U.S. patent application number 16/168935 was filed with the patent office on 2019-02-21 for floor underlayment.
The applicant listed for this patent is MP Global Products, L.L.C.. Invention is credited to Alan B. COLLISON.
Application Number | 20190054726 16/168935 |
Document ID | / |
Family ID | 61011988 |
Filed Date | 2019-02-21 |
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United States Patent
Application |
20190054726 |
Kind Code |
A1 |
COLLISON; Alan B. |
February 21, 2019 |
Floor Underlayment
Abstract
A method of installing a laminate wood floor over a subflooring
is provided. The method includes a layered composition including a
foam sheet and a melted portion, the melted portion being a surface
polymer layer that provides a smooth surface. The foam sheet being
a polymer that provides cushioning, the foam sheet and the melted
portion being formed of the same material. The method includes
placing the layered melted portion-foam composition over the
subflooring. The method further includes laying the laminate wood
floor over the layered melted portion-foam composition.
Inventors: |
COLLISON; Alan B.; (Pierce,
NE) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
MP Global Products, L.L.C. |
Norfolk |
NE |
US |
|
|
Family ID: |
61011988 |
Appl. No.: |
16/168935 |
Filed: |
October 24, 2018 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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15219821 |
Jul 26, 2016 |
10112371 |
|
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16168935 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
E04F 15/203 20130101;
B32B 2317/16 20130101; B32B 2323/046 20130101; E04F 15/187
20130101; B32B 37/06 20130101; B32B 2307/304 20130101; B32B 2419/00
20130101; B32B 38/004 20130101; B32B 2305/022 20130101 |
International
Class: |
B32B 37/06 20060101
B32B037/06; E04F 15/20 20060101 E04F015/20; E04F 15/18 20060101
E04F015/18; B32B 38/00 20060101 B32B038/00 |
Claims
1. A method of forming a floor underlayment for placement between a
laminate wood floor and a subflooring, the method comprising:
forming a foam sheet from a polymer; and heating at least one
surface of the foam sheet to form a melted portion that is
integrally formed with the foam sheet.
2. The method of claim 1 further comprising forming the foam sheet
by extruding the foam sheet.
3. The method of claim 2 further comprising heating the at least
one surface of the foam sheet to form the melted portion after
extruding the foam sheet.
4. The method of claim 3 further comprising heating the at least
one surface of the foam sheet until the melted portion of the foam
sheet reaches a molten or semi-molten state.
5. The method of claim 3 further comprising heating the at least
one surface of the foam sheet using at least one heated roller.
6. The method of claim 3 further comprising heating the at least
one surface of the foam sheet using at least one laser diode.
7. The method of claim 1 wherein the at least one surface of the
foam sheet includes a bottom surface of the foam sheet.
8. The method of claim 1 wherein the at least one surface of the
foam sheet includes top and bottom surfaces of the foam sheet.
9. The method of claim 1 further comprising coupling a polymer film
to the melted portion so that the polymer film extends beyond one
side of the foam sheet.
10. A method of forming a floor underlayment for placement between
a laminate wood floor and a subflooring, the method comprising:
forming a foam sheet from a polymer; and cooling at least one
surface of the foam sheet to form a vapor barrier portion that is
integrally formed with the foam sheet.
11. The method of claim 10 further comprising forming the foam
sheet by extruding the foam sheet.
12. The method of claim 11 further comprising cooling the at least
one surface of the foam sheet to form the vapor barrier portion
after extruding the foam sheet.
13. The method of claim 12 further comprising cooling the at least
one surface of the foam sheet to form the vapor barrier portion
while the foam sheet is in a molten state as a result of extruding
the foam sheet.
14. The method of claim 12 further comprising cooling the at least
one surface of the foam sheet using at least one chill roll.
15. A floor underlayment for placement between a laminate wood
floor and a subflooring, the floor underlayment comprising: a foam
sheet made from a polymer and configured to provide cushioning; and
a melted portion integrally formed with the foam sheet and
configured to act as a vapor barrier.
16. The floor underlayment of claim 15 further comprising a polymer
film coupled to the melted portion and extending beyond one side of
the foam sheet.
17. The floor underlayment of claim 15, wherein the foam sheet is
made from a low-density polyethylene.
18. The floor underlayment of claim 15, wherein the foam sheet has
a thickness between about 0.03 inches and about 0.1 inches.
19. The floor underlayment of claim 15, wherein the melted portion
has a thickness between about 1 millimeters and about 10
millimeters.
20. The floor underlayment of claim 15, wherein the foam sheet has
a density between about 1 pounds per cubic foot and about 6 pounds
per cubic foot.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present disclosure is a continuation of U.S. patent
application Ser. No. 15/219,821 filed on Jul. 26, 2016. The entire
disclosure of the application referenced above is incorporated
herein by reference.
