US20190338535A1 - Flooring underlayment with dimple endcaps and related methods - Google Patents
Flooring underlayment with dimple endcaps and related methods Download PDFInfo
- Publication number
- US20190338535A1 US20190338535A1 US16/404,016 US201916404016A US2019338535A1 US 20190338535 A1 US20190338535 A1 US 20190338535A1 US 201916404016 A US201916404016 A US 201916404016A US 2019338535 A1 US2019338535 A1 US 2019338535A1
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- United States
- Prior art keywords
- dimple
- underlayment
- panel
- endcap
- endcaps
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Classifications
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- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
- E04F15/00—Flooring
- E04F15/22—Resiliently-mounted floors, e.g. sprung floors
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
- E04F15/00—Flooring
- E04F15/18—Separately-laid insulating layers; Other additional insulating measures; Floating floors
- E04F15/185—Underlayers in the form of studded or ribbed plates
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
- E04F15/00—Flooring
- E04F15/02—Flooring or floor layers composed of a number of similar elements
- E04F15/02005—Construction of joints, e.g. dividing strips
- E04F15/02016—Construction of joints, e.g. dividing strips with sealing elements between flooring elements
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
- E04F15/00—Flooring
- E04F15/02—Flooring or floor layers composed of a number of similar elements
- E04F15/0215—Flooring or floor layers composed of a number of similar elements specially adapted for being adhesively fixed to an underlayer; Fastening means therefor; Fixing by means of plastics materials hardening after application
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
- E04F15/00—Flooring
- E04F15/18—Separately-laid insulating layers; Other additional insulating measures; Floating floors
- E04F15/182—Underlayers coated with adhesive or mortar to receive the flooring
- E04F15/183—Underlayers coated with adhesive or mortar to receive the flooring for areas prone to frost damage, e.g. for balconies or terraces
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
- E04F15/00—Flooring
- E04F15/18—Separately-laid insulating layers; Other additional insulating measures; Floating floors
- E04F15/20—Separately-laid insulating layers; Other additional insulating measures; Floating floors for sound insulation
- E04F15/203—Separately-laid layers for sound insulation
Definitions
- the specification generally relates to underlayments, and more specifically, to flooring underlayments for installation between a base surface and a flooring material.
- U.S. Pat. No. 9,869,100 discloses an underlayment for a floor.
- the underlayment includes a dimpled substrate having a generally planar top side, an opposed bottom side, and a plurality of dimples formed therein. Each dimple is bounded by a dimple wall, and includes a dimple opening along the top side.
- a smoothing layer is bonded beneficial to the top side of the dimpled substrate and overlays and occludes the dimple openings.
- U.S. Pat. App. Pub. No. 2014/0311075 (Cormier et al.) purports to disclose a recoiling energy absorbing system having an upper impact surface that is exposed to percussive impact.
- An energy absorbing layer is positioned below or inside the upper impact surface.
- the energy absorbing layer includes one or more thermoformed energy absorbing modules. At least some of the modules are provided with one or more energy absorbing units that extend from an upper platform. Several of the energy absorbing units are provided with a flexible wall that extends from the upper platform.
- a lateral reinforcement member secures the energy absorbing units to prevent them from splaying.
- the energy absorbing units at least partially absorb energy generated by an impacting object due to the flexible wall bending inwardly or outwardly and recoiling nondestructively after single or multiple impacts to its un-deflected configuration.
- U.S. Pat. App. Pub. No. 2014/0202626 discloses a decoupling assembly for positioning between an underlying surface and a flooring material, the decoupling assembly including a decoupling membrane having a base panel having opposing upper and lower surfaces and a plurality of projections extending from the lower surface for contacting an underlying surface and supporting the base panel above the underlying surface. Each projection includes a bottom surface.
- the assembly further includes a plurality of adhesive fasteners, each adhesive fastener having an inner surface fixed to the bottom surface of a respective one of the plurality of projections, and an adhesive outer surface opposite the inner surface.
- the assembly further includes a plurality of release members, each release member covering the outer surface of one respective adhesive fastener, each release member being removable to expose the outer surface of the respective adhesive fastener for adhering the decoupling membrane to the underlying surface.
- an underlayment for installation between a base surface and a flooring material includes: (a) a structural membrane formed of a first, structural material and including a panel having a panel top surface and a panel underside surface opposite the panel top surface.
- the membrane further includes a plurality of dimples projecting from the panel underside surface for supporting the panel above the base surface. Each dimple has a dimple tip spaced apart from the panel underside surface.
- the underlayment further includes (b) a plurality of discrete dimple endcaps formed of a second, resilient material, different than the first material. Each dimple endcap is fixed relative to and covers at least a portion of the dimple tip of a respective dimple. The endcaps support the dimples above the base surface when the underlayment is installed.
- the endcaps comprise an elastomeric material.
- the elastomeric material comprises a thermoplastic elastomer.
- the panel underside surface is generally free of and unobstructed by the elastomeric material.
- each endcap has an endcap peripheral edge spaced apart from the panel underside surface.
- each dimple includes an endwall spaced apart from the panel underside surface and comprising the dimple tip, and a sidewall extending from the panel to the endwall.
- Each dimple endcap covers at least a portion of the endwall, and at least a portion of the sidewall is generally free of and unobstructed by the elastomeric material.
