WO2014210610A1

WO2014210610A1 - Underlayment with folded film flap

Info

Publication number: WO2014210610A1
Application number: PCT/US2014/044946
Authority: WO
Inventors: Thomas D. Wetsch
Original assignee: Pregis Innovative Packaging Inc.
Priority date: 2013-06-28
Filing date: 2014-06-30
Publication date: 2014-12-31

Abstract

A foam-film sheet can be attachable to first and second other sheets of similar construction thereto and can comprise a foam sheet member that can have first and second lateral edges on opposite sides of the foam sheet member. The film sheet member can have a lip that can extend laterally beyond the first lateral edge of the foam sheet. The foam-film sheet can also have an adhesion member on the lip and another on an attachment location. The adhesion members can be cohesives. The lip can be folded back over the foam-film sheet.

Description

UNDERLAYMENT WITH FOLDED FILM FLAP

CROSS-REFERENCE TO RELATED APPLICATION

[0001] This application claims priority to U.S. Patent Application No. 61/840,875, filed on June 28, 2013, entitled "Underlayment with Film Flap Cohesives" and to 61/872,042, filed on August 30, 2013, and entitled "Underlayment of Folded Film Flap" the entire disclosure of each of which is incorporated herein by reference in its entirety.

FIELD OF THE DISCLOSURE

[0002] The present disclosure relates generally to underlayment compositions for use in combination with flooring.

BACKGROUND INFORMATION

[0003] A typical type of flooring can include an underlayment on which a flooring material is overlaid. Known ways of providing underlayment include stacking sheets of plastic and foam on a subfloor.

[0004] There are different types of underlayment arrangements typically used in flooring installations. U.S. Patent No. 5,968,630, for instance, discloses an example of a laminate composition with a film and foam sheets. A portion of the film extends beyond one side of the foam sheet and is adhered thereto.

[0005] There is a need, however, for an improved underlayment having an adhesive arrangement that facilitates positioning the underlayment during installation.

SUMMARY OF THE DISCLOSURE

[0006] According to an embodiment of the present disclosure, a foam- film sheet can be attachable to first and second other sheets of similar construction thereto. The foam- film sheet can comprise a foam sheet member with first and second lateral edges on opposite sides of the foam sheet. The film sheet member can have an overlay portion attached to the foam sheet and a lip that can extend laterally beyond the first lateral edge of the foam sheet. The foam-film sheet can also have a first adhesion member, disposed, for example on the lip, and a second adhesion member that can be attached on the foam-film sheet in a location to contact the first adhesion member of the second other sheet when placed adjacent to the foam-film sheet. Similarly, the first adhesion member can be disposed in a location on the lip to contact the second adhesion member of the first other sheet placed adjacent the foam-film

1

4839-1940-0988M sheet. The first and second adhesion members can be made of materials that adhere to each other.

[0007] The adhesion members, in some embodiments, can be made of the same or different cohesive material, which are cohesive with respect to each other, that bond to each other stronger than to adjacent exposed surfaces of the foam-film sheet. The adhesion members can be made of cohesive material that forms a bond having a bond strength at least about 80% stronger than a bond formed between the adhesions member and the film or foam sheet members. In other embodiments, the adhesion members can be made of a cohesive material that can form a stronger bond to each other than the tear strength of the film or foam sheet members, such as when measured in shear between the substrates to which the adhesion members or cohesives are attached such as when the cohesively attached foam-film sheets are pulled in plane with the major surfaces of the foam-film sheets. In the embodiment of Fig. 3, such shear could be experienced if the film layers were pulled horizontally away from each other. Often, when these substrates are peeled, the cohesive bond between the adhesion members is stronger than to the substrates to which they are attached, and one or both or the cohesion members will delaminate from the substrate before breaking the bond to each other.

[0008] In some embodiments, the first adhesion member covers an area at a first distance outboard from the first lateral edge of the foam sheet member, and the second adhesion member can cover an area at the same first distance inboard from the second lateral edge of the foam sheet member, such that the first adhesion member of the foam-film sheet overlays the second adhesion member of the first other foam-film sheet, and the second adhesion member of the foam- film sheet overlays first adhesion members of the second other foam- film sheet when the lateral edges of the foam sheet of the foam-film sheet and of the first and second other foam-film sheets are placed in contact with each other.

[0009] At least one of the adhesion members can be spaced from the first or second lateral edges of the foam sheet member. The adhesion members can have similar widths. In other configurations, at least one of the adhesion members is wider than the other adhesion member.

[0010] In some configurations, the foam-film sheet can have a first major surface, and a second major surface opposite from the first major surface. The first adhesion member can be disposed on the first major surface. The second adhesion member can be disposed on the second major surface.

[0011] The second adhesion member can be attached directly on the foam sheet member of the foam-film sheet in a location to contact the first adhesion member of the second other foam-film sheet when placed adjacent the foam- film sheet. In an embodiment, the second adhesion member can be provided directly attached on the film sheet member of the foam- film sheet in a location to contact the first adhesion member of the second other sheet placed adjacent the foam-film sheet.

[0012] The film sheet member can be laminated to the foam sheet member by coextrusion, by hot-glue melt, or by other suitable methods. In some configurations, the entire overlay portion of the film sheet member can be sealed to the foam sheet member. In other configurations, less than the entire overlay portion of the film sheet member is sealed to the foam sheet member. In some embodiments, the overlay portion extends only partially across the foam sheet member. In certain embodiments, the overlay portion can have a width that is less than about ½ of the width of the foam sheet member. The overlay portion of the film sheet member can completely cover the foam sheet member, such as to prove an extensive or complete vapor barrier.

[0013] The foam-film sheet can be a flooring underlayment sheet. In some embodiments, a flooring assembly can comprise of a plurality of foam-film sheets. The lip one of the foam- film sheets can be disposed in overlap with, under or over, another of the foam- film sheets, with its adhesion member cohesively adhered to the second adhesion member of the other of the film-foam sheets. The lip of can be sealed to the other foam-film sheet to provide a moisture barrier across any gap between the adjacent foam-film sheets.

[0014] An embodiment of the foam-film sheet can have a width of about 30 inches and about 80 inches. An embodiment of the foam-film sheet can have a length of about 30 feet to about 80 feet, such as in a roll. The lip of the film sheet member in an embodiment can have a width of about 1 inch to about 6 inches, and the foam sheet member can have a width of about 40 inches to about 60 inches. The foam-film sheet can be rolled longitudinally to form a roll of foam-film sheet.

