U.S. patent application number 12/101373 was filed with the patent office on 2008-10-16 for acoustical and energy absorbent flooring underlayment.
Invention is credited to Matthew Kriesel.
Application Number | 20080250729 12/101373 |
Document ID | / |
Family ID | 39852454 |
Filed Date | 2008-10-16 |
United States Patent
Application |
20080250729 |
Kind Code |
A1 |
Kriesel; Matthew |
October 16, 2008 |
ACOUSTICAL AND ENERGY ABSORBENT FLOORING UNDERLAYMENT
Abstract
Disclosed is an acoustical flooring underlayment comprised of an
energy absorbing layer formed from a polymeric gel, a first
moisture barrier for engaging a subfloor and optionally a second
moisture barrier for engaging hard flooring. The energy absorbing
layer includes a first side surface, a second side surface and a
plurality of edge surfaces. The flooring underlayment provides
sound attenuating and energy absorbing properties to a flooring
underlayment.
Inventors: |
Kriesel; Matthew; (Melrose,
WI) |
Correspondence
Address: |
Steven L. Schmid
1824 Hickory Trace Dr.
Fleming Island
FL
32003
US
|
Family ID: |
39852454 |
Appl. No.: |
12/101373 |
Filed: |
April 11, 2008 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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60911284 |
Apr 12, 2007 |
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Current U.S.
Class: |
52/145 |
Current CPC
Class: |
E04F 15/203 20130101;
E04F 15/20 20130101 |
Class at
Publication: |
52/145 |
International
Class: |
E04B 1/72 20060101
E04B001/72 |
Claims
1. A flooring underlayment comprising: an energy absorbing layer
formed from a polymeric gel; a first moisture barrier for engaging
a subfloor and a second moisture barrier for engaging a
flooring.
2. The flooring underlayment of claim 1, wherein the energy
absorbing layer includes a first side surface, a second side
surface and a plurality of edge surfaces.
3. The flooring underlayment of claim 2, wherein a first moisture
barrier is laminated to the first side surface of the energy
absorbing layer and includes at least one edge surface laying flush
with a corresponding one of the edge surfaces of the energy
absorbing layer and at least one edge surface projecting past a
corresponding one of the edge surfaces of the energy absorbing
layer.
4. The flooring underlayment of claim 3, wherein a second moisture
barrier is laminated to the second side surface of the energy
absorbing layer and includes plural edge surfaces, each of which
corresponds to and lays flush with one of the edge surfaces of the
energy absorbing layer.
Description
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims the benefit of U.S. Provisional
Application No. Ser. No. 60/911,284 filed Apr. 12, 2007 and is
incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The present invention generally relates to an underlayment
for a floor and more specifically the flooring underlayment
provides sound attenuating and energy absorbing properties to a
flooring underlayment.
BACKGROUND
[0003] A typical hardwood, laminate, or engineered flooring system
may include two or more layers. A top layer typically details the
pattern and texture of the product, and may include a protective
layer, such as a hard coating, for durability. A core layer may be
prepared from pressed fiberboard, for example, or from other
suitable materials. A bottom layer may be included to stabilize the
product and to protect it from deleterious effects of moisture.
Frequently, laminate or engineered flooring systems employ some
type of tongue and groove design to allow the pieces of the
flooring to bond together without requiring the use of
adhesive.
[0004] Most hard flooring systems, particularly those which include
wood and/or laminate flooring, include an underlayment which serves
as a moisture barrier, an energy absorber and a leveler for the
hard flooring. When used in a hard flooring system, the moisture
barrier will prevent the migration of moisture from the subfloor
into the hard flooring. As a result, whether or not an underlayment
is capable of functioning as a moisture barrier is often an
important consideration when selecting an underlayment for use with
a hard flooring system. This is particularly true if the hard
flooring system is to cover a concrete subfloor as moisture
frequently seeps through the concrete subfloor and, in the absence
of a moisture barrier, into the wood or laminate flooring where it
causes the wood flooring to warp or the laminate flooring to
delaminate.
