U.S. patent application number 14/815113 was filed with the patent office on 2016-02-04 for non-skid underlayment.
The applicant listed for this patent is CRAIG PATRICK KEANE. Invention is credited to CRAIG PATRICK KEANE.
Application Number | 20160032597 14/815113 |
Document ID | / |
Family ID | 55179480 |
Filed Date | 2016-02-04 |
United States Patent
Application |
20160032597 |
Kind Code |
A1 |
KEANE; CRAIG PATRICK |
February 4, 2016 |
NON-SKID UNDERLAYMENT
Abstract
Described are flooring systems which include an underlayment
material that has a non-skid surface. The non-skid performance may
arise from frictional properties, as opposed to adhesive
properties. Such a flooring system may include a top flooring
layer, a subfloor, and an underlayment material disposed between
the subfloor and the top flooring layer. Methods for a non-skid
underlayment are disclosed herein, as well as methods of
manufacture. The underlayment material may comprise at least one
layer and a non-skid surface for engaging the subfloor, the surface
comprising thermoplastic rubber.
Inventors: |
KEANE; CRAIG PATRICK;
(Mullica Hill, NJ) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
KEANE; CRAIG PATRICK |
Mullica Hill |
NJ |
US |
|
|
Family ID: |
55179480 |
Appl. No.: |
14/815113 |
Filed: |
July 31, 2015 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
62031703 |
Jul 31, 2014 |
|
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|
Current U.S.
Class: |
52/309.9 ;
52/403.1; 52/741.1 |
Current CPC
Class: |
E04F 15/166 20130101;
E04F 15/10 20130101; E04F 15/18 20130101 |
International
Class: |
E04F 15/10 20060101
E04F015/10; E04F 15/18 20060101 E04F015/18 |
Claims
1. A flooring system, comprising: a top flooring layer; a subfloor;
and an underlayment material disposed between the subfloor and the
top flooring layer, wherein the underlayment material comprises: at
least one layer; and a non-skid surface disposed on the layer for
engaging the subfloor, the surface comprising thermoplastic
rubber.
2. The flooring system of claim 1, wherein the layer of the
underlayment material is a cross-linked polyolefin foam.
3. The flooring system of claim 2, wherein the cross-linked
polyolefin foam is produced from a resin composition comprising a
blend of polyethylene and polypropylene.
4. The flooring system of claim 1, wherein the layer of the
underlayment material is a non-cross-linked foam.
5. The flooring system of claim 4, wherein the non-cross-linked
foam is a polyolefin foam.
6. The flooring system of claim 4, wherein the non-cross-linked
foam consists essentially of polyethylene.
7. The flooring system of claim 1, further comprising a non-woven
layer laminated to the layer of the underlayment material.
8. The flooring system of claim 1, wherein the surface is on both
surfaces of the underlayment material.
9. A flooring system, comprising: a top flooring layer; a subfloor;
and an underlayment material disposed between the subfloor and the
top flooring layer, wherein the underlayment material comprises: at
least one polyolefin layer; a non-woven layer; and a non-skid
surface disposed on the polyolefin layer for engaging the subfloor,
the surface comprising thermoplastic rubber.
10. The flooring system of claim 9, wherein the at least one
polyolefin layer is a cross-linked polyolefin foam.
11. The flooring system of claim 10, wherein the cross-linked
polyolefin foam comprises a blend of polyethylene and
polypropylene.
12. The flooring system of claim 9, wherein the at least one
polyolefin layer is a non-cross-linked polyolefin foam that
consists essentially of polyethylene.
13. The flooring system of claim 9, wherein the underlayment
material includes at least one of an anti-microbial additive, a
flame retardant additive, and an adhesion promoter.
14. The flooring system of claim 9, wherein at least one polyolefin
layer is partially debossed.
15. A method, comprising: placing an underlayment material between
a subfloor and a top flooring layer, wherein the underlayment
material comprises a non-skid surface for engaging the subfloor,
the surface comprising thermoplastic rubber.
16. The method of claim 15, wherein the thermoplastic rubber
provides a frictional resistance to movement for the underlayment
material relative to at least one of the subfloor and the top
flooring layer.
17. The method of claim 15, wherein the thermoplastic rubber does
not provide an adhesive resistance to movement for the underlayment
material relative to at least one of the subfloor and the top
flooring layer.
18. An underlayment material for placing between a subfloor and a
top flooring layer, wherein the underlayment material comprises: a
non-skid surface for engaging the subfloor, the surface comprising
thermoplastic rubber.