[0015] According to an embodiment of a method of connecting a plurality of film-foam sheets, first and second foam-film sheets can be provided. Each of the foam-film sheets can include a foam sheet member and a film sheet member. The foam sheet member can have first and second lateral edges on opposite sides of the foam sheet. The film sheet member can have an overlay portion that can be attached to the foam sheet member on a first major surface of the film sheet member, and a lip that can extend laterally beyond the first lateral edge of the foam sheet member. Each of the foam-film sheets can also include a first adhesion member disposed on the first major surface on the lip and a second adhesion member that can be disposed on the foam-film sheet on a second major surface of the foam- film sheet opposite from the first major surface in a location disposed over the foam sheet member. The first and second adhesion members can be cohesive with respect to each other. The method can comprise positioning the first and second foam-film sheets to place the first lateral edge of the second foam-film sheet next to the second lateral edge of the first foam- film sheet so that the lip of the second foam-film sheet and the first foam-film sheet and the first and second adhesion members contact each to cohesively bond the first and second adhesion members. The foam-film sheets can be flooring underlayment sheets, and the second foam- film sheet can be laid down next to the first foam-film sheet, with the flap of the second foam- film sheet laid on top of the first foam- film sheet to adhere thereto. The overlay portion of the film sheet member can substantially completely cover the foam sheet member to prove a vapor barrier.

[0016] In some embodiments, the lip is lays over the foam sheet member and is hinged to extend laterally beyond the first lateral edge in an extended position. The hinge can be a fold in the film sheet material and can be located at or near the first lateral edge of the foam sheet member, allowing the lip to be unfolded to the extended position. Depending on the extent and position of the overlay portion of the film sheet member that overlays the foam sheet member, the lip can be pivoted or otherwise folded onto, and preferably against or into contact with, the overlay portion or the foam sheet member.

[0017] In an embodiment with the first adhesion member disposed on the lip, it can face in a direction away from the foam sheet member when laid thereover, with the first adhesive member disposed on an opposite side of the lip from the foam sheet member. The foam- film sheet can have a second adhesion member attached on the foam-film sheet in the location near the second edge to contact the first adhesion member of a second other sheet placed adjacent the foam-film sheet. In one such embodiment, the first adhesion member on the flap, when laying over the foam sheet member, faces in a same direction as the second adhesion member, away from the foam sheet member. The second adhesion member can be attached directly on the film sheet member in a location to contact the first adhesion member of the second other sheet placed adjacent the foam- film sheet when the lip of the foam-film sheet is in the extended position.

[0018] The foam-film sheet can be provided rolled longitudinally with the lip laying over the rolled foam-sheet member, such as folded back over the foam sheet member to provide a compact configuration of the roll compared to an embodiment in which the lip is left extended beyond the first lateral edge in the roll. The first and second lateral edges are preferably at axial ends of the roll, the lip lays over the foam sheet member, and the first adhesion member on one layer of the rolled foam-film sheet faces away from the foam sheet member of the one layer towards an adjacent roll layer of the foam-film sheet. One or both adhesion members on the one layer can be in direct contact with the adjacent layer, such as by being in direct contact with the foam or film member of the adjacent roll layer.

[0019] In an embodiment of a method of making a film-foam sheet roll, the foam-film sheet is rolled with the lip laying over the foam sheet member so that the first adhesion member on one layer of the rolled foam- film sheet faces away from the foam sheet member of the one layer towards an adjacent roll layer of the foam-film sheet. An embodiment of a method of connecting a plurality of film-foam sheets includes positioning the first lateral edge of a second foam-film sheet next to the second lateral edge of a first foam-film sheet, and pivoting or hinging the lip of the second foam- film sheet about the hinge from over the foam sheet member thereof to the extended position onto the first foam-film sheet to adhere the first adhesion member of the second foam-film sheet to the first foam- film sheet.

[0020] Additional advantages and novel features of the examples will be set forth in part in the description which follows, and in part will become apparent to those skilled in the art upon examination of the following description and the accompanying drawings or may be learned by production or operation of the examples. The advantages of the concepts may be realized and attained by means of the methodologies, instrumentalities and combinations particularly pointed out in the appended claims.

BRIEF DESCRIPTION OF THE DRAWINGS

[0021] Further features and advantages of the present disclosure will become apparent from the following detailed description taken in conjunction with the accompanying Figures showing illustrative embodiments of the present disclosure, in which:

[0022] Fig. 1 is an exploded view of a foam-film sheet constructed according to an embodiment of the disclosure;

[0023] Fig. 2 is a longitudinal end, cross-sectional view of the foam-film sheet;

[0024] Fig. 3 is a longitudinal end, cross-sectional view of a foam-film sheet being installed as flooring underlayment;

[0025] Fig. 4 is a perspective view of a partially unrolled foam-film sheet roll;

[0026] Fig. 5 is a perspective view of two foam-film sheets of similar construction during installation;

[0027] Fig. 6 is an exemplary flowchart of a method of installing the foam-film sheet as flooring underlayment; [0028] Fig. 7 is an illustration of another embodiment of a foam-film sheet;

[0029] Fig. 8 is a side view of an embodiment of a method of laminating an embodiment of a foam-film sheet;

[0030] Fig. 9 is a cross-sectional view of another embodiment of a foam-film sheet roll with a folded lip;

[0031] Figs. 10 and 11 are perspective views of rolls as shown in Fig. 9 being installed;

[0032] Fig. 12 is an exemplary flowchart of a method of making a roll of the foam-film sheet of Fig. 9; and

[0033] Fig. 13 is an exemplary flowchart of a method of installing, foam- film sheets as shown in Fig. 9, as flooring underlayment.

[0034] Throughout the drawings, the same reference numerals and characters, unless otherwise stated, are used to denote like features, elements, components, or portions of the illustrated embodiments. Moreover, while the present disclosure will now be described in detail with reference to the figures, it is done so in connection with the illustrative embodiments and is not limited by the particular embodiments illustrated in the figures.

DETAILED DESCRIPTION OF THE DISCLOSURE

[0035] Referring to Figs. 1 and 2, an embodiment of a foam-film composite sheet 100 that includes a foam sheet member, such as foam sheet 102, and a film sheet member, such as film sheet 104. A typical use of this embodiment is as flooring underlayment.

[0036] The foam-film sheet 100 can be provided as an elongated strip that is rolled into a roll for packaging and shipping, and which can be unrolled on-site for installation. In this configuration, the foam- film sheet 100 strip is preferably rectangular, preferably with an elongated, longitudinal dimension that is rolled, and a lateral dimension about which the sheet 100 is rolled. The foam-film sheet 100 can have lateral edges 105,107 on opposite lateral sides of the foam-film sheet 100, preferably parallel to one another. The foam sheet 102 can have lateral edges 106,108 on opposite lateral sides of the foam sheet 102, preferably parallel to one another. The film sheet 102 can have lateral edges 120,122 on opposite lateral sides of the film sheet 104, preferably parallel to one another. In some embodiments, the lateral edges 120,122 of the film sheet 102 and/or the lateral edges 106,108 of the foam sheet 104 can correspond to the lateral edges 105,107 of the foam-film sheet 100.