[0005] Likewise, energy absorption is often an important
consideration when selecting an underlayment for use with a hard
flooring system because such an underlayment would absorb some of
the sound or "echo" created by a person walking on the hard
flooring. As a result, the hard flooring would be quieter and,
therefore, more appealing to those concerned with the noise
typically generated by hard flooring. Finally, by smoothing high
points (peaks), low points (valleys), and other irregularities in a
subfloor, an underlayment can help ensure that the relatively
inflexible hard flooring rests on a more level surface.
[0006] A wide variety of underlayments are used in conjunction with
hard flooring. For example, a thin, continuous film of a polymeric
material, for example, polyethylene or vinyl, may be installed over
the subfloor to provide a moisture barrier for the hard flooring.
Oftentimes, a polymeric open cell foam layer is positioned over the
polymer film to provide a degree of cushioning to the hard flooring
placed above it. Variously, the polymer film and open cell foam
layer may be laminated to one another or may be discrete components
installed one over the other. Alternatively, a solid sheet of
polymer having some cushioning characteristics, for example, a
slightly polymerized vinyl chloride polymer, can function as both a
moisture barrier and a cushion between the subfloor and the hard
flooring. Another suitable underlayment is a laminate composite
formed of a moisture impervious vinyl, polyethylene, or polyester
film attached to latex or vinyl foam. Other underlayments used with
hard flooring include nonwoven fiber batts of polyester, nylon, or
polypropylene with a moisture barrier attached to one side of the
fiber batt
[0007] It is well-known that moisture may cause undesirable cupping
or warping of the flooring system. A vapor barrier may be employed
to protect the laminate or engineered flooring system from damage
caused by moisture. Though a vapor barrier may provide some
protection against moisture damage, vapor barriers tend to increase
the cost and installation complexity of such flooring systems.
[0008] Another issue that may be experienced with flooring systems
is the sound that may be produced when the floor is used. In
multi-story structures, for example, sound created by use of an
upper unit floor may be transmitted down into the unit below.
Likewise, sound may be reflected back into the unit in which it is
created. A sound barrier layer may be employed to reduce one or
both of transmitted and reflected noise. Typical sound barrier
layers include dense rubber and plastic sheets, corks, recycled
fibers, and various types of foams. Such sound barriers, however,
tend to be heavy and to add to the complexity and overall cost of
installation.
[0009] Examples of conventional foams used in flooring applications
have EPC contents, and densities resulting in compressive strengths
below about 0.50 kg/cmsup2. These properties of conventional olefin
foam underlayments combine to produce relatively high reflected
sound pressure levels (i.e., greater than about 13.5 dB average) in
the 300 Hz to 1000 Hz range. Other underlayment materials, such as
fiber pad, cork, and non-cross-linked foam, for example, also tend
to produce relatively high reflected sound pressure levels in the
300 Hz to 1000 Hz frequency range. Such materials also tend to
produce high moisture vapor transmission rates (MVTR) unless
additional vapor barrier layers are incorporated.
[0010] Accordingly, it would be desirable if there were available
flooring systems that produced relatively low sound reflections and
moisture vapor transmission rates.
SUMMARY
[0011] The present invention includes a flooring underlayment
configured for installation between hard flooring and a subfloor.
The flooring underlayment is comprised of an energy absorbing layer
formed from a polymeric gel compound such as that disclosed in U.S.
Pat. No. 7,041,719, the contents of which are hereby incorporated
by referenced in their entirety. The polymeric gel compound is
affixed to a first moisture barrier affixed to a first side surface
of the energy absorbing layer. When mechanical energy is applied to
the hard flooring, the energy absorbing layer absorbs at least a
portion of the acoustic energy produced by the hard flooring.
[0012] In further aspects thereof, the first moisture barrier may
be a moisture impermeable film laminated to the first side surface
of the energy absorbing layer or a closed cell foam attached to the
first side surface of the energy absorbing layer. In still further
aspects thereof, the flooring underlayment may further include a
second moisture barrier laminated onto a second side surface of the
energy absorbing layer. In this aspect, the first moisture barrier
engages the subfloor while the second moisture barrier engages the
hard flooring.
[0013] In another embodiment, a flooring underlayment configured
for installation between hard flooring and a subfloor is disclosed.