19. The underlayment material of claim 18, wherein the underlayment
material comprises a film that has been treated with the surface
laminated to a foam layer.
20. The underlayment material of claim 19, wherein the film is a
polyethylene film or a polypropylene film.
Description
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims the benefit of U.S. Provisional
Patent Application No. 62/031,703 filed Jul. 31, 2014, which is
incorporated by reference herein as if fully set forth.
BACKGROUND
[0002] Flooring systems generally comprise an aesthetic (e.g.,
decorative) top flooring layer installed over a structural
substrate (commonly referred to as a subfloor). An underlayment
layer may be interposed between the top flooring layer and the
substrate for purposes of sound reduction, cushioning, moisture
barrier, and/or protection.
[0003] The top flooring layer must be installed on a flat, level,
substrate for both structural and aesthetic reasons. For example,
any bumps or irregularities in the substrate may be visible to the
consumer, which is not aesthetically pleasing. Moreover, beyond
undesirable light reflection and other cosmetic drawbacks, top
flooring layers are generally fragile enough that such
irregularities eventually lead to transfer through to the top
layer, increased wear, cracking, or other damage. In cases of
interlocking top flooring layer components (e.g., laminate
flooring, engineered flooring), irregularities in the substrate may
prevent proper mechanical interaction, thereby undermining the
integrity of the top flooring layer and creating unsightly gaps or
even trip hazards.
[0004] One type of irregularity in a flooring system can result
from the underlayment slipping or bunching to create wrinkles
during installation of the underlayment, or more often, during
installation of the top flooring layer. For example, in some
installations, components of the top flooring layer are slid into
place. If the friction between the top flooring layer component and
the underlayment is greater than the friction between the
underlayment and the substrate, the underlayment may bunch.
Therefore, better systems, methods, and non-skid compositions are
needed.
SUMMARY
[0005] A flooring system as disclosed herein may include an
underlayment material that has a non-skid surface. The non-skid
performance may arise from frictional properties, as opposed to
adhesive properties. Such a flooring system may include a top
flooring layer, a subfloor, and an underlayment material disposed
between the subfloor and the top flooring layer. Methods for a
non-skid underlayment are disclosed herein, as well as methods of
manufacture. The underlayment material may comprise at least one
layer having a non-skid surface for engaging the subfloor, the
surface comprising thermoplastic rubber.
BRIEF DESCRIPTION OF THE FIGURES
[0006] FIG. 1 depicts a top perspective sectional view of a
flooring system having a non-skid underlayment material.
[0007] FIG. 2 depicts a cross-sectional view of a flooring system
having a non-skid underlayment material.
[0008] FIG. 3 depicts a cross-sectional view of a non-skid
underlayment material.
[0009] FIG. 4 depicts a bottom perspective sectional view of a
non-skid underlayment material.
[0010] FIG. 5 depicts a cross-sectional view of a non-skid
underlayment material.
[0011] FIG. 6 depicts a cross-sectional view of a non-skid
underlayment material.
[0012] FIG. 7 is a diagram of a method for manufacturing a non-skid
underlayment material.
DETAILED DESCRIPTION
[0013] FIG. 1 illustrates a flooring system 100. The flooring
system 100 may be used in a commercial or residential setting. The
flooring system 100 may include a top flooring layer 102, which may
also be referred to as flooring. The top flooring layer 102 may be
mainly for decorative purposes. Examples of top flooring layers 102
include carpet, tile, sheet vinyl, luxury vinyl tile (or planks),
solid hardwood, engineered wood, and laminate flooring.
[0014] The flooring system 100 may include a subfloor 104. The term
"subfloor" refers to the structural substrate above which a top
flooring layer 102 is installed. Examples of subfloors 104 include
concrete, plywood, oriented strand board (OSB), composite wood, and
in some cases, existing vinyl or hardwood flooring. Often, the
subfloor 104 may contain multiple irregularities in its surface.
For example, the subfloor 104 may include a depression 106. The
depression 106 may be a dimple, a gouge, or a low spot. The
subfloor 104 may include projections from its surface such as a
bump (e.g., a high spot) 108, or in cases where the subfloor is of
plywood, oriented strand board (OSB), or composite wood, a
projecting nail head 110. The subfloor may have a multiplicity of
irregularities of differing heights and depths. For example, in
concrete subfloors, both high spots and low spots are fairly
typical.