[0037] The film sheet 104 of this embodiment is preferably also rectangular, although other shapes can alternatively be used. The film sheet 104 can include an overlay portion 114 and overhang portion, such as a lip 116. The overlay portion 114 is overlaid on the foam sheet 102. The lip 116 extends beyond foam sheet lateral edge 106, with the lateral edge 122 of the film sheet 104 being disposed at the lateral side of the lip 116. In this embodiment, a single lip 116 is provided, extending from only one foam sheet lateral edge 106, but in an alternative embodiment, another lip can be provided extending beyond both foam sheet lateral edges 106,108. In other embodiments with a single lip 116, one of the lateral edges 120,122 can be disposed at one of the foam sheet lateral edges 106,108, or inward therefrom.

[0038] The foam-film sheet 100 includes adhesion members that cooperatively bond to adhesion member on other, adjacent, foam-film sheets. The adjacent foam-film sheets can thus be arranged to collectively form a large sheet, useful, for example, as an underlayment on subflooring. Preferably, the adhesion members are selected to form a cold seal with each other.

[0039] In the preferred embodiment, the foam-film sheet 100 includes an adhesion member 128 positioned on the lip 116 proximate the lateral edge 107 of the foam-film sheet 100 and another adhesion member 130 disposed at an attachment location on the foam-film sheet 100 proximate the opposite lateral edge 105 of the foam-film sheet 100, or opposite lateral edge 106 and/or 120 of the foam and/or film sheets 102,104, as applicable. In the preferred embodiment, in which the film sheet includes a portion that extends to the opposite side of the foam sheet 102 from the lip 116, the adhesion member 130 can be positioned directly on the film sheet 104, as shown in Figs. 2 and 4. In other configurations, the adhesion member 130 can be positioned directly on the foam sheet 102, such as in embodiments in which the film sheet 102 does not extend to or cover the opposite lateral edge 106 or opposite side of the foam sheet 102 from the lip 116, or where the film sheet 104 does not cover the desired location of the adhesion member 130.

[0040] Referring to Fig. 3, two adjacent foam-film sheets 100a,100b are shown being installed with the lip 116 of sheet 100a functioning as a flap, which is laid over the opposite side of an adjacent foam-film sheet 100b. The lip 116 is preferably adhered to the other sheet 100b by the overlaid adhesion members 128,130 of the two adjacent foam-film sheets 100a,100b. The adhesion member 128 of the lip 116 of sheet 100a bonds with the adhesion member 130 of the adjacent foam-film sheet 100b, preferably upon contact, and in some embodiments upon application of pressure or other further action. The foam-film sheets

100a, 100b are preferably of similar or identical construction, so the description of either one applies to both sheets in this embodiment. In other embodiments, one or more of the foam- film or other sheets installed together can be of a different shape, configuration, or construction. [0041] In the preferred embodiment, the lip adhesion member 128a of the lip 116a is positioned on a foam-facing surface of the film material 104a, which faces towards the foam sheet 102 of the same foam-film sheet 100a and forms part of one of the two major surfaces of the foam-film sheet 100. In this location, the lip adhesion member 128a faces and is in a position to lay over a corresponding adhesion member 130b of adjacent foam-film sheet 100b, which is laid out adjacent foam-film sheet 100a, preferably with foam sheet lateral edges 108a,106b abutting or placed closely adjacent or against each other.

[0042] Adhesion member 130b is positioned on another major surface of the foam-film sheet 100b opposite from the foam-side major surface. In the embodiment shown, the opposite major surface is the film side surface on which the film sheet 104 is disposed. When installed as flooring underlayment, the adhesion member 130b faces toward the superimposed lip 116a. When two foam- film sheets are positioned adjacent each other, the adhesion member 128 of the foam-film sheet bonds to the adhesion member 130 of the adjacent foam- film sheet upon contact with each other.

[0043] Preferably, the adhesion members 128,130 are made of a cohesive material, or of two materials that are cohesive with respect to each other. "Cohesive materials," as referred to in the present disclosure, are materials that form a strong bond to each other, but do not form a strong bond to other surrounding materials, such as to the material of the film sheet 104, foam sheet 102, or other exposed materials of the foam-film sheet 100.

[0044] Preferably the bond between the cohesive adhesion members 128,130 is stronger than the yield or tear strength of the film sheet 104, foam sheet 102 or the laminated foam- film sheet 100, such that when pulling the bonded adhesion members 128,130 apart (for example in sheer), the film material 104, foam material 102, or the laminated foam-film sheet 100 will stretch, and in some situations break, before the bond between the cohesive adhesions members 128,130 is broken, thus providing a permanent cohesion. In some embodiments, the bond between the cohesive adhesion members is less strong than the material that it is based on, i.e., the film and or foam material, allowing the cohesively attached adhesion members 128,130 to become unstuck and repositioned, thereby providing a detachable cohesion. In some embodiments, much more force is required to detach the bonded adhesion members 128,130 from each other compared to the force required to detach an adhesion member 128,130 bonded to the film 104, foam 102, or the laminated foam- film sheet 100. The foam-film sheet 100 can also, in some embodiments, include other laminations, sheets, and/or layers. [0045] Typically, the bond strength between two bonded adhesion members 128,130 is at least about 50% greater than the bond strength between an adhesion member 128,130 and the film 104, foam 102, or other portion of the laminated foam-film sheet 100. More typically, the bond strength between two bonded adhesion members 128,130 is at least about 80% stronger than the bond strength between an adhesion member 128,130 and the film 104, foam 102, or other portion of the laminated foam-film sheet 100, and in some embodiments, the bond strength between two bonded adhesion members 128,130 is at least about 90% stronger. Preferably, the bond between the adhesion members 128,130 does not require setting, and the above bond strength is available substantially immediately after beginning bonding with each other by, for example, contact or pressure. But in some embodiments, the bond strength of the adhesions members 128,130 becomes available, such as by the cohesive materials setting after a few seconds, and preferably in less that about 2 minutes, 5 minutes, or 10 minutes. Other setting times may be used for different compounds.

[0046] In an embodiment, the cohesive adhesion members 128,130 cohesively bond with each other. Other embodiments require other actions, such as pressure for pressure-sensitive cohesives, or in some embodiments heat is added. A cold bond is typically preferred. In some embodiments, the cohesive material(s) is selected so that force applied against the lip 116 and adhesion members 128,130 in contact with each other solidify or strengthen the bond between the two. Preferably, the force can be applied using a person's hand (e.g., palm force), a roller, a spatula, or other suitable mechanism can be pressed against the lip 116 and adhesion members 128,130.