- Each dimple has an outer surface. In some examples, the dimple endcap covers less than 75% of the outer surface. In some examples, each dimple endcap has an endcap thickness measured normal to the outer surface, and the thickness is between about 0.5 mm and 1 mm.
- an underlayment for installation between a base surface and a flooring material includes (a) a structural membrane formed of a structural material and including a panel and a plurality of dimples projecting from an underside surface of the panel. Each dimple has a dimple tip spaced apart from the underside surface.
- the underlayment further includes (b) a plurality of dimple endcaps formed of a resilient material. Each endcap is fixed relative to and covers at least a portion of the dimple tip of a respective dimple. The endcaps support the dimples above the base surface when the underlayment is installed.
- the dimple endcaps comprise a thermoplastic elastomer.
- a method of producing an underlayment for installation between a base surface and a flooring material includes: (a) providing a structural membrane having a panel and a plurality of dimples extending from the panel for supporting the panel above the base surface; (b) heating an elastomeric material to form a melt; (c) applying the melt over a tip of each dimple; and (d) solidifying the melt to form a plurality of discrete dimple endcaps.
- Each dimple endcap is fixed relative to and covers at least a portion of the dimple tip of a respective dimple. The endcaps support the dimples above the base surface when the underlayment is installed.
- the elastomeric material comprises a thermoplastic elastomer
- step (b) includes heating the elastomeric material to above a glass transition temperature.
- step (d) includes cooling the melt to below the glass transition temperature.
- step (c) includes applying the melt over less than 75% of an outer surface of the dimple.
- step (c) includes passing a roller over each dimple tip, the roller holding the melt.
- the dimple endcaps are formed with a peripheral edge spaced apart from the panel.
- the panel is generally free of the melt during steps (c) and (d).
- the method further includes (e), after step (d), rolling up the underlayment into a roll with at least some of the endcaps directed toward and exposed to the panel top surface.
- a method of producing an underlayment for installation between a base surface and a flooring material includes (a) providing a structural membrane having a panel and a plurality of dimples extending from the panel for supporting the panel above the base surface. The method further includes (b) applying an elastomeric material to a tip of each dimple to form a plurality of discrete dimple endcaps. Each dimple endcap is fixed relative to and covers at least a portion of the dimple tip of a respective dimple. The endcaps support the dimples above the base surface when the underlayment is installed.
- the elastomeric material is applied to the tip in one of a liquid and semi-liquid state, and the method further includes solidifying the elastomeric material to form the dimple endcaps.
- the method includes applying an adhesive to each dimple tip prior to step (b), and step (b) includes dipping the dimple tips into a supply of solid elastomeric granules to adhere the granules to the dimple tips.
- FIG. 1 is a perspective view of a roll of an example underlayment
- FIG. 2 is an elevation view of a portion of the underlayment of FIG. 1 installed between a base and flooring;
- FIG. 3 is a cross-sectional view of the underlayment of FIG. 1 , taken along line 3 - 3 of FIG. 2 ;
- FIG. 4 is a flow chart showing an example method of producing the underlayment of FIG. 1 ;
- FIG. 5 is a schematic showing melt being applied to a substrate of the underlayment of FIG. 1 .
- an example flooring underlayment 100 is shown. A portion of the underlayment 100 is rolled into an underlayment roll 102 . The roll 102 can be unrolled for installation of the underlayment 100 , as will be described below.
- the underlayment 100 is for installation between a base surface 104 and a flooring material 106 .
- the underlayment 100 can space the flooring material 106 from the base surface 104 , and may help protect the flooring material from water, moisture, and/or microbial growth.
- the underlayment 100 can facilitate drainage of water, may help dampen noise and/or vibration, and/or may help provide cushioning for people walking on the flooring material 106 .
- the base surface 104 can be, for example, a concrete or wood floor surface in a basement.
- the flooring material 106 can be a finished flooring material such as, for example, carpet, laminate, engineered hardwood, stone plastic composite (“SPC”) flooring, wood plastic composite (“WPC”) flooring, and/or vinyl flooring.
- SPC stone plastic composite
- WPC wood plastic composite
- vinyl flooring e.g., vinyl flooring
- Some types of finished flooring material e.g. laminate and engineered hardwood
- OSB oriented strand board
- the underlayment 100 includes a structural membrane 108 having a panel 110 and a plurality of dimples 112 projecting from the panel 110 for supporting the panel 110 above the base surface 104 .
- the dimples 112 can help to space the flooring material 106 from the base surface 104 , which can provide a number of benefits, for example, facilitating drainage of moisture from between the dimples 112 .
- the membrane 108 can provide structural strength, and in particular compression resistance, to the underlayment 100 .
- the membrane 108 may be made from, for example, polyethylene, high-density polyethylene, polypropylene, and/or another suitable structural plastic or composite. In the example illustrated, the membrane 108 is of integral, unitary, one-piece construction.
- the panel 110 has a panel top surface 114 and a panel underside surface 116 opposite the panel top surface 114 .
- the panel top surface 114 is generally planar and directed toward the flooring material 106 when the underlayment 100 is installed.
- the panel underside surface 116 is generally planar and directed toward the base surface 104 when the underlayment is installed.