[0015] The flooring system may include a non-skid underlayment
material 120 interposed between the top flooring layer 102 and
subfloor 104. The underlayment material 120 may have greater
frictional properties with respect to the subfloor 104 than its
frictional properties with respect to the top flooring layer 102,
as will be described. The flooring system 100 may have additional
layers (not depicted).
[0016] The top flooring layer 102, underlayment material 120, and
subfloor 104, may be assembled by any practicable means. The
underlayment material 120 may be laid on the subfloor 104 and the
top flooring layer 102 laid upon the underlayment material without
affixing them to each other (e.g., a floating installation method).
The underlayment material 120 may be glued to the subfloor 104 with
adhesive and the top flooring layer 102 glued to the underlayment
material with adhesive (e.g., a double glue down installation). One
layer of the top flooring layer 102, underlayment material 120, and
subfloor 104 may be glued to its adjacent layer with adhesive
without affixing the top flooring layer to the subfloor (e.g., a
single glue down installation). Similarly, one layer of the top
flooring layer 102, underlayment material 120, and subfloor 104 may
nailed or tacked to another layer, or both. Examples of nailing
and/or tacking installations include carpet installation and
hardwood flooring installation over a wood-based subfloor.
Advantages of the underlayment material 120 for a floating
installation in particular will be described.
[0017] Turning to FIG. 2, a cross section of a flooring system 200
is depicted. The flooring system 200 may be used in a commercial or
residential setting. The flooring system 200 may include a top
flooring layer 202, which may be carpet, tile, sheet vinyl, luxury
vinyl tile (or planks), solid hardwood, engineered wood, and
laminate flooring.
[0018] The flooring system 200 may include a subfloor 204 similar
to that described in FIG. 1.
[0019] The flooring system 200 may include a non-skid underlayment
material 220 interposed between the top flooring layer 202 and
subfloor 204. The underlayment material 220 may have greater
frictional properties with respect to the subfloor 204 than its
frictional properties with respect to the top flooring layer 202.
The underlayment material 220 may be lightweight and easy to
handle.
[0020] The flooring system 200 may include an optional vapor
barrier layer 230. As described in detail herein with respect to
FIG. 3, the underlayment material 220 itself may have moisture
vapor transmission properties that are suitable for certain
applications. In some applications, however, additional moisture
vapor protection may be desirable. If desired, a vapor barrier
layer 230 may be disposed between the top flooring layer 202 and
the subfloor 204. The vapor barrier layer 230 may be a film, which
may be a polypropylene film, or a polyethylene film, or a foil,
disposed between the underlayment material 220 and the subfloor
204. The vapor barrier layer 230 may be adhered to the underlayment
material 220 and/or to the subfloor 204. The flooring system 200
may be assembled by any practicable means, generally depending on
the type of subfloor 204 and top flooring layer 202.
[0021] Turning to FIG. 3, a cross section of a non-skid
underlayment material 320 which can be used in the flooring systems
of FIG. 1 and/or FIG. 2 is depicted. The underlayment material 320
may have at least two layers of distinct composition and/or
mechanical properties, and may be a bilaminate (as illustrated).
The underlayment material 320 may have additional layers (not
depicted). The underlayment material 320 may be a single layer
(such as depicted in FIGS. 5 and 6).
[0022] The underlayment material 320 may comprise a first layer
322. In a flooring system, the layer 322 may be adjacent to a top
flooring layer (not depicted).
[0023] The layer 322 may comprise a fiber (such as a non-woven), a
film (such as a thermoplastic polyolefin film, a PVC film, an EVA
film, a vinyl film, or other membrane), a foil (such as a metallic
foil), or a foam (such as a memory foam, polyurethane foam, EVA
foam, PVC foam, latex foam, or a polyolefin foam). The layer 322
may comprise polyethylene, may consist essentially of polyethylene,
or may consist essentially of a polyethylene foam. The layer 322
may comprise a non-cross-linked foam. The layer 322 may comprise a
memory foam. The layer 322 may comprise non-cross-linked
polyethylene. The layer 322 may have a density less than about 25
kg/m3. The layer 322 may have a density less than about 20 kg/m3.
The layer 322 may have a density selected to compress under
loading. The layer 322 may have a 25% compressive strength of less
than about 1 kg/cm2 as measured by JIS K6767. The layer 322 may
have a 25% compressive strength of less than about 0.8 kg/cm2 as
measured by JIS K6767. The layer 322 may contribute to the SLP and
MVTR of the underlayment material 320.
[0024] The layer 322 may be a non-woven fiber.