[0047] In an embodiment, release layers are not required nor provided, as the cohesive materials of the adhesion members 128,130 do not bond strongly to surfaces that are likely to be adjacent thereto, such as to surfaces of the foam-film sheet 100 other than the adhesion members 128,130 Some embodiment, however, can be provided with release layers on the adhesion members 128,130, which are removed upon installation of the foam-film sheets 100 to expose the adhesion members 128,130 for cohesion with corresponding adhesion members 128,130 of an adjacent foam-film sheet 100.

[0048] As shown in Fig. 4, the adhesion members 128,130 of one embodiment are continuous and solid strips that extend longitudinally along the foam-film sheet 102 and proximate the lateral edges 120,122. Preferably, the adhesion members 128,130 are positioned at a distance 132 from the lateral edges 120,122, preferably near, and optionally at the lateral edges 120,122. For example, the adhesion members 128,130 can be positioned at a distance 132 that is about at least a ¼ inch from the lateral edges 120,122, and most preferably the adhesion members 128,130 are positioned at a distance 132 that is about at least a ½ inch from the lateral edges 120,122. Typically, the adhesion members 128,130 are positioned at a distance 132 that is up to about 2 to 3 inches from the lateral edges 120,122. With respect to the width 118 of the lip 116, the adhesion members 128,130 can be positioned generally centered on the lip 116, or alternatively off center towards the foam sheet edge 108 or towards the lip edge, which is at lateral edge 122 of the film sheet 104 in Fig.l. Preferably, the adhesions members 128,130 are positioned such that the adhesion member 128 of the lip 116 generally aligns with the adhesion member 130 of an adjacent foam-film sheet. It is appreciated, however, that different positions of the adhesion members 128,130 can be employed for different dimensions of the lip 116. The adhesion strips typically has a width 134 of at least about a ¼ inch or at least about a ½ or 1 inch to about the width 118 of the lip 116, more preferably to about 1 inch to about 4 inches, and most preferably up to about 2 inches or to about 3 inches. The width 134 of the adhesion members 128,130 is often at least about 5%, and often up to 50% or 90% of the width 118 of the lip 116, but other suitable sizes can be used, such as by fully covering the lip 116 with the adhesion member and using a similar or larger size corresponding adhesion member on the opposite side and major surface of the foam-film sheet. The width 134 of the lip adhesion member 128 can be different from the adhesion member 130. It is appreciated that other suitable dimensions of the adhesion strip can also be used.

[0049] Alternatively, one or both of the adhesion members 128,130 are a series of dots, dashes, lines, or other discrete, spaced or connected shapes that cover an area to make contact with the opposing adhesion member 128,130. For example, one adhesion member 128 can be continuously extensive strip, while the opposing adhesion member 130 is a series of dots that are positioned to make contact with the adhesion member 128. The series of dots can either be random or organized in lines. In other embodiments, the adhesion members 128,130 can comprise of multiple strips of adhesion members or other suitable shapes.

[0050] Examples of a suitable cohesive material from which the adhesion members can be made include natural and synthetic latex-based cohesives. The cohesive material in some embodiments is applied as a liquid to the appropriate portion of the foam-film sheet 100. Often, the latex or other cohesive material is mixed with water without additional adhesives to bond to the respective portion of the foam-film sheet 100. When the cohesive dries, it is stuck to the respective substrate to which is has been applied. In some embodiments, the cohesive material can be mixed with an adhesive liquid applied, typically as a liquid, onto the film and foam-film sheet 100 in liquid form. After applying the cohesive and adhesive liquid mixture on the film, the adhesive liquid evaporates, leaving the cohesive bonded to the film 104. One method of liquid application is spraying, although brushing or other methods can be used.

[0051] In a preferred embodiment, the foam-film sheet is conveniently wound onto mandrels to provide master rolls. Typically the master rolls produced at the production site are shipped to a converter to provide the smaller or mini-rolls, for example as shown in Figs. 4 and 5, for sale to distributors or end users. Preferably, the foam-film sheet 100 has a width 138 that is about 30 inches to about 80 inches (including the width of the lip 116), and more preferably about 52 inches wide (including the width of the lip 116). Typically, the foam- film sheet 100 in the master rolls has a length 140 of about 30 to about 80 (linear) feet long, and more preferably has a length 140 of about 50 (linear) feet long. Although other dimensions can be used.

[0052] When provided in the master rolls, the cohesive material causes the foam-film sheet 100 to bond weakly, or not at all, to itself. For example, as illustrated in Fig. 5, the cohesive material of the adhesion member 130 bonds weakly, or not at all, to the foam sheet 102 when in a rolled configuration. As a result, preferably, a release layer is neither required nor necessary on the adhesion members 128, 130, although in some embodiments, a release layer can be used. Because a release layer is not required, the cohesive bonding of the adhesion members 128, 130 greatly reduces manufacturing costs.

[0053] In a method of installing the foam-film sheets 100 as underlayment, a series of foam-film sheets 100 are laid adjacent to each other, with lateral edges touching or near each other, laterally side by side, to form an underlayment arrangement. Because the floor installers must continuously walk across the underlayment arrangement during installation of the flooring, having the lip 116 of the foam-film sheet 100 adhere to another foam-film sheet adjacent thereto prevents the foam-film sheets 100 from shifting with respect to one another and keeps the lips 116 from being flipped out of position, such as by the installers feet. Such arrangement prevents installers from falling, slipping, or tripping on the foam-film sheets and also ensures that the foam-film sheets are properly aligned and positioned throughout installation.

[0054] Fig. 6 illustrates an exemplary flowchart of installing the foam-film sheet to form the underlayment. To install the underlayment, a first foam-film sheet 100a is unrolled onto a subfloor (step 200). A second foam-film sheet 100b is unrolled onto the subfloor adjacent the first foam-film sheet 100a (step 202). Preferably, the foam sheet of the second foam-film sheet is placed adjacent to the foam sheet of the first foam-film sheet. The lip 116b of the second foam-film sheet 100b is positioned in overlap with the first foam-film sheet 100a so that the adhesion member 128b of the lip 116b is aligned with the adhesion member 13ab of the first foam-film sheet 100a (step 204). The adhesion members 128b, 130a cohesively form a bond with each other (step 206), where cohesives are used. In some embodiments, pressure can be applied against lip 116b to further strengthen or solidify the bond between the adhesion members 128b, 130a. Additional foam-film sheets can be similarly installed until the desired number of foam-film sheets are installed (step 208). The flooring is then installed on the laid-out underlayment (step 210). As will be understood, other methods can be employed. For example, the film sheet member can be placed under or over the foam sheet member of the foam-film sheet, with the film sheet member, for instance, contacting the subfloor or the flooring, and the lip placed below or above the portion of the adjacent foam- film sheet that it is in overlap with.