The flooring underlayment is comprised of an energy absorbing layer
formed from a polymeric gel, a first moisture barrier for engaging
a subfloor and a second moisture barrier for engaging hard
flooring. The energy absorbing layer includes a first side surface,
a second side surface and a plurality of edge surfaces. The first
moisture barrier is laminated to the first side surface of the
energy absorbing layer and includes at least one edge surface
laying flush with a corresponding one of the edge surfaces of the
energy absorbing layer and at least one edge surface projecting
past a corresponding one of the edge surfaces of the energy
absorbing layer. The second moisture barrier is laminated to the
second side surface of the energy absorbing layer and includes
plural edge surfaces, each of which corresponds to and lays flush
with one of the edge surfaces of the energy absorbing layer. When
mechanical energy is applied to the hard flooring, the energy
absorbing layer absorbs at least a portion of the acoustic energy
produced by the hard flooring.
[0014] In still another embodiment, disclosed herein is a hard
flooring system configured for installation in a space defined by a
subfloor, a first wall and a second wall. The hard flooring system
is comprise of a first energy absorptive/moisture resistive
underlayment section, a second energy absorptive/moisture resistive
underlayment section, a hard flooring and a moisture resistive
section. In turn, each of the first and second energy
absorptive/moisture resistive underlayment sections is comprised of
an energy absorbing layer formed from a recycled material, a first
moisture barrier for engaging a subfloor and a second moisture
barrier engaging the hard flooring. The first moisture barrier is
laminated to a first side surface of the energy absorbing layer and
includes at least one edge surface laying flush with a
corresponding one of the edge surfaces of the energy absorbing
layer and at least one edge surface projecting past a corresponding
one of the edge surfaces of the energy absorbing layer. The second
moisture barrier is laminated to a second side surface of the
energy absorbing layer and includes plural edge surfaces, each of
which lays flush with one of the plurality of edge surfaces of the
energy absorbing layer.
[0015] As further disclosed herein, the projecting edge surface of
the first moisture barrier laminated to the energy absorbing layer
of the first energy absorptive/moisture resistive underlayment
section engages a portion of the first wall while the projecting
edge surface of the first moisture barrier laminated to the energy
absorbing layer of the second energy absorptive/moisture resistive
underlayment is positioned underneath a portion of the first
moisture barrier laminated to the energy absorbing layer of the
first energy absorptive/moisture resistive underlayment section.
Finally, the moisture resistive section engages the second wall and
an edge surface of the energy absorbing layer of the second energy
absorptive/moisture resistive underlayment section which abuts the
second wall.
DRAWINGS
[0016] In the Drawings:
[0017] FIG. 1 illustrates the flooring underlayment and in
combination with a wood flooring laminate.
DETAILED DESCRIPTION
[0018] Disclosed is a flooring underlayment comprised of an energy
absorbing layer formed from a polymeric gel, a first moisture
barrier for engaging a subfloor and a second moisture barrier for
engaging hard flooring. The energy absorbing layer includes a first
side surface, a second side surface and a plurality of edge
surfaces. The first moisture barrier is laminated to the first side
surface of the energy absorbing layer and includes at least one
edge surface laying flush with a corresponding one of the edge
surfaces of the energy absorbing layer and at least one edge
surface projecting past a corresponding one of the edge surfaces of
the energy absorbing layer. The second moisture barrier is
laminated to the second side surface of the energy absorbing layer
and includes plural edge surfaces, each of which corresponds to and
lays flush with one of the edge surfaces of the energy absorbing
layer.
[0019] Referring now in greater detail to the drawing in which like
numerals indicate like parts throughout the several views, FIG. 1
depicts the flooring underlayment 2 comprised of energy absorbing
layer 4 formed from in part a polymeric gel compound having a
moisture barrier 6. Additionally depicted is the subfloor 10 and
the wood laminate flooring 8.
[0020] While Applicants have set forth embodiments as illustrated
and described above, it is recognized that variations may be made
with respect to disclosed embodiments. Therefore, while the
invention has been disclosed in various forms only, it will be
obvious to those skilled in the art that many additions, deletions
and modifications can be made without departing from the spirit and
scope of this invention, and no undue limits should be imposed
except as set forth in the following claims.
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