[0025] The layer 322 may have a thickness in a range from about 0.5
mm to about 6.0 mm. The thickness of the layer 322 may be in a
range from about 1.5 mm to about 2.5 mm.
[0026] The underlayment material 320 may comprise a second layer
324 affixed to the layer 322. The layer 322 may be laminated to the
layer 324 at the interface of their surfaces. Alternatively, the
layer 322 may be connected to the layer 324 by any known means
(e.g., mechanical).
[0027] The layer 324 may comprise a fiber (such as a non-woven), a
film (such as a thermoplastic polyolefin film, a PVC film, an EVA
film, a vinyl film, or other membrane), a foil (such as a metallic
foil), or a foam (such as a memory foam, polyurethane foam, EVA
foam, PVC foam, latex foam, or a polyolefin foam).
[0028] The layer 324 may comprise a cross-linked polypropylene
copolymer (EPC) and a linear low density/polyethylene (LLDPE) blend
foam with an EPC content of about 20% to 90% by weight. Preferably,
the EPC content is between 50% and 90%. More preferably, the EPC
content is between 70% and 90%. Other olefin materials that are
suitable for use include, for example, homopolymers and copolymers
of polyethylene, including high-density polyethylene (HDPE),
low-density polyethylene (LDPE), very-low-density polyethylene
(VLDPE), ultra-low-density polyethylene (ULDPE), and polymers or
copolymers of polypropylenes, including cross-linked ethylene
propylene copolymer.
[0029] The layer 324 may comprise a foam underlayment material such
as, the FLOORMUFFLER.TM. underlayment available from Diversified
Foam Products, Inc. (www.floormuffler.com).
[0030] The layer 324 may have a 25% compressive strength of at
least about 0.85 kg/cm2, as measured by JIS K6767. Preferably, the
layer 324 has a 25% compressive strength of at least about 1.0
kg/cm2. More preferably, the layer 324 has a 25% compressive
strength of at least about 1.2 kg/cm2. Compressive strength is a
property of the foam structure obtained primarily by the selection
of resin, foam density, and the manufacturing processes used to
convert resin into foam. It should be understood that higher
polypropylene content may produce higher compressive strength and,
accordingly, lower average reflected SPL. Density may also be a
factor. For example, to increase compressive strength from
approximately 3 kg/cm2 to approximately 6 kg/cm2, the foam density
may be increased from about 100 kg/m3 to about 121 kg/m3.
[0031] The layer 324 may contribute reduced moisture vapor
transmission rates (MVTR) to the underlayment material 320 without
the need for the additional barrier layers. The layer 324 may have
a MVTR of <3.0 lb/1000 ft.sup.2/24 hr. Flooring industry
standards for MVTR of less than 3.0 lb/1000 ft.sup.2/24 hr are
typically achieved by adding additional vapor barrier layers that
add to both product cost and weight.
[0032] The layer 324 may contribute a desirable reflected sound
pressure level (SPL) to the underlayment material 320. SPL varies
with foam composition, extent of cross-linking, density, and
thickness. The layer 324 may have a polypropylene content of
greater than about 60% to greater than about 90%. The layer 324 may
have a cross-link percentage or cross-link level that may range
from about 40% to about 80%. Higher cross-link levels are possible;
however, if cross-linking is too high, the foam will be difficult
to roll onto a core, and will be difficult to lay flat. The type of
resins selected, the amount of chemical cross-linking agent used,
and the amount of exposure to a radiation source, such as an
electron beam irradiation device, dictate the degree of
cross-linking Also, in general, higher cross-link percentage
provides slightly higher compressive strength. It is expected,
therefore, that higher cross-link percentage should lead to
slightly lower reflected SPL for the layer 324. It is also expected
that higher cross-link percentage should also lead to lower
MVTR.
[0033] The density of the layer 324 as determined by method ASTM
D3575, may be about 20 to about 200 kg/m3. The layer 324 may have a
range of density from about 40 to about 100 kg/m3. The layer 324
may have a range of density from about 50 to about 60 kg/m3. Higher
density tends to increase the compressive strength of the foam and
thereby reduce the reflected SPL. Increasing foam density, however,
tends to add to product cost due to increased raw material
consumption to manufacture. Density may be controlled by a number
of factors, the types of resins used, the degree of cross-linking,
process conditions, and the type and amount of foaming agent used.