[0055] Different suitable widths of the foam-film sheet 100 can be used depending on what the foam-film sheet 100 is used for. For example, when used as an underlayment, the width 110 of the foam sheet 102 between the lateral edges 106,108 is typically between about 20 inches to about 100 inches, more typically about 40 inches to about 60 inches, and in one embodiment, about 48 inches. The thickness 112 of the foam sheet 102 is generally be between about 0.01 and about 0.2 inches, more preferably between about 0.05 inches and about 0.15 inches, and most preferably between about 0.07 and 0.08 inches. In general, the width 110 and thickness 112 of the foam sheet 102 is relatively consistent along its length, although variations of thickness and width are possible in some embodiments.

[0056] The foam sheet 102 typically made of a suitable plastic material. Preferably, the foam sheet 102 is made of a polymer material, including, but not limited to, polyethylenes, polypropylenes, polyvinyls, polyure thanes, and any other polymer as may be known in the art, including combinations and mixtures thereof. Most preferably, the foam sheet 102 is made of a low density polyethylene (LDPE). The material can be consistent throughout the foam sheet 102, although variations in composition are possible in some embodiments. The polyethylene foam sheet 102 can be formed by means of a conventional polyethylene foam sheet extrusion process or other suitable foam sheet-forming process.

[0057] The foam sheet 102 provides sound reduction and cushioning. The density of the polyethylene foam sheet 102 is preferably a low density, typically between about 1 pcf and about 5 pcf. For example, the density of the foam sheet 102 is typically between about 2.2 pcf. [0058] The polyethylene foam sheet 102 in a preferred embodiment is closed celled, with at least half of the cells being closed cells, and preferably at least 80 percent of the cells being closed cells. A high closed-cell content is often used to provide a polyethylene foam sheet 102 with a desired degree of elasticity while having the necessary structural integrity and resilience when subjected to transient or static loads of light or comparative heavy values as known in the art. The typical desired degree of elasticity helps to eliminate the "pounding" which the feet, legs, knees, back, etc., of a person walking or standing on the floor are otherwise subjected to when no foam sheet is located between the wood finish flooring and the concrete subfloor. The polyethylene foam sheet 102 must also have enough foam structure integrity so as not to compress too much when a heavy load is applied to the wood finish flooring.

[0059] The width 126 of the film sheet 104 (including the lip 116), i.e., the distance between lateral edges, may generally be between about 30 inches and about 150 inches, more preferably between about 40 inches and about 115 inches, and more preferably between about 50 inches and about 110 inches. In an exemplary embodiment, the width of the film sheet is about 52 inches. Preferably, the width 118 of the lip 116 is typically under about 1/10 of the width of the foam sheet member 110, and in some embodiments is at least about 1 inch or 2 inches, and is up to about 5 or 6 inches. In a preferred embodiment, the width 118 is about 4 inches.

[0060] In the preferred embodiment, the lip 116 of the film 104 extends to the lateral edge 108 of the foam sheet 102 opposite the lip 116 and spans the entirety of the foam surface 136. Where the film sheets 104 of adjacent foam-film sheets 100 substantially completely cover the installed foam sheets 102, the film sheets 104 can cooperatively provide a moisture barrier. This is often advantageous when providing an underlayment for laminate finishing flooring, such as over a concrete subfloor, in which the laminate finish flooring often has a moisture resistant lower ply, but the flooring does not provide a vapor barrier. Other types of flooring and subflooring can alternatively be used.

[0061] Alternatively, the overlaying portion of the film sheet 102 can be smaller in width and/or length than the width of the foam sheet 110, as shown, for example, in the

embodiment of a foam-film sheet 150 shown in Fig. 7. In such embodiment, in which the a film sheet, such as film sheet 154, does not extend to the lateral edge 106, the adhesion member 130 can be provided directly on the foam surface 136 of the foam sheet 102 and positioned to contact and bond to the adhesion member 128 of lip 116 of an adjacent foam- film sheet 100. In some embodiments, the film sheet 154 can be provided in multiple strips that are applied on the foam sheet 102. The overlay portion 114 of foam- film sheet 150 has a width of close to the lateral width of the lip 116, but other suitable widths can be used. Also, the overlay portion can be attached to other parts of the foam sheet 102.

[0062] Referring again to Fig. 2, the thickness 124 of the film sheet 104 can generally about 0.1 mils up to about 10 mils, more preferably about 0.1 mils up to about 5 mils, and most preferably up to about 3 mils. In general, the width 126 and thickness 104 of the film layer is relatively consistent along its length, although variations of thickness and width are possible in some embodiments.

[0063] The film sheet 104 is generally made of a suitable plastic material. Preferably, the film sheet 104 is made of a polymer material, such as, poly ethylenes, polypropylenes, polyvinyls, polyure thanes, and any other polymer as may be known in the art, including combinations and mixtures thereof. Most preferably, the film sheet 104 is made of a high density polyethylene (HDPE). In general, the material of the film sheet 104 is consistent throughout the sheet 104, although variations in composition are possible in some embodiments.

[0064] The polyethylene film 104 can be formed by means of a conventional polyethylene film extrusion process or any other suitable film-forming process. In a typical, conventional polyethylene film 104 extrusion process termed the blown tubing process, the thin polyethylene film 104 is extruded on a continuous basis by extruding a tube of the polyethylene in molten state through an annular nozzle behind which is a device through which air is introduced into the emerging tube. Other conventional polyethylene film 104 extrusion processes are the chill roll process and the water quench process. A slot die is used in the chill roll process. Molten polyethylene from the die goes to a highly polished, temperature-controlled roll which cools and solidifies it. The water quench method is similar to the chill roll process except that the extrudate is cooled in a water bath.

[0065] The thin polyethylene film 104 and/or foam sheet 102 can also contain flame retardants, stabilizers, antioxidants, colorants, fillers, plasticizers or any other conventional or suitable additives.

[0066] Preferably, the polyethylene foam sheet 102 and the polyethylene film 104 are adhered or laminated together by any suitable means or scheme. In the preferred

embodiment, the foam sheet 102 and film sheet 104 are adhered together by means of a low density polyethylene virgin resin. The polyethylene foam 102 is preferably extruded in sheet form and essentially immediately thereafter laminated to the polyethylene film 104. The polyethylene film 104 and the polyethylene foam 102 sheet can be laminated together by the use of heat and/or adhesive. Once laminated, the foam sheet 102 provides the foam member or layer and the film sheet 104 provides the film member or layer of the foam-film sheet 100.