- the panel underside surface 116 lies parallel to the base surface 104 when installed, and generally in a horizontal plane.
- the dimples 112 project from the panel underside surface 116 .
- Each dimple 112 has a dimple tip 118 spaced apart from the panel underside surface 116 .
- the underlayment 100 further includes a plurality of dimple endcaps 122 .
- each dimple endcap 122 is fixed relative to and covers at least a portion of the dimple tip 118 of a respective dimple 112 .
- each dimple endcap 122 covers an entirety of the dimple tip 118 .
- the endcaps 122 support the dimples 112 above the base surface 104 when the underlayment 100 is installed.
- the dimple endcaps 122 are formed of a resilient material for resiliently supporting the dimples 112 above the base surface 104 .
- the dimple endcaps 122 comprise an elastomeric material. This may help to, for example, dampen noise and/or vibration.
- the elastomeric material can comprise, for example, a thermoplastic elastomer (also referred to as thermoplastic rubber) or a thermoset elastomer (also referred to as thermoset rubber).
- the elastomeric material comprises a thermoplastic elastomer. This may facilitate more efficient (e.g. cost effective) production of the underlayment when compared to underlayments utilizing other types of materials, such as, for example, foam layers (e.g. high-density polyethylene foam, polyurethane foam, and/or polypropylene foams).
- the elastomeric material can have a density greater than 0.50 g/cm 3 . In some examples, the elastomeric material can have a density greater than 0.80 g/cm 3 .
- the dimple endcaps 122 are non-adhesive. This can help simplify manufacturing and packaging of the underlayment by, for example, not making a release member necessary for preventing unintended adhesion of the tips 108 to adjacent surfaces prior to installation. This can also help to provide for easier manipulation and repositioning of the underlayment 100 during installation.
- the endcaps 122 are discrete portions of elastomeric material, the endcaps 122 being isolated from one another and not integrally connected.
- Each dimple endcap 122 can be a continuous layer of elastomeric material applied in a liquid or semi-liquid state, or in some examples, can be an aggregation of fine elastomeric granules adhered to the dimples in a solid state.
- the panel underside surface 116 is generally free of and unobstructed by the elastomeric material. This can help reduce raw material requirements and facilitate more cost-effective production of the underlayment 100 when compared to underlayments having layers (e.g. foam layers) extending over large portions of the panel underside surface 116 .
- each endcap 122 has a peripheral edge 124 spaced apart from the panel underside surface 116 .
- each dimple 112 includes a dimple endwall 128 spaced apart from the panel 110 and comprising the dimple tip 118 , and a dimple sidewall 130 extending from the panel 110 to the endwall 128 .
- each dimple endcap 122 covers at least a portion of the endwall 128 of a respective dimple 112 .
- each dimple endcap 122 covers an entirety of the endwall 128 .
- each dimple endcap covers at least a portion of the sidewall 130 .
- at least a portion of each sidewall 130 is generally free of and unobstructed by the elastomeric material.
- each dimple 112 has an upper root edge 132 opposite the dimple tip 118 and joined to the panel 110 .
- the panel underside surface 116 extends horizontally between the root edges 132 of the dimples 112 when the underlayment 100 is installed.
- the portion of the sidewall 130 extending from the root edge 132 to the dimple endcap 122 is generally free of and unobstructed by the elastomeric material.
- Each dimple includes a dimple outer surface 120 .
- the outer surface 120 extends from the panel underside surface 116 and comprises the dimple tip 118 .
- each endcap 122 is fixed to the outer surface 120 of a respective dimple 112 .
- the endcap 122 can cover less than 75% of the outer surface 120 . In some examples, the endcap 122 can cover less than 50% of the outer surface 120 .
- each dimple endcap 122 has an endcap thickness 134 measured normal to the dimple outer surface 120 .
- the thickness 134 can be between about, for example, 0.5 mm and 5 mm.
- each dimple 112 includes an interior 136 open to the panel top surface 114 .
- the dimple endwall 128 and the dimple sidewall 130 bound the interior 136 .
- the dimple 112 is generally frustoconical.
- the dimple 112 can be another shape, for example, generally frustopyramidal, cubic, cylindrical, or hemispherical.
- a method 200 for producing the underlayment 100 is shown.
- the membrane 108 is provided.
- an elastomeric material is heated to form a melt.
- the elastomeric material comprises a thermoplastic elastomer, and the elastomeric material is heated to above a glass transition temperature to form the melt.
- step 230 the melt is applied over the tip 118 of each dimple 112 .
- step 230 includes applying the melt over less than 75% of the dimple outer surface 120 .
- step 230 includes passing a roller 138 over each dimple tip 118 , with the roller 138 holding the melt for application to the dimple tips 118 .
- the thickness of the layer of melt applied to tip 118 of each dimple can be controlled by, for example, controlling the size of the gap between the roller and the tips 118 as the roller passes over the tips.
- the thickness of the layer of melt applied to the tips 118 can be controlled by controlling the thickness of the layer of melt on the outer surface of the roller 138 picked up from a supply of melt, for example, from a heated trough. Rotating the roller while holding a blade positioned at a desired spacing from the outer surface of the roller can facilitate achieving a desired thickness of melt on the roller 138 prior to passing the roller 138 over the tips 118 of the dimples.