FIELD
[0002] The present teachings relate to foam compositions for use in
combination with wood laminate flooring over concrete or wood
subflooring.
BACKGROUND
[0003] This section provides background information related to the
present disclosure that is not necessarily prior art. Example
embodiments will now be described more fully with reference to the
accompanying drawings. As indicated above, processes for preparing
floor underlayment, such as medium density floor underlayment, are
known to those skilled in this art.
[0004] Textile pads are widely used in flooring applications. A pad
is desirable when wood flooring is applied over sub flooring. These
pads used in flooring applications serve multiple purposes. They
may absorb impact, such as from persons walking on the flooring.
They may provide sound deadening, and may provide insulating
properties against heat transfer. Pads also may accommodate
roughness, unevenness, or other flaws in the sub flooring, and may
provide a barrier against moisture and dirt. Finally, pads may
lessen impact stresses on the flooring to lengthen the life of the
flooring and make the flooring appear to be more durable and of a
higher quality. Traditionally, these pads are formed when fibers of
various sizes and materials are mixed and bound together. The
binding can occur using know techniques such as needling or by the
use of meltable binder fibers such as polypropylene. These
techniques, while functional have several disadvantages which lead
to slow throughput, high energy and cost, and environmental
emissions.
[0005] In the construction of buildings having concrete subfloors,
it is known to install a thin layer of integral polyethylene foam
having a separate vapor barrier layered thereon. The concrete
subflooring, followed by a layer of polyethylene foam sheet on the
thin integral polyethylene vapor barrier, and vice versa, and then
to install wood flooring on top of the polyethylene foam sheet
layer. None of the layers or flooring are adhered to any of the
other layers or flooring. The polyethylene foam sheet takes out
small irregularities in the top surface of the concrete. The
polyethylene foam sheet also provides some sound reduction. Slight
cushioning is provided by the polyethylene foam sheet to alleviate
the problems suffered by persons walking and standing on such
floors. These foam insulative pads are unfortunately expensive to
make and if made of a bi-material construction not recyclable.
SUMMARY
[0006] This section provides a general summary of the disclosure,
and is not a comprehensive disclosure of its full scope or all of
its features.
[0007] The objects and advantages of the teachings are achieved by
the compositions, products, articles of manufacture and processes
of the teachings.
[0008] The teachings involves a layered composition of polyethylene
foam sheet and integral polyethylene melted portion used in the
installation of laminate wood floors to provide both a
vapor-barrier and cushioning.
[0009] The laminate composition is installed in a free-floating
manner on the subflooring, with the integral polyethylene melted
portion or the polyethylene foam sheet contacting the surface of
the concrete subflooring. The laminate composition is usually in
long layers that come in rolls. In the preferred embodiment where
one side of the integral polyethylene melted portion has a thin
film that extends a vapor barrier beyond one edge of the
polyethylene foam sheet, the integral polyethylene melted portion
and film being placed adjacent the concrete subflooring. The
laminate composition is installed so that one edge of one layer
overlies the extended portion of the integral polyethylene melted
portion of another layer. In this manner the edges of the two
layers do not have to be coupled together to keep the layers from
moving during installation of the laminate wood flooring.
[0010] According to another teaching, a laminate composition of a
thin polyethylene foam sheet integrally coupled to a thin integral
polyethylene melted portion is used in the installation of laminate
wood floors to provide a vapor-barrier, cushioning, sound
reduction, etc.
[0011] The laminate composition of the teachings is a combination
of sound-reducing polyethylene foam sheet and vapor-barrier
integral polyethylene melted portion. The laminate composition can
be provided in the form of a single-roll foam/melted portion
underlayment, which reduces labor cost and time in its
installation. If the foam sheet and the melted portion (in the form
of a separate film), were in separate form, installers would have
to deal with two separate rolls and the increased labor cost and
installation time. Separate melted portion and foam sheet would
make installation more difficult and costly.
[0012] The teachings also involves a process of preparing the
layered composition, a process of installing the teachings laminate
composition in a flooring arrangement of a concrete subflooring and
a laminate wood flooring, and such flooring arrangement which
includes the laminate composition.
[0013] Further areas of applicability will become apparent from the
description provided herein. The description and specific examples
in this summary are intended for purposes of illustration only and
are not intended to limit the scope of the present disclosure.
DRAWINGS
[0014] The drawings described herein are for illustrative purposes
only of selected embodiments and not all possible implementations,
and are not intended to limit the scope of the present
disclosure.
[0015] FIG. 1 is a cross-sectional view of the layered composition
of the preset teachings;
[0016] FIG. 2 is a side view of one method of forming the layered
composition of FIG. 1; and
[0017] FIG. 3 is a cross-sectional view of a floor including the
laminate composition of FIG. 1.