[0067] One process of preparing the foam-film sheet 100 involves bringing together a moving continuous web of a thin sheet of polyethylene foam 102 and a moving continuous web of a thin film 104 of polyethylene. An adhesive is applied to the facing surfaces of the moving webs at the point of contact between the moving webs, and then sufficient pressure (without damaging the polyethylene foam 102) is applied by two opposing rollers to the contacting webs at the point of contact of the moving webs to achieve the form-film sheet composition 100. The moving continuous web of thin polyethylene foam sheet 102 in some embodiments is formed by extrusion, passed through at least one oven, and, while being at a temperature between about 350 °F and about 500 °F, brought into contact with the moving continuous web of thin polyethylene film 102.

[0068] In an embodiment, the moving continuous webs move downward and, before contacting each other, are oriented at opposing slight angles to the vertical. The adhesive is in a liquid form and is dropped into the point of contact of the moving webs. Preferably, the liquid adhesive is molten low density polyethylene, the web of polyethylene foam sheet 102 is composed of low density polyethylene, and the web of polyethylene film 104 is composed of low density polyethylene. Other suitable adhesive can be used, but low density polyethylene is preferred, for laminating the foam sheet 102 and the film sheet 104.

[0069] The foam sheet 102 can be reheated just before it is laminated with the polyethylene film. But most preferably the lamination is done using extruded foam sheet 102 at an elevated temperature immediately after exiting the oven(s) downstream from the extruder.

[0070] Fig. 8 illustrates one embodiment of a suitable process of preparing the foam- film sheet 100, which is described in U.S. Patent 7,047,705, although alternative processes can be used. An extruded web 312 of low density polyethylene foam sheet and an extruded web 311 of low density polyethylene film are fed downwardly between chill rolls 324,325. Webs 311,312 form a vee (v) as they approach chill rolls 324,325. The nip pressure at chill rolls 324,325 is preferably about 60 psi. The surface temperature of chill rolls 324,325 is preferably about 60 °F. Stream 323 of molten low density polyethylene virgin resin drops from container arrangement 319 into and, along the entire length of, the apex of the vee (v) formed by webs 311,312 as they enter the nip of chill rolls 324,325. The low density polyethylene is in molten form in container 322 and flows downward through nozzle 321 to form a stream. The molten low density polyethylene stream (extrudate) 323 is formed into thin adhesive layer 313 (having a thickness of about 1 mil) as webs 311,312 pass through chill rolls 324,325. Thin adhesive layer 313 bonds webs 311,312 together to form the foam- film sheet 100. Foam-film sheet 100, in web form, progresses to a winder (not shown) to form large rolls (e.g., of 1500 linear feet). Other methods of manufacturing the foam-film sheet 100 can be used.

[0071] In alternative embodiments, the foam sheet 102 and film sheet 104 can be adhered using one or more seals provided therebetween, as described in U.S. Application No.

13/453,502. For example, in some embodiments, a seal is disposed between a portion of the foam sheet 102 and the film sheet 104 proximate lateral edge 106. Another seal is disposed between a portion of the foam sheet 102 and film sheet 104 proximate the opposite lateral edge 108. The foam sheet 102 and film sheet 104 remain substantially unsealed along the entire transverse width between the first and second sealed portions near the lateral edges of the foam material 102. In embodiments in which the overlay portion 114 of the film sheet 104 does not extend across the entire surface 136 of the foam sheet 102, one or more seals can seal the overlay portion 114 of the film sheet 102 and the foam sheet 102. For example, a first seal can be disposed proximate the lateral edge 120 of the film sheet 104 and overlay portion 114, and a second seal can be disposed on the overlay portion 114 proximate the lateral edge 108 of the foam sheet 102 such that the area therebetween remains substantially unsealed. In yet other embodiments, the sealed areas between the foam sheet 102 and film sheet 104 can be less than the entire area of the film sheet 104, and preferably at least near the edges of the overlay portion 114.

[0072] The seals between the film sheet 104 and foam sheet 102 can generally be provided in a suitable manner capable of adhering a film sheet to a foam sheet, including, but not limited to adhesives, tapes, glues, hot-melts, thermo or heat-sealing, thermo or heat- welding, sonic-welding, and lamination, among others. In an exemplary embodiment, the seals are provided as a hot melt glue, and preferably a PSA (pressure sensitive adhesive), such as a hot-melt PSA or another type of known PSA.

[0073] In alternative embodiments, a removable release layer, as known in the art, can be provided on the adhesive member 128 which can be removed before adhering to the adjacent sheet. The adhesive on the lip can alternatively be provided on the opposite side of the sheet 100, on the side of the film material 104 or other surface of the sheet 100 that faces away from the foam material, for adhering to the lip of an adjacent foam-film sheet that is laid thereover. With cohesive used as the adhesion members, however, many embodiments will not have release layers as the cohesive will not form strong bonds to other surrounding materials during installation.

[0074] While the figures provided herein illustrate the film sheet 104 disposed on the top surface of the foam sheet 102, it is appreciated that the foam-film sheet 100 can be arranged with the film sheet 104 extending from the bottom surface of the foam sheet 104 and the adhesion member 128 facing upward. Alternatively, one foam-film sheet 100 can be configured with the film sheet 104 extending from the bottom surface of the foam sheet 104 and the adhesions member 128 facing upward, and an adjacent foam-film sheet 100 can be configured with the film sheet 104 extending from the top surface of the foam sheet 104 with the adhesions member 128 facing downward.

[0075] The foam-film sheet 100, in some alternative embodiments, can have multiple layers of film and/or foam. For example, the foam-film sheet 100 can have a top and a bottom film sheets and a foam sheet therebetween. In such configurations, the lateral edges of either one or both of the top and bottom film sheets can extend beyond the lateral edges 106,108 of the foam sheet 102 to form the lip.

[0076] In alternative embodiments, the foam-film sheet 100 described herein is not limited to a flooring underlayment. The foam-film sheet 100 can also be used as a padded mat or an insulation sheet (for example, around pipes, coffee cups, and the like).

[0077] The foam-film sheets of the embodiments described above, including of foam-film sheets 100, can be modified by folding the flaps back towards the opposite edge 106 from where the flap 116 extends, placing the lip 116 upside down from its extended position. Preferably, the flap 116 is folded back over the foam sheet 102 to provide a more compact configuration for storage and shipping and to facilitate installation. Figs. 9-11 illustrate an embodiment of the foam- film sheet, such as the foam- film sheet 100 of Fig. 1, rolled into a roll 400 configuration, in which the lip 116 is folded back over the foam sheet member 102 and the overlay portion 104 at a hinge 452, such as a living hinge formed by folding the film sheet 104. It is appreciated that the foam-film sheet 400 can include the features and elements of the embodiments described above.