- step 230 can include dipping the dimple tips 118 into a bath of the melt.
- the melt is solidified to form the plurality of dimple endcaps 122 .
- the elastomeric material comprises a thermoplastic elastomer and step 240 includes cooling the melt to below the glass transition temperature to form the plurality of dimple endcaps 122 .
- the dimple endcaps 122 are formed with the peripheral edge 124 spaced apart from the panel 110 .
- the panel 110 is generally free of the melt during steps 230 and 240 .
- step 240 can include curing the elastomeric material to form the dimple endcaps.
- the curing step can include forming cross-links in the elastomeric material.
- an adhesive can be applied to the tips of the dimples, and the tips can then be dipped in a supply of solid elastomeric granules.
- the elastomeric granules can be sized in the range of, for example, about 0.5 mm to about 5 mm, and can be presented in a vibratory container to facilitate maintaining a loose, even layer of granules in the container for engagement by the adhesive layer on the dimple tips 118 .
- the container can have a porous or screen-like bottom to allow granule fines or otherwise undersized particles to be evacuated from the supply presented for pick-up by the tips 118 .
- the underlayment 100 can optionally be rolled up into the roll 102 ( FIG. 1 ), and the roll 102 can be packaged for shipment.
- the underlayment 100 when the underlayment 100 is in the roll 102 , at least some of the endcaps 122 are directed toward and exposed to the panel top surface 114 . In some examples, when the underlayment 100 is in the roll 102 , at least some of the endcaps 122 can be in direct engagement with the panel top surface 114 .
- installation of the underlayment 100 includes unrolling the roll 102 and laying the underlayment 100 on the base surface 104 with the dimple endcaps 122 in engagement with the base surface 104 .
- the underlayment 100 is cut into pieces of desired size to cover the base surface 104 . Seams between adjacent pieces of underlayment 100 can be secured with, for example, acrylic tape to join the pieces together and maintain moisture barrier properties of the underlayment 100 .
- the flooring material 106 is placed over the underlayment 100 .
- the flooring material 106 is placed over and supported by the panel top surface 114 .
- the flooring material 106 can include a finished flooring material placed directly on the panel top surface 114 .
- the flooring material 106 can include a finished flooring material and a subfloor (such as an OSB subfloor or plywood) installed between the underlayment 100 and the finished flooring material.
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Abstract
An underlayment for installation between a base surface and a flooring material includes (a) a structural membrane formed of a structural material and including a panel and a plurality of dimples projecting from an underside surface of the panel. Each dimple has a dimple tip spaced apart from the underside surface. The underlayment further includes (b) a plurality of discrete dimple endcaps comprising a resilient material. Each endcap is fixed relative to, and covers at least a portion of, the dimple tip of a respective dimple. The endcaps support the dimples above the base surface when the underlayment is installed.
Description
- This application claims the benefit of U.S. Provisional Application Ser. No. 62/667,092, filed May 4, 2018, which is hereby incorporated herein by reference.
- The specification generally relates to underlayments, and more specifically, to flooring underlayments for installation between a base surface and a flooring material.
- U.S. Pat. No. 9,869,100 (Sennik) discloses an underlayment for a floor. The underlayment includes a dimpled substrate having a generally planar top side, an opposed bottom side, and a plurality of dimples formed therein. Each dimple is bounded by a dimple wall, and includes a dimple opening along the top side. A smoothing layer is bonded beneficial to the top side of the dimpled substrate and overlays and occludes the dimple openings.
- U.S. Pat. App. Pub. No. 2014/0311075 (Cormier et al.) purports to disclose a recoiling energy absorbing system having an upper impact surface that is exposed to percussive impact. An energy absorbing layer is positioned below or inside the upper impact surface. The energy absorbing layer includes one or more thermoformed energy absorbing modules. At least some of the modules are provided with one or more energy absorbing units that extend from an upper platform. Several of the energy absorbing units are provided with a flexible wall that extends from the upper platform. A lateral reinforcement member secures the energy absorbing units to prevent them from splaying. The energy absorbing units at least partially absorb energy generated by an impacting object due to the flexible wall bending inwardly or outwardly and recoiling nondestructively after single or multiple impacts to its un-deflected configuration.
- U.S. Pat. App. Pub. No. 2014/0202626 (Sennik) discloses a decoupling assembly for positioning between an underlying surface and a flooring material, the decoupling assembly including a decoupling membrane having a base panel having opposing upper and lower surfaces and a plurality of projections extending from the lower surface for contacting an underlying surface and supporting the base panel above the underlying surface. Each projection includes a bottom surface. The assembly further includes a plurality of adhesive fasteners, each adhesive fastener having an inner surface fixed to the bottom surface of a respective one of the plurality of projections, and an adhesive outer surface opposite the inner surface. The assembly further includes a plurality of release members, each release member covering the outer surface of one respective adhesive fastener, each release member being removable to expose the outer surface of the respective adhesive fastener for adhering the decoupling membrane to the underlying surface.
- The following summary is intended to introduce the reader to various aspects of the applicant's teaching, but not to define any invention.