The thickness of the layer 324 may be in a range from about 0.5 mm
to about 6.0 mm. The thickness of the layer 324 may be in a range
from about 1.5 mm to about 2.5 mm. Thickness is dictated by the
resin selection, type and amount of chemical foaming agent used,
extruded sheet thickness, tension during the foaming operation, and
the amount of heat applied during the conversion of sheet into
foam. A 100 ft.sup.2 roll of layer 324 may weigh less than about 5
lbs, while providing low reflected sound pressure levels in the 300
Hz to 1000 Hz range and MVTR performance that meets flooring
industry standards.
[0034] The layer 324 has a surface 326. The surface 326 provides
non-skid properties to the underlayment material 320. The surface
326 may provide non-skid properties to the underlayment material
320 without imparting adhesive properties. The surface 326 may
comprise thermoplastic rubber. The surface 326 may comprise a
melt-process-able rubber. The surface 326 may be a natural rubber,
a thermoplastic urethane, a styrene-butadiene rubber, a styrene
ethylene butylene styrene block copolymer, an ethylene propylene
diene monomer rubber, a nitrile rubber, or a blend of any of these,
with or without a thermoplastic rubber.
[0035] The surface 326 may comprise polypropylene or
polyethylene.
[0036] The surface 326 may comprise a cling foam, such as an
emulsion cling foam, a PVC foam plastisol, a highly plasticized PVC
solid, an ethylene vinyl acetate, an acrylic, polyethylene, or
polyurethane foam or solid, or any polymer that can be formed with
frictional, but not tacky, properties (e.g., frictional properties,
as opposed to adhesive properties).
[0037] The surface 326 may be formed as a coating.
[0038] The surface 326 may be formed by laminating a layer
comprising the material that comprises the surface to the layer
324.
[0039] The surface 326 may describe the boundary (e.g., the
physical exterior) of the layer 324. For example, the surface 326
may be formed by dispersing the material comprising the surface
throughout the layer 324, such that the face of the layer 324 is a
surface with non-skid properties.
[0040] The underlayment material 320 may comprise additional
layers. For example, a vapor barrier polypropylene film or
polyethylene film may be adhered to the underlayment material 320
before the underlayment is rolled (as described below). Thus, the
underlayment material 320 may be delivered to the point of
installation with the optional vapor barrier already adhered
thereto, thus simplifying installation of the underlayment material
and vapor barrier.
[0041] The underlayment material 320 may include non-skid elements
affixed, adhered to, or resulting from, the layer 322, layer 324,
or both.
[0042] The underlayment material 320 may include a foil layer to
reflect heat.
[0043] The underlayment material 320 may include means to adhere
adjoining sections of underlayment. The underlayment material 320
may include a tape strip (not depicted) to facilitate installation.
The underlayment material 320 may comprise a first roll (not
depicted) having a tape strip on a first planar surface of the
underlayment, and a pull-out lip (not depicted) on the first planar
surface, axial to the tape strip, such that when the first roll is
unrolled and laid out next to a second roll that has also been
unrolled and laid out, the tape strip of the first roll will engage
the lip of the second roll, thereby connecting the first and second
rolls. This may include creating a moisture resistant engagement
between the tape strip and the lip (e.g., sealing what otherwise
may be a vapor gap between two adjacent underlayment sections). The
lip may extend axially from the roll in a range from about 0.5 in
to about 8 in. The lip may be formed from a layer affixed to the
underlayment 320 that extends axially fully across the roll, or may
be a strip.
[0044] The underlayment material 320 may include at least one of an
anti-microbial additive, a flame retardant additive, and an
adhesion promoter.
[0045] The underlayment material 320 may be embossed or de-bossed
for lamination, traction, or alignment purposes. The underlayment
material 320 may receive printed materials, such as instructions,
trademarks, or other communications.
[0046] The underlayment material 320 may have an Impact Insulation
Class (IIC) value greater than about 40, greater than about 50,
and/or greater than about 55, but less than about 80.
[0047] The thickness of the underlayment material 320 may be in a
range from about 1 mm to about 15 mm. The thickness of the
underlayment material 320 may be in a range from about 3 mm to
about 10 mm. Relatively thick layers of around 6.0 millimeters or
more may interfere with wall molding or door clearances. The
thickness of the underlayment material 320 may be in a range from
about 4 mm to about 6 mm.
[0048] Turning to FIG. 4, a bottom perspective sectional view of a
non-skid underlayment material 420 which can be used in the
flooring systems of FIG. 1 and/or FIG. 2 is depicted. The
underlayment material 420 may have at least two layers of distinct
composition and/or mechanical properties, and may be a bilaminate
(as illustrated). The underlayment material 420 may have additional
layers (not depicted). The underlayment material 420 may be a
single layer (such as depicted in FIGS. 5 and 6).