[0018] Corresponding reference numerals indicate corresponding
parts throughout the several views of the drawings.
DETAILED DESCRIPTION
[0019] Example embodiments will now be described more fully with
reference to the accompanying drawings.
[0020] The description in this specification is primarily done with
polyethylene for the polyethylene foam sheet and the integral
polyethylene melted portion. The polyethylene, for example, can be
high density polyethylene or low density polyethylene, but the
preferred polyethylene is low density polyethylene. But the
teachings also more broadly include the use of polyethylenic
resins.
[0021] In FIG. 1, laminate composition 10 includes bottom melted
portion 11 and top foam sheet 12. An optional film portion 14
coupled to the bottom melted portion 11 extends (preferably 6
inches) beyond one side of foam sheet 12. Bottom melted portion 11
is composed of low density polyethylene. Top foam sheet 12 is
composed of low density polyethylene foam having a density of about
2 pounds per cubic foot. The process of preparing laminate is
described below in the description of FIG. 2.
[0022] The polyethylenic resins used in the teachings process can
be those obtained by polymerizing ethylene, or polymerizing
ethylene with other aliphatic monoolefins, such as, propylene,
1-butene, 1-pentene, 3-methyl-1-butene, 4-methyl-1-pentene,
4-methyl-1-hexene, or 5-methyl-1-hexene alone or mixtures.
[0023] Examples of polyethylenic resins which can be advantageously
employed in the teachings are low-, medium- and high-density
polyethylenes, ethylene/vinyl acetate copolymer, ethylene/propylene
copolymer, copolymers of ethylene and methyl or ethyl acrylate,
blends of polyethylene and polypropylene, blends of polyethylene
and ethylene/vinyl acetate copolymer, and blends of polyethylene
and ethylene/propylene copolymer. Of these, the medium density
polyethylenes, low density polyethylenes, and ethylene/propylene
copolymers are especially suitable. The density can be 2.0 pounds
per cubic foot nominal (+/-10%) having a range of 1.8-2.2 pounds
per cubic foot. It is envisioned the density can have a range of
1.5-2.5 pounds per cubic foot. By way of definition, integral
polyethylene melted portions are 10 mils thick or less, and
polyethylene foam sheets are greater than 10 mils thick.
[0024] The polyethylene foam sheet can be formed by means of a
conventional polyethylene foam sheet extrusion process or any other
suitable foam sheet-forming process. In a typical, conventional
polyethylene foam sheet extrusion process, pellets of the
thermoplastic polyethylene resin are blended with a solid phase
nucleating agent and, then, are melted in a heated extruded where
the plastic and nucleating agent combination is held at both a high
temperature and a high pressure.
[0025] The physical blowing agent(s), which generally liquefies
within the extruder, and which will vaporize at die melt
temperatures and atmospheric pressure, is added to the pressurized
melted material. Within the molten extrudate, the blowing agent(s)
tends to act as a plasticizer to reduce the viscosity of the
extrudate, and, thus, it lowers the level of temperature necessary
to maintain the hot melt condition of the mixture of thermoplastic
polyethylene material and nucleating agent. The blowing agent(s) is
mixed with the melted polyethylenic plastic and nucleating agent,
and the combination is, subsequently, cooled to an extrusion
temperature suitable for foaming.
[0026] The process can be usually operated on a continuous basis
using a conventional extruder system. A nucleating agent (cell size
control agent) can be any conventional or useful nucleating
agent(s). The cell size agent can be used in an amount of 0.5 to
2.0 weight percent, depending upon the desired cell size, based
upon the weight of the polyethylenic resin. Examples of the cell
size control agents are inorganic cell size-controlling agents (in
very small particulate form), such as, clay, talc, silica, and
organic cell size-controlling agents which decompose or react at
the heating temperature within the extruder to evolve gases.
[0027] Suitable volatile blowing agents include halocarbons such as
fluorocarbons and chlorofluorocarbons; hydrohalocarbons such as
hydrofluorocarbons and hydrochlorofluorocarbons; alkylhalides such
as methyl chloride and ethyl chloride; hydrocarbons such as alkanes
or alkenes; and the like. Other suitable blowing agents include
pristine blowing agents such as air, carbon dioxide, nitrogen,
argon, water, and the like. The blowing agent may comprise a
mixture of two or more of any of the above blowing agents.
[0028] The blowing agent(s) can be inorganic halogen-free blowing
agents which are environmentally acceptable and inflammable.
Examples of the inert inorganic atmospheric gases are argon, carbon
dioxide, water, nitrogen, neon, helium and krypton (but not, for
example, oxygen, ozone, sulfur dioxide, methane or nitrous oxide).