- According to some aspects, an underlayment for installation between a base surface and a flooring material includes: (a) a structural membrane formed of a first, structural material and including a panel having a panel top surface and a panel underside surface opposite the panel top surface. The membrane further includes a plurality of dimples projecting from the panel underside surface for supporting the panel above the base surface. Each dimple has a dimple tip spaced apart from the panel underside surface. The underlayment further includes (b) a plurality of discrete dimple endcaps formed of a second, resilient material, different than the first material. Each dimple endcap is fixed relative to and covers at least a portion of the dimple tip of a respective dimple. The endcaps support the dimples above the base surface when the underlayment is installed.
- In some examples, the endcaps comprise an elastomeric material. In some examples, the elastomeric material comprises a thermoplastic elastomer. In some examples, the panel underside surface is generally free of and unobstructed by the elastomeric material. In some examples, each endcap has an endcap peripheral edge spaced apart from the panel underside surface. In some examples, each dimple includes an endwall spaced apart from the panel underside surface and comprising the dimple tip, and a sidewall extending from the panel to the endwall. Each dimple endcap covers at least a portion of the endwall, and at least a portion of the sidewall is generally free of and unobstructed by the elastomeric material. Each dimple has an outer surface. In some examples, the dimple endcap covers less than 75% of the outer surface. In some examples, each dimple endcap has an endcap thickness measured normal to the outer surface, and the thickness is between about 0.5 mm and 1 mm.
- According to some aspects, an underlayment for installation between a base surface and a flooring material includes (a) a structural membrane formed of a structural material and including a panel and a plurality of dimples projecting from an underside surface of the panel. Each dimple has a dimple tip spaced apart from the underside surface. The underlayment further includes (b) a plurality of dimple endcaps formed of a resilient material. Each endcap is fixed relative to and covers at least a portion of the dimple tip of a respective dimple. The endcaps support the dimples above the base surface when the underlayment is installed. In some examples, the dimple endcaps comprise a thermoplastic elastomer.
- According to some aspects, a method of producing an underlayment for installation between a base surface and a flooring material includes: (a) providing a structural membrane having a panel and a plurality of dimples extending from the panel for supporting the panel above the base surface; (b) heating an elastomeric material to form a melt; (c) applying the melt over a tip of each dimple; and (d) solidifying the melt to form a plurality of discrete dimple endcaps. Each dimple endcap is fixed relative to and covers at least a portion of the dimple tip of a respective dimple. The endcaps support the dimples above the base surface when the underlayment is installed.
- In some examples, the elastomeric material comprises a thermoplastic elastomer, and step (b) includes heating the elastomeric material to above a glass transition temperature. In some examples, step (d) includes cooling the melt to below the glass transition temperature.
- In some examples, step (c) includes applying the melt over less than 75% of an outer surface of the dimple.
- In some examples, step (c) includes passing a roller over each dimple tip, the roller holding the melt.
- In some examples, the dimple endcaps are formed with a peripheral edge spaced apart from the panel.
- In some examples, the panel is generally free of the melt during steps (c) and (d).
- In some examples, the method further includes (e), after step (d), rolling up the underlayment into a roll with at least some of the endcaps directed toward and exposed to the panel top surface.
- According to some aspects, a method of producing an underlayment for installation between a base surface and a flooring material includes (a) providing a structural membrane having a panel and a plurality of dimples extending from the panel for supporting the panel above the base surface. The method further includes (b) applying an elastomeric material to a tip of each dimple to form a plurality of discrete dimple endcaps. Each dimple endcap is fixed relative to and covers at least a portion of the dimple tip of a respective dimple. The endcaps support the dimples above the base surface when the underlayment is installed.
- In some examples, the elastomeric material is applied to the tip in one of a liquid and semi-liquid state, and the method further includes solidifying the elastomeric material to form the dimple endcaps.
- In some examples, the method includes applying an adhesive to each dimple tip prior to step (b), and step (b) includes dipping the dimple tips into a supply of solid elastomeric granules to adhere the granules to the dimple tips.
- The drawings included herewith are for illustrating various examples of articles, methods, and apparatuses of the present specification and are not intended to limit the scope of what is taught in any way. In the drawings:
-
FIG. 1 is a perspective view of a roll of an example underlayment; -
FIG. 2 is an elevation view of a portion of the underlayment ofFIG. 1 installed between a base and flooring; -
FIG. 3 is a cross-sectional view of the underlayment ofFIG. 1 , taken along line 3-3 ofFIG. 2 ; -
FIG. 4 is a flow chart showing an example method of producing the underlayment ofFIG. 1 ; and -
FIG. 5 is a schematic showing melt being applied to a substrate of the underlayment ofFIG. 1 . - Various apparatuses or processes will be described below to provide an example of an embodiment of each claimed invention. No embodiment described below limits any claimed invention and any claimed invention may cover processes or apparatuses that differ from those described below. The claimed inventions are not limited to apparatuses or processes having all of the features of any one apparatus or process described below or to features common to multiple or all of the apparatuses described below. It is possible that an apparatus or process described below is not an embodiment of any claimed invention. Any invention disclosed in an apparatus or process described below that is not claimed in this document may be the subject matter of another protective instrument, for example, a continuing patent application, and the applicants, inventors or owners do not intend to abandon, disclaim, or dedicate to the public any such invention by its disclosure in this document.