[0049] The underlayment material 420 may comprise a first layer 422
and a second layer 424. In a flooring system, the layer 422 may be
adjacent to a top flooring layer (not depicted).
[0050] As discussed above, the layer 422 and the layer 424 may
comprise a fiber (such as a non-woven), a film (such as a
thermoplastic polyolefin film, a PVC film, an EVA film, a vinyl
film, or other membrane), a foil (such as a metallic foil), or a
foam (such as a memory foam, polyurethane foam, EVA foam, PVC foam,
latex foam, or a polyolefin foam), provided that the layers have
distinct compositional differences and/or differences in mechanical
properties.
[0051] A surface 426 is disposed upon at least a portion of the
layer 424. The surface 426 may be applied to the surface of the
underlayment 420 which contacts the subfloor. The surface 426
provides non-skid properties to the underlayment material 420. The
surface 426 may provide non-skid properties to the underlayment
material 420 without imparting adhesive properties. The surface 426
may comprise thermoplastic rubber. The surface 426 may comprise a
melt-process-able rubber. The surface 426 may comprise a natural
rubber, a thermoplastic urethane, a styrene-butadiene rubber, a
styrene ethylene butylene styrene block copolymer, an ethylene
propylene diene monomer rubber, a nitrile rubber, or a blend of any
of these, with or without a thermoplastic rubber.
[0052] The surface 426 may comprise polypropylene or
polyethylene.
[0053] The surface 426 may comprise a cling foam, such as an
emulsion cling foam, a PVC foam plastisol, a highly plasticized PVC
solid, an ethylene vinyl acetate, an acrylic, polyethylene, or
polyurethane foam or solid, or any polymer that can be formed with
frictional, but not tacky, properties (e.g., frictional properties,
as opposed to adhesive properties).
[0054] The surface 426 may be formed as a coating.
[0055] The surface 426 may be formed by laminating a layer
comprising the material that comprises the surface to the layer
424.
[0056] The surface 426 may describe the boundary (e.g., the
physical exterior) of the layer 424. For example, the surface 426
may be formed by dispersing the material comprising the surface
throughout the layer 424, such that the face of the layer 424 is a
surface with non-skid properties.
[0057] Recessed features 428 may be disposed in the layer 424, such
as may be created by de-bossing. The recessed features 428 may
balance against the non-skid effects of the surface 426, by
reducing surface area of layer 424 that contacts the subfloor (not
depicted). The features 428 may be absent in some embodiments.
Additional embossed features or textures (not depicted) may be
present.
[0058] Turning to FIG. 5, a sectional view of a non-skid
underlayment material 520 which comprises a single layer 524 is
depicted. The underlayment material 520 can be used in the flooring
systems of FIG. 1 and/or FIG. 2. The underlayment material 520 may
have additional layers (not depicted).
[0059] The layer 524 may comprise a fiber (such as a non-woven), a
film (such as a thermoplastic polyolefin film, a PVC film, an EVA
film, a vinyl film, or other membrane), a foil (such as a metallic
foil), or a foam (such as a memory foam, polyurethane foam, EVA
foam, PVC foam, latex foam, or a polyolefin foam). The layer 524
may comprise a cross-linked polypropylene copolymer (EPC) and a
linear low density/polyethylene (LLDPE) blend foam with an EPC
content of about 20% to 90% by weight. Preferably, the EPC content
is between 50% and 90%. More preferably, the EPC content is between
70% and 90%. Other olefin materials that are suitable for use
include, for example, homopolymers and copolymers of polyethylene,
including high-density polyethylene (HDPE), low-density
polyethylene (LDPE), very-low-density polyethylene (VLDPE),
ultra-low-density polyethylene (ULDPE), and polymers or copolymers
of polypropylenes, including cross-linked ethylene propylene
copolymer.
[0060] The layer 524 may comprise a foam underlayment material such
as, the FLOORMUFFLER.sup.TM underlayment available from Diversified
Foam Products, Inc. (www.floormuffler.com).
[0061] A surface 526 is applied to at least a portion of the layer
524. The surface 526 provides non-skid properties to the
underlayment material 520. The surface 526 may provide non-skid
properties to the underlayment material 520 without imparting
adhesive properties. The surface 526 may comprise thermoplastic
rubber. The surface 526 may comprise a melt-process-able rubber.