[0078] Depending on the lateral extent and position of the film sheet 104 on the foam sheet 102, when in the folded configuration, the lip 116 can be in direct contact with the foam sheet 102 or the overlay portion 114 of the film sheet 104. While the hinge is shown at the lateral edge 108 of the foam sheet 104, in alternative embodiments, the hinge 452 can be located beyond or inward of the lateral edge 108, and preferably near the lateral edge 108. In some cases with the hinge extending through the lip 116, so that the lip is folded over itself to a fraction of its lateral width. The embodiment of Fig. 9 has the lateral edges 106 and 108 positioned at the axial ends 454 of the roll, although the hinge can be positioned at an axial end of the roll where the hinge is located laterally beyond lateral edge 108.

[0079] In the folded configuration, the adhesion member 128 on the lip 116 preferably faces in a direction away from the foam sheet 102. In the roll 400, both the adhesion member 128 on the lip 116 and the adhesion member 130 at the attachment location are on a radially inward side of each layer of the roll 400, facing radially inward. Thus, in this embodiment, both adhesion members 128,130 face in a same direction, when the flap 116 is in the compact, folded position, and in opposite directions (to contact the corresponding adhesion member of an adjacent foam-film sheet) when the flap 116 is hinged to its extended position (shown, for example, in Fig. 2). The layers of the roll 400 preferably are oriented with the foam sheet 102 radially outward of the film sheet 104. The lip 116 is preferably folded onto the inward surface of the layer. Alternative embodiments can have other rolled

configurations, and additional film layers, for example. They can also fold the lip in other directions or provide a different orientation and location of the adhesion members.

[0080] The lip 116 of each sandwiched layer in the roll 400, while preferably facing away from the foam layer 102, preferably faces towards an adjacent layer of the roll 400. Including in embodiments that are free of a release layer over one or both adhesion members 128,130 (typically when cohesives are used as the adhesive members), those adhesion layers 128,130 can be in direct contact with the adjacent layer of the roll 400.

[0081] Referring to Fig. 10, in an embodiment of a method of making the foam-film sheet 100, after laminating the film sheet 104 onto the foam sheet 102 in step 460, the lip 116 is folded back at the hinge, for example over the foam sheet 102, in step 462. The adhesion member 130 is applies, and adhesion member 128, such as a cohesive, is applied on the exposed surface of the lipl 16 in step 464, which can be done before or after the folding step 462. The foam-film sheet 100 is then rolled into the rolled configuration in step 466. Other suitable methods can be employed.

[0082] Installation of the foam-film sheet 100 as underlayment is similar to the methods described above, but includes unfolding the lip 116 to the extended configuration, so other features of the above methods can be combined with the embodiment of the method of installing the foam-film sheet from roll 400. Referring to Figs. 11-13, a foam-film sheet 100b can be laid onto a subfloor adjacent to another similar foam-film sheet 100a, with lateral edges touching or near each other, laterally side by side, to form an underlayment arrangement (steps 468,470). At this point, the lip 116b of the second foam-film sheet 100b is still in its folded position (Fig. 11), and the foam-film sheet 100 has a narrower lateral width than with the lip 116b unfolded. Also, the folded lip 116b allows close placement of the adjacent foam-film sheets 100 as the lip does not cover or extend across the adjacent lateral edges of the foam-film sheets 100, or across any gap therebetween. Additionally, in embodiments in which no release layer is provided, or on embodiments in which no release layer remains on the adhesive member 128 when roll 400 is unrolled, the folded edge keeps the adhesion members 128b, 130a from contacting before the underlayment sheets are properly arranged on the subfloor and with respect to each other. It is noted that in embodiments in which regular adhesives are used instead of cohesives, a release layer is not required to stay on the lip 116b after unrolling and before unfolding, as the adhesion member thereon is not yet in contact with another surface, and some embodiments can have a release layer that stays on the facing part of the adjacent layer of the roll and prevents adhesion between roll layers.

[0083] If the roll 400 has a length of foam-film sheet 100 that is longer than the length desired for a particular flooring installation, the foam-film sheet 100 can be cut to length.

The lip 116b is hinged to unfold it onto foam-film sheet 100a, as indicated by arrow 456, typically after cutting the roll 400 to length, so that the adhesion member 128b of the lip 116b is aligned with the adhesion member 130a of the first foam-film sheet 100a (step 472; Fig.

13). The adhesion members 128b, 130a cohesively form a bond with each other, where cohesives are used (step 474). Additional foam-film sheets can be similarly installed until the desired number of foam-film sheets are installed (step 476). The flooring is then installed on the laid-out underlayment (step 478).

[0084] As will be understood, other methods can be employed. For example, the film sheet member can be placed under or over the foam sheet member of the foam-film sheet, with the film sheet member, for instance, contacting the subfloor or the flooring, and the lip placed below or above the portion of the adjacent foam- film sheet that it is in overlap with. In such embodiments, the lip may be unfolded as the foam- film sheet is laid onto the subfloor.

[0085] It will be appreciated that with regard to any of the above-described embodiments in this disclosure, the word "layer" or "sheet" may refer to a single layer or sheet of material, or it may refer to multiple layers or sheets of material. Such multiple layers or sheet may be made from a single material, or a combination of materials, as described above.

[0086] Any and all references specifically identified in the specification of the present application are expressly incorporated herein in their entirety by reference thereto. The term "about," as used herein, should generally be understood to refer to both the corresponding number and a range of numbers. Moreover, all numerical ranges herein should be understood to include each whole integer within the range.

[0087] While illustrative embodiments of the disclosure are disclosed herein, it will be appreciated that numerous modifications and other embodiments may be devised by those skilled in the art. For example, the features for the various embodiments can be used in other embodiments. Therefore, it will be understood that the appended claims are intended to cover all such modifications and embodiments that come within the spirit and scope of the present disclosure.

Claims

CLAIMS What is claimed is:

1. A foam-film sheet that is attachable to a first other sheet of similar construction thereto, the foam-film sheet comprising:

a foam sheet member having first and second lateral edges on opposite sides of the foam sheet member, and an attachment region near the second lateral edge;

a film sheet member attached to the foam sheet member and including:

a lip hinged to extend laterally beyond the first lateral edge in an extended position, wherein the lip is hinged back towards the second lateral edge; and

a first adhesion member disposed on the lip or attachment region of the foam-film sheet in a location to attach the lip or attachment region to the attachment region or lip, respectively, of the first other sheet placed adjacent the foam-film sheet when the lip of the foam-film sheet is in the extended position.