- Referring to
FIG. 1 , anexample flooring underlayment 100 is shown. A portion of theunderlayment 100 is rolled into anunderlayment roll 102. Theroll 102 can be unrolled for installation of theunderlayment 100, as will be described below. - Referring to
FIG. 2 , in the example illustrated, theunderlayment 100 is for installation between abase surface 104 and aflooring material 106. Theunderlayment 100 can space theflooring material 106 from thebase surface 104, and may help protect the flooring material from water, moisture, and/or microbial growth. Theunderlayment 100 can facilitate drainage of water, may help dampen noise and/or vibration, and/or may help provide cushioning for people walking on theflooring material 106. - The
base surface 104 can be, for example, a concrete or wood floor surface in a basement. Theflooring material 106 can be a finished flooring material such as, for example, carpet, laminate, engineered hardwood, stone plastic composite (“SPC”) flooring, wood plastic composite (“WPC”) flooring, and/or vinyl flooring. Some types of finished flooring material (e.g. laminate and engineered hardwood) may be installed directly on theunderlayment 100, without necessarily requiring the use of an additional subfloor (such as oriented strand board (“OSB”) subflooring or plywood) between the underlayment 100 and theflooring material 106. This may allow for, for example, ease of installation, a decrease in the total flooring height, and/or a decrease in cost. - In the example illustrated, the
underlayment 100 includes astructural membrane 108 having apanel 110 and a plurality ofdimples 112 projecting from thepanel 110 for supporting thepanel 110 above thebase surface 104. Thedimples 112 can help to space theflooring material 106 from thebase surface 104, which can provide a number of benefits, for example, facilitating drainage of moisture from between thedimples 112. Themembrane 108 can provide structural strength, and in particular compression resistance, to theunderlayment 100. Themembrane 108 may be made from, for example, polyethylene, high-density polyethylene, polypropylene, and/or another suitable structural plastic or composite. In the example illustrated, themembrane 108 is of integral, unitary, one-piece construction. - In the example illustrated, the
panel 110 has a paneltop surface 114 and apanel underside surface 116 opposite the paneltop surface 114. In the example illustrated, the paneltop surface 114 is generally planar and directed toward theflooring material 106 when theunderlayment 100 is installed. In the example illustrated, thepanel underside surface 116 is generally planar and directed toward thebase surface 104 when the underlayment is installed. In the example illustrated, thepanel underside surface 116 lies parallel to thebase surface 104 when installed, and generally in a horizontal plane. - Referring to
FIG. 3 , in the example illustrated, thedimples 112 project from thepanel underside surface 116. Eachdimple 112 has adimple tip 118 spaced apart from thepanel underside surface 116. - In the example illustrated, the
underlayment 100 further includes a plurality ofdimple endcaps 122. In the example illustrated, eachdimple endcap 122 is fixed relative to and covers at least a portion of thedimple tip 118 of arespective dimple 112. In the example illustrated, eachdimple endcap 122 covers an entirety of thedimple tip 118. Referring toFIG. 2 , theendcaps 122 support thedimples 112 above thebase surface 104 when theunderlayment 100 is installed. In the example illustrated, thedimple endcaps 122 are formed of a resilient material for resiliently supporting thedimples 112 above thebase surface 104. - In the example illustrated, the
dimple endcaps 122 comprise an elastomeric material. This may help to, for example, dampen noise and/or vibration. The elastomeric material can comprise, for example, a thermoplastic elastomer (also referred to as thermoplastic rubber) or a thermoset elastomer (also referred to as thermoset rubber). In the example illustrated, the elastomeric material comprises a thermoplastic elastomer. This may facilitate more efficient (e.g. cost effective) production of the underlayment when compared to underlayments utilizing other types of materials, such as, for example, foam layers (e.g. high-density polyethylene foam, polyurethane foam, and/or polypropylene foams). This may also facilitate recycling of the elastomeric material. In some examples, the elastomeric material can have a density greater than 0.50 g/cm3. In some examples, the elastomeric material can have a density greater than 0.80 g/cm3. - In the example illustrated, the
dimple endcaps 122 are non-adhesive. This can help simplify manufacturing and packaging of the underlayment by, for example, not making a release member necessary for preventing unintended adhesion of thetips 108 to adjacent surfaces prior to installation. This can also help to provide for easier manipulation and repositioning of theunderlayment 100 during installation. - Referring to
FIG. 2 , in the example illustrated, theendcaps 122 are discrete portions of elastomeric material, theendcaps 122 being isolated from one another and not integrally connected. Eachdimple endcap 122 can be a continuous layer of elastomeric material applied in a liquid or semi-liquid state, or in some examples, can be an aggregation of fine elastomeric granules adhered to the dimples in a solid state. In the example illustrated, thepanel underside surface 116 is generally free of and unobstructed by the elastomeric material. This can help reduce raw material requirements and facilitate more cost-effective production of theunderlayment 100 when compared to underlayments having layers (e.g. foam layers) extending over large portions of thepanel underside surface 116. In the example illustrated, eachendcap 122 has aperipheral edge 124 spaced apart from thepanel underside surface 116. - Referring to
FIG. 3 , in the example illustrated, eachdimple 112 includes adimple endwall 128 spaced apart from thepanel 110 and comprising thedimple tip 118, and adimple sidewall 130 extending from thepanel 110 to theendwall 128. In the example illustrated, eachdimple endcap 122 covers at least a portion of theendwall 128 of arespective dimple 112. In the example illustrated, eachdimple endcap 122 covers an entirety of theendwall 128. In the example illustrated, each dimple endcap covers at least a portion of thesidewall 130. In the example illustrated, at least a portion of eachsidewall 130 is generally free of and unobstructed by the elastomeric material. - In the example illustrated, each