The surface 526 may comprise a natural rubber, a thermoplastic
urethane, a styrene-butadiene rubber, a styrene ethylene butylene
styrene block copolymer, an ethylene propylene diene monomer
rubber, a nitrile rubber, or a blend of any of these, with or
without a thermoplastic rubber.
[0062] The surface 526 may comprise polypropylene or
polyethylene.
[0063] The surface 526 may comprise a cling foam, such as an
emulsion cling foam, a PVC foam plastisol, a highly plasticized PVC
solid, an ethylene vinyl acetate, an acrylic, polyethylene, or
polyurethane foam or solid, or any polymer that can be formed with
frictional, but not tacky, properties (e.g., frictional properties,
as opposed to adhesive properties).
[0064] The surface 526 may be formed as a coating.
[0065] The surface 526 may be formed by laminating a layer
comprising the material that comprises the surface to the layer
524.
[0066] The surface 526 may describe the boundary (e.g., the
physical exterior) of the layer 524. For example, the surface 526
may be formed by dispersing the material comprising the surface
throughout the layer 524, such that the face of the layer 524 is a
surface with non-skid properties.
[0067] Turning to FIG. 6, a non-skid underlayment material 620
which comprises a single layer 624 is depicted. The underlayment
material 620 can be used in the flooring systems of FIG. 1 and/or
FIG. 2. The underlayment material 620 may have additional layers
(not depicted).
[0068] The layer 624 may comprise a fiber (such as a non-woven), a
film (such as a thermoplastic polyolefin film, a PVC film, an EVA
film, a vinyl film, or other membrane), a foil (such as a metallic
foil), or a foam (such as a memory foam, polyurethane foam, EVA
foam, PVC foam, latex foam, or a polyolefin foam). The layer 624
may comprise a cross-linked polypropylene copolymer (EPC) and a
linear low density/polyethylene (LLDPE) blend foam with an EPC
content of about 20% to 90% by weight. Preferably, the EPC content
is between 50% and 90%. More preferably, the EPC content is between
70% and 90%. Other olefin materials that are suitable for use
include, for example, homopolymers and copolymers of polyethylene,
including high-density polyethylene (HDPE), low-density
polyethylene (LDPE), very-low-density polyethylene (VLDPE),
ultra-low-density polyethylene (ULDPE), and polymers or copolymers
of polypropylenes, including cross-linked ethylene propylene
copolymer.
[0069] The layer 624 may comprise a foam underlayment material such
as, the FLOORMUFFLER.TM. underlayment available from Diversified
Foam Products, Inc. (www.floormuffler.com).
[0070] The layer 624 has a pair of surfaces 626. The surface 626
provides non-skid properties to the underlayment material 620 on
both surfaces (such as the surface contacting the subfloor and the
surface contacting the top flooring layer). The surface 626 may
provide non-skid properties to the underlayment material 620
without imparting adhesive properties. The surface 626 may comprise
thermoplastic rubber. The surface 626 may comprise a
melt-process-able rubber. The surface 626 may be a natural rubber,
a thermoplastic urethane, a styrene-butadiene rubber, a styrene
ethylene butylene styrene block copolymer, an ethylene propylene
diene monomer rubber, a nitrile rubber, or a blend of any of these,
with or without a thermoplastic rubber.
[0071] The surface 626 may comprise polypropylene or
polyethylene.
[0072] The surface 626 may comprise a cling foam, such as an
emulsion cling foam, a PVC foam plastisol, a highly plasticized PVC
solid, an ethylene vinyl acetate, an acrylic, polyethylene, or
polyurethane foam or solid, or any polymer that can be formed with
frictional, but not tacky, properties (e.g., frictional properties,
as opposed to adhesive properties).
[0073] The surface 626 may be formed as a coating.
[0074] The surface 626 may be formed by laminating a layer
comprising the material that comprises the surface to the layer
624.
[0075] The surface 626 may describe the boundary (e.g., the
physical exterior) of the layer 624. For example, the surface 626
may be formed by dispersing the material comprising the surface
throughout the layer 624, such that the face of the layer 624 is a
surface with non-skid properties.
[0076] FIG. 7 provides a flowchart of an example method 700 for
manufacturing a polyolefin foam underlayment material. At 702, one
or more polyolefin resins may be mixed with a foaming agent, one or
more cross-linking agents, and/or one or more additives, into a
homogenous mixture. Examples of polyolefin resins include
polyethylene and/or polypropylene. Examples of cross-linking agents
include peroxides (e.g., di cumyl peroxide, etc.) for
polyethylenes, and di vinyl benzene for polypropylenes. Examples of
additives include flame retardants, adhesion promoters, colorants,
and anti-microbial agents. A homogenous mixture may be achieved by
spinning the mixture in a mechanical mixer designed for compounding
plastic resins. Examples of such mixers are well-known. To ensure
complete and proper mixing, agitation rate, temperature, and
processing duration may be selectively controlled during this step
by well-known industrial process control means.