2. The foam-film sheet of claim 1 , wherein the foam-film sheet lip is hinged at the first lateral edge.

3. The foam-film sheet of claim 1, wherein the lip lays over the foam sheet member.

4. The foam-film sheet of claim 1 , wherein the film sheet member includes an overlay portion attached to the foam sheet member, and the lip extends from the overlay portion.

5. The foam-film sheet of claim 4, wherein the foam-film sheet lip lays over the overlay portion, over the foam sheet member.

6. The foam-film sheet of claim 5, wherein the foam-film sheet lip lays against the overlay portion.

7. The foam-film sheet of claim 1, wherein the lip is in a folded configuration on the foam sheet member, and is configured for unfolding to the extended position.

8. The foam-film sheet of claim 1, wherein the first adhesion member faces in a direction away from the foam sheet member and is disposed on the lip of the foam-film sheet in said location to attach to the attachment region of the first other sheet placed adjacent the foam-film sheet when the lip of the foam-film sheet is in the extended position.

9. The foam-film sheet of claim 1, wherein the foam-film sheet is attachable to a second other sheet of similar construction thereto, the foam-film sheet further comprising a second adhesion member attached on the foam-film sheet in the attachment location to contact the first adhesion member of a second other sheet placed adjacent the foam-film sheet, wherein the first adhesion member of the foam-film sheet is disposed in a location on the lip to contact the second adhesion member of the first other sheet placed adjacent the foam-film sheet when the lip of the foam-film sheet is hinged to the extended position.

10. The foam-film sheet of claim 9, wherein the first and second adhesion members are made of cohesive materials that adhere cohesively to each other.

11. The foam-film sheet of claim 10, wherein the cohesive materials bond to each other stronger than to adjacent exposed surfaces of the foam-film sheet.

12. The foam-film sheet of claim 10, wherein:

the first adhesion member covers an area at a first distance outboard from the first lateral edge of the foam sheet member; and

the second adhesion member covers an area at the first distance inboard from the second lateral edge of the foam sheet member, such that the first and second adhesion members of the foam-film sheet overlay the second and first adhesion members of the first and second other foam-film sheet members, respectively, when the lateral edges of the foam sheet members thereof are placed in contact with each other and the lip of the foam-film sheet is hinged to the extended position.

13. The foam-film sheet of claim 10, wherein:

the foam-film sheet member has a first major surface and a second major surface opposite from the first major surface;

the first adhesion member is disposed on the first major surface; and

the second adhesion member is disposed on the second major surface, the first and second adhesion members facing in a same direction with the lip hinged back towards the second lateral edge.

14. The foam-film sheet of claim 10, where in the second adhesion member is attached directly on the film sheet member of the foam-film sheet in a location to contact the first adhesion member of the second other sheet placed adjacent the foam-film sheet when the lip of the foam-film sheet is in the extended position.

15. The foam-film sheet of claim 1, wherein the foam-film sheet is a flooring

underlayment sheet.

16. The foam-film sheet of claim 1, wherein the foam-film sheet is rolled longitudinally as a roll, so that the lateral edges are positioned on or near axial ends of the roll, with the first adhesion member on one layer of the roll facing away from the foam sheet member of the one layer and towards an adjacent layer of the roll.

17. The foam-film sheet of claim 16, wherein the first adhesion member on the one layer is in direct contact with the adjacent layer.

18. The foam-film sheet of claim 17, wherein the first adhesion member is free of a release layer between the first adhesion member and the adjacent layer of the roll.

19. The foam- film sheet of claim 18, wherein the first adhesion member on the one layer is in direct contact with the foam or film sheet member of the adjacent layer of the roll.

20. A supply roll foam-film sheet, comprising:

a foam sheet member having foam surface and first and second lateral edges on opposite sides of the foam sheet;

a film sheet member having:

an overlay portion attached to the foam sheet member, and

a lip that lays over the foam sheet member and is hinged to extend laterally beyond the first lateral edge in an extended position; and

a first adhesion member disposed on the lip; and

a second adhesion member attached on the foam-film sheet in a location to contact the first adhesion member of the second other sheet placed adjacent the foam-film sheet when the rolled foam-film sheet is unrolled, wherein the first adhesion member is disposed in a location on the lip to contact the second adhesion member of the first other sheet placed adjacent the foam-film sheet when the lip is in the extended position;

wherein the foam-film sheet is rolled with the lip laying over the foam sheet member and the first adhesion member on one layer of the roll facing away from the foam sheet member of the one layer and towards an adjacent layer of the roll.

21. The foam- film sheet of claim 20, wherein the adhesion members on the one layer are in direct contact with the adjacent layer, and the location of the second adhesion member is near the second edge.

22. The foam- film sheet of claim 21, wherein at least one of the adhesion members on the one layer is in direct contact with the foam or film member of the adjacent rolled layer.

23. A method of making a film-foam sheet roll, comprising:

providing a foam-film sheet including:

a foam sheet member having first and second lateral edges on opposite sides of the foam sheet member, and an attachment region near the second lateral edge,

a film sheet member having:

a lip hinged to extend laterally beyond the first lateral edge in an extended position, wherein the lip is hinged back towards the second lateral edge; providing a first adhesion member on one of the lip or attachment region of the foam- film sheet in a location to attach the lip or attachment region to an attachment region or lip, respectively, of the first other sheet placed adjacent the foam-film sheet; and

rolling the foam-film sheet with the lip laying over the foam sheet member so that the first adhesion member on one layer of the roll faces away from the foam sheet member of the one layer and towards an adjacent layer of the roll.

24. The method of claim 23, wherein:

the first adhesion member is disposed on the lip,

a second adhesion member is provided attached on the foam-film sheet in a location to contact the first adhesion member of a second other sheet placed adjacent the foam- film sheet;

the foam-film sheet is rolled so that the adhesion members on the one layer are in direct contact with the other layer without light or no adhesion thereto;

the adhesion members are made of latex-based cohesive material to adhere cohesively to each other stronger than they bond to adjacent exposed surfaces of the foam-film sheet.

25. A method of connecting a plurality of film-foam sheets, comprising:

providing first and second foam-film sheets, each of the foam-film sheets including: a foam sheet member having first and second lateral edges on opposite sides of the foam sheet member, and an attachment region near the second lateral edge;

a film sheet member attached to the foam sheet member and including:

a first adhesion member disposed on the lip or attachment region of the foam- film sheet in a location to attach the lip or attachment region to the attachment region or lip, respectively, of the first other sheet placed adjacent the foam-film sheet when the lip of the foam-film sheet is in the extended position;

positioning the first lateral edge of the second foam- film sheet next to the second lateral edge of the first foam-film sheet; and

hinging the lip of the second foam-film sheet to the extended position onto the first foam-film sheet to adhere the first adhesion member of the second foam-film sheet to the first foam-film sheet.