dimple 112 has anupper root edge 132 opposite thedimple tip 118 and joined to thepanel 110. In the example illustrated, thepanel underside surface 116 extends horizontally between the root edges 132 of thedimples 112 when theunderlayment 100 is installed. In the example illustrated, the portion of thesidewall 130 extending from theroot edge 132 to thedimple endcap 122 is generally free of and unobstructed by the elastomeric material. - Each dimple includes a dimple
outer surface 120. In the example illustrated, theouter surface 120 extends from thepanel underside surface 116 and comprises thedimple tip 118. In the example illustrated, eachendcap 122 is fixed to theouter surface 120 of arespective dimple 112. In some examples, theendcap 122 can cover less than 75% of theouter surface 120. In some examples, theendcap 122 can cover less than 50% of theouter surface 120. - Referring to
FIG. 3 , in the example illustrated, eachdimple endcap 122 has anendcap thickness 134 measured normal to the dimpleouter surface 120. Thethickness 134 can be between about, for example, 0.5 mm and 5 mm. - In the example illustrated, each
dimple 112 includes an interior 136 open to the paneltop surface 114. In the example illustrated, the dimple endwall 128 and thedimple sidewall 130 bound the interior 136. - In the example illustrated, the
dimple 112 is generally frustoconical. In some examples, thedimple 112 can be another shape, for example, generally frustopyramidal, cubic, cylindrical, or hemispherical. - Referring to
FIGS. 4 and 5 , in the example illustrated, amethod 200 for producing theunderlayment 100 is shown. Atstep 210, themembrane 108 is provided. Atstep 220, an elastomeric material is heated to form a melt. In the example illustrated, the elastomeric material comprises a thermoplastic elastomer, and the elastomeric material is heated to above a glass transition temperature to form the melt. - At
step 230, the melt is applied over thetip 118 of eachdimple 112. In the example illustrated,step 230 includes applying the melt over less than 75% of the dimpleouter surface 120. In the example illustrated,step 230 includes passing aroller 138 over eachdimple tip 118, with theroller 138 holding the melt for application to thedimple tips 118. The thickness of the layer of melt applied to tip 118 of each dimple can be controlled by, for example, controlling the size of the gap between the roller and thetips 118 as the roller passes over the tips. Alternatively or additionally, the thickness of the layer of melt applied to thetips 118 can be controlled by controlling the thickness of the layer of melt on the outer surface of theroller 138 picked up from a supply of melt, for example, from a heated trough. Rotating the roller while holding a blade positioned at a desired spacing from the outer surface of the roller can facilitate achieving a desired thickness of melt on theroller 138 prior to passing theroller 138 over thetips 118 of the dimples. - In an alternate method, step 230 can include dipping the
dimple tips 118 into a bath of the melt. - At
step 240, the melt is solidified to form the plurality ofdimple endcaps 122. In the example illustrated, the elastomeric material comprises a thermoplastic elastomer and step 240 includes cooling the melt to below the glass transition temperature to form the plurality ofdimple endcaps 122. In the example illustrated, thedimple endcaps 122 are formed with theperipheral edge 124 spaced apart from thepanel 110. In the example illustrated, thepanel 110 is generally free of the melt duringsteps - In an alternate method, step 240 can include curing the elastomeric material to form the dimple endcaps. In some examples, the curing step can include forming cross-links in the elastomeric material.
- In an alternate method, an adhesive can be applied to the tips of the dimples, and the tips can then be dipped in a supply of solid elastomeric granules. The elastomeric granules can be sized in the range of, for example, about 0.5 mm to about 5 mm, and can be presented in a vibratory container to facilitate maintaining a loose, even layer of granules in the container for engagement by the adhesive layer on the
dimple tips 118. The container can have a porous or screen-like bottom to allow granule fines or otherwise undersized particles to be evacuated from the supply presented for pick-up by thetips 118. - In the example illustrated, after
step 240, theunderlayment 100 can optionally be rolled up into the roll 102 (FIG. 1 ), and theroll 102 can be packaged for shipment. Referring toFIG. 1 , in the example illustrated, when theunderlayment 100 is in theroll 102, at least some of theendcaps 122 are directed toward and exposed to the paneltop surface 114. In some examples, when theunderlayment 100 is in theroll 102, at least some of theendcaps 122 can be in direct engagement with the paneltop surface 114. - Referring to
FIG. 2 , in the example illustrated, installation of theunderlayment 100 includes unrolling theroll 102 and laying theunderlayment 100 on thebase surface 104 with thedimple endcaps 122 in engagement with thebase surface 104. Optionally, theunderlayment 100 is cut into pieces of desired size to cover thebase surface 104. Seams between adjacent pieces ofunderlayment 100 can be secured with, for example, acrylic tape to join the pieces together and maintain moisture barrier properties of theunderlayment 100. After theunderlayment 100 is laid over thebase surface 104, theflooring material 106 is placed over theunderlayment 100. In the example illustrated, theflooring material 106 is placed over and supported by the paneltop surface 114. In some examples, theflooring material 106 can include a finished flooring material placed directly on the paneltop surface 114. In some examples, theflooring material 106 can include a finished flooring material and a subfloor (such as an OSB subfloor or plywood) installed between the underlayment 100 and the finished flooring material.
