A flooring underlayment comprising:
- an integral first polymeric layer having a first surface and a second surface, and a netting connected to the second surface of the first polymeric layer.
25. The flooring underlayment of claim 24, the netting has a matrix of openings, and wherein a plurality of the openings have a cross-sectional area of at least 10 mm2.
26. The flooring underlayment of claim 25, wherein a plurality of the openings have a cross-sectional area of at least 40 mm2, and wherein the netting comprises a polymeric material.
27. The flooring underlayment of claim 24, wherein the first polymeric layer is formed of polyethylene foam.
28. The flooring underlayment of claim 27, wherein the netting is made of polyethylene.
29. A flooring underlayment comprising:
- a substantially integral first layer, and a second layer at least partially housed within the first layer, the second layer having a plurality of cell-like openings having a surface opening of at least 10 mm2.
30. The flooring underlayment of claim 28, wherein the first layer is formed of polyethylene foam.
31. The flooring underlayment of claim 28, wherein the second layer is embedded within the first layer.
Type: Application
Filed: Jul 30, 2004
Publication Date: Feb 16, 2006
Inventors: Raymond Vershum (Youngstown, OH), Sam Saladino (Woodbridge)
Application Number: 10/903,850
International Classification: E04B 7/00 (20060101); E04G 23/00 (20060101);