[0077] At 704, the mixture may charged, for example, into a
conventional plastics extruder, into which the ingredients are
conveyed in a barrel by a screw, to produce a solid, thin, plastic
web. The ingredients may be initially compressed and mixed as the
materials move along the screw.
[0078] Heater elements, along with the shearing action of materials
against each other and the screw and barrel, cause the resins to
melt into a viscous liquid state. Additives and/or colorants may be
added to the product at this stage of the process as well. The
screw pushes the melted extrudate through a die opening to produce
the thin, solid web. The web may typically be between about 0.2 and
about 3.0 millimeters in thickness, although not limited, as
thicker or thinner webs can be produced as desired. As it is
extruded, the web may cool from a molten state to a solid state.
The web may then be trimmed, and wound into a roll.
[0079] At 706, the polymer resins may be cross-linked, for example
by irradiation by electron beam. Other methods, such as chemical
cross-linking, for example, may be employed. The degree of
cross-linking may be controlled to result in a typical cross-link
density of about 15% to about 80%. A higher percentage level of
cross-linking is possible if desired. A desired degree of
cross-linking may be achieved by the type of resins selected, the
amount of chemical cross-linking agent used, and/or the exposure to
a radiation source such as an electron beam irradiation device.
[0080] At 708, the continuous polymer web may be converted into a
relatively low-density foam. For example, the foam may be heated by
radiant heaters, molten salt, hot air, or other heating devices.
The heat causes a reaction of the chemical foaming agent that
causes the foaming agent to releases gases, thus forming a cellular
structure in the web. The combination of resins selected,
cross-linking, and the process used may be selected to create a
fine-celled structure, with typical cells ranging from about 0.1 to
about 1.0 millimeter. It should be understood that larger and
smaller cell sizes are possible.
[0081] A desired thickness may be achieved by the resin selection,
type and amount of chemical foaming agent used, extruded sheet
thickness, tension during the foaming operation, amount of heat
applied during the conversion of sheet into foam. For example, an
extruded sheet having a thickness of about 1 millimeter may produce
a relatively high density polyolefin foam having a thickness of
about 1.5 millimeter if little foaming agent is used. A relatively
low density foam having a thickness of about 2.5 millimeter may be
produced if a greater quantity of foaming agent is used. A desired
density may be achieved by the selection of resins used, the degree
of cross-linking, process conditions, and the type and amount of
foaming agent used.
[0082] The continuous polymer web may be converted into a
relatively low-density foam. For example, the foam may be heated by
radiant heaters, molten salt, hot air, or other heating devices.
The heat causes a reaction of the chemical foaming agent that
causes the foaming agent to releases gases, thus forming a cellular
structure in the web.
[0083] A desired thickness may be achieved by the resin selection,
type and amount of chemical foaming agent used, extruded sheet
thickness, tension during the foaming operation, amount of heat
applied during the conversion of sheet into foam. For example, an
extruded sheet having a thickness of about 1 millimeter may produce
a relatively high density polyolefin foam having a thickness of
about 1.5 millimeter if little foaming agent is used. A relatively
low density foam having a thickness of about 2.5 millimeter may be
produced if a greater quantity of foaming agent is used. A desired
density may be achieved by the selection of resins used, process
conditions, and the type and amount of foaming agent used. The
layer may be laminated to another layer (see FIG. 3).
[0084] At 710, at least one layer is provided (e.g., at least
partially provided with) with a surface as described herein to
provide non-skid properties to the underlayment material.
[0085] At 712, the finished foam web may be rolled onto a core,
such as a cardboard or paper tube, for example.
[0086] At 714, the finished foam web may undergo further
processing, for example, the foam web may be coated with an
adhesive layer or release layer, laminated with films (including,
for example, lips and tape strips as described above), foils,
fabrics, nonwovens, or other foams, or molded for any of a variety
of uses.
[0087] In another method, the underlayment material may be a
lamination of a foam to a coated film (e.g., polyethylene,
polypropylene, or others coated with the thermoplastic rubber) to
provide a non-skid surface. For example, the film may be coated,
and then the film could be laminated to the foam.
* * * * *