Claims (17)
1. An underlayment for installation between a base surface and a flooring material, the underlayment comprising:
a) a structural membrane formed of a structural material and including a panel having a panel top surface and a panel underside surface opposite the panel top surface, the structural membrane further including a plurality of dimples projecting from the panel underside surface for supporting the panel above the base surface, each dimple having a dimple tip spaced apart from the panel underside surface and a dimple outer surface extending from the panel underside surface to the dimple tip; and
b) a plurality of discrete dimple endcaps comprising a resilient material, each dimple endcap fixed to the dimple outer surface and covering the dimple tip of a respective dimple, the endcaps supporting the dimple tips above the base surface when the underlayment is installed.
2. The underlayment of claim 1 , wherein the resilient material comprises an elastomeric material.
3. The underlayment of claim 1 , wherein the resilient material comprises a thermoplastic elastomer.
4. The underlayment of claim 1 , wherein the panel underside surface is generally free of and unobstructed by the resilient material.
5. The underlayment of claim 1 , wherein each endcap has an endcap peripheral edge spaced apart from the panel underside surface.
6. The underlayment of claim 1 , wherein the dimple includes an end wall comprising the dimple tip and a sidewall extending from the panel to the endwall, each dimple endcap covering the endwall, and wherein at least a portion of the sidewall is generally free of and unobstructed by the resilient material.
7. The underlayment of claim 1 , wherein each dimple endcap has an endcap thickness measured normal to the dimple outer surface, and the thickness is between about 0.5 mm and 1 mm.
8. The underlayment of claim 1 , wherein the endcap covers less than 90% of the dimple outer surface.
9. The underlayment of claim 8 , wherein the dimple endcap covers less than 60% of the dimple outer surface.
10. The underlayment of claim 9 , wherein the dimple endcap covers less than 30% of the dimple outer surface.
11. An underlayment for installation between a base surface and a flooring material, the underlayment comprising:
a) a structural membrane formed of a first material and including a panel and a plurality of dimples projecting from an underside surface of the panel, each dimple having a dimple tip spaced apart from the underside surface and a dimple outer surface extending from the panel underside surface to the dimple tip; and
b) a plurality of dimple endcaps formed of a second material different than the first material, each endcap fixed to the dimple outer surface and covering the dimple tip of a respective dimple, the endcaps supporting the dimple tips above the base surface when the underlayment is installed.
12. The underlayment of claim 11 , wherein the second material comprises a thermoplastic elastomer.
13. A method of producing an underlayment for installation between a base surface and a flooring material, the method comprising:
a) providing a structural membrane having a panel and a plurality of dimples extending from the panel for supporting the panel above the base surface;
b) heating a thermoplastic elastomer to above a glass transition temperature to form an elastomer melt;
c) applying the elastomer melt to a tip of each dimple; and
d) cooling the elastomer melt to below the glass transition temperature to form a plurality of discrete dimple endcaps, each dimple endcap fixed to the dimple and covering the dimple tip, the endcaps supporting the dimple tips above the base surface when the underlayment is installed.
14. The method of claim 13 , wherein step (c) includes passing a roller over each dimple tip, the roller holding the elastomer melt.
15. The method of claim 13 , wherein the dimple endcaps are formed with a peripheral edge spaced apart from the panel.
16. The method of claim 13 , wherein the panel is generally free of the elastomer melt during steps (c) and (d).
17. The method of claim 13 , further including (d), after step (c), rolling up the underlayment into a roll with at least some of the endcaps directed toward and exposed to the panel top surface.
Priority Applications (1)
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US16/404,016 US20190338535A1 (en) | 2018-05-04 | 2019-05-06 | Flooring underlayment with dimple endcaps and related methods |
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US201862667092P | 2018-05-04 | 2018-05-04 | |
US16/404,016 US20190338535A1 (en) | 2018-05-04 | 2019-05-06 | Flooring underlayment with dimple endcaps and related methods |
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US20190338535A1 true US20190338535A1 (en) | 2019-11-07 |
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US16/404,016 Abandoned US20190338535A1 (en) | 2018-05-04 | 2019-05-06 | Flooring underlayment with dimple endcaps and related methods |
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Cited By (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
USD971449S1 (en) * | 2016-04-13 | 2022-11-29 | Progress Profiles S.P.A. | Floor underlayment |
US11846432B2 (en) | 2009-08-28 | 2023-12-19 | Progress Profiles Spa | Method and apparatus for positioning heating elements |
-
2019
- 2019-05-06 US US16/404,016 patent/US20190338535A1/en not_active Abandoned
Cited By (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US11846432B2 (en) | 2009-08-28 | 2023-12-19 | Progress Profiles Spa | Method and apparatus for positioning heating elements |
USD971449S1 (en) * | 2016-04-13 | 2022-11-29 | Progress Profiles S.P.A. | Floor underlayment |
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