Mixtures can be used. When two blowing agents are used, they can be
individually injected into separate injection ports or they can be
injected together into the same injection port in the mixing
extruder. The argon blowing agent usually is used at a rate of 0.1
to 4 weight percent, preferably 0.1 to 2.0 weight percent, of the
total extruder flow rate. The carbon dioxide blowing agent usually
is used at a rate of 0.5 to 7.0 weight percent, preferably 0.5 to
5.0 weight percent, of the total extruder flow rate. The nitrogen
blowing agent usually is used at a rate of 0.1 to 2 weight percent
of the total extruder flow rate.
[0029] The foam sheet provides sound reduction and cushioning. The
density of the polyethylene foam sheet is a low density, usually
between 1 pounds per cubic foot and 6 pounds per cubic foot,
typically between about 1.0 pounds per cubic foot and about 2.5
pounds per cubic foot, preferably about 1.9 pounds per cubic foot
to about 2.1 pounds per cubic foot. The polyethylene foam sheet is
preferably can have any other suitable thickness (e.g., between
about 0.03 inch and about 0.25 inch in thickness).
[0030] The polyethylene foam sheet should preferably be a closed
celled in the sense that the at least half of the cells are closed
cells and preferably at least 80 percent of the cells are closed
cells. A high closed cell content is advantageous because the
polyethylene foam sheet then has a slight degree of elasticity
while having the necessary structural integrity and resilience when
subjected to transient or static loads of light or comparative
heavy values.
[0031] As shown in FIG. 2, the integral polyethylene melted portion
can be formed by means of a heating process or any other suitable
melted portion-forming process. The melted portion can be formed by
the application of heat to the top or top and bottom surfaces of
the foam sheet. The thin integral polyethylene melted portion is
formed on the foam sheet using a continuous basis by elevating the
surface temperature of the foam until it reaches a molten or
semi-molten state by use of heated rollers 20, a series of
radiation emitters such as laser diodes 22, or the application of
heated gas. The polyethylene foam is then pressed between rollers
over which the melted portion passes as a double layer.
[0032] Other conventional integral polyethylene melted portion
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.
[0033] The thin integral polyethylene melted portion can also
contain flame retardants, stabilizers, antioxidants, colorants,
fillers, plasticizers or any other conventional or suitable
additives.
[0034] The thin integral polyethylene melted portion preferably is
about 5 mils (0.005 inch) thick but can have any other suitable
thickness [e.g., between about 0.001 (or about 0.00075 inch) and
about 0.1 inch in thickness]. Preferably the polyethylene foam
sheet is low-density polyethylene foam sheet having a thickness of
about 0.006 inch to about 0.00075 inch.
[0035] The edge portion of one longitudinal side of the integral
polyethylene melted portion preferably has a film layer that
extends (6 inches) beyond the longitudinal side of the polyethylene
foam sheet. When two layers of the laminate composition are
installed adjacent to each other, one edge of one layer overlies
the extended edge portion of the integral polyethylene melted
portion of another layer. The edges of the two do not have to be
taped, due to the overlay, to keep the layers from moving during
installation of the laminate wood flooring, etc.
[0036] The polyethylene foam sheet and the integral polyethylene
melted portion are integrally layered together by any suitable
means. Preferably the polyethylene foam is extruded in sheet form
and essentially immediately thereafter the integral polyethylene
melted portion is formed using a heated non-stick roller or the
application of radiant energy or forced heated gas.
[0037] One process of preparing the laminate composition involves
heating a moving continuous web of a thin sheet of polyethylene
foam. An energy is applied to the facing surfaces of the moving
under sufficient pressure (without damaging the polyethylene foam)
is applied by two opposing rollers to the contacting webs at the
point of contact of the moving webs to achieve the laminate
composition.
[0038] In FIG. 2, an extruded web 12 of low density polyethylene
foam is subjected to heat to melt the upper foam surface. This heat
can be applied using rollers, light, or heated air. The sheet and
low density integral polyethylene melted portion are fed between
chill rolls 24 and 25. Extruded web 12, coming from an extruder and
an oven(s) at the proper cell height and preferably at a
temperature of about 4500.degree. F., is immediately fed to chill
rolls 24 and 25. At this point, extruded web 12 has a density of
about 2.1 to about 2.2 pounds per cubic foot. Extruded web 11 is
usually at room temperature or slightly higher as it is fed to
chill rolls 24 and 25.
[0039] As shown in FIG. 3, the subflooring is preformed or precast
concrete, cast-in-place concrete or reinforced concrete (i.e.,
contains added material of high strength, such as, steel rods or
bars). The laminate wood flooring can be any suitable one including
those which are commercially available. (Any other suitable
free-floating finish flooring can be used in place of the laminate
wood finish flooring.)
[0040] An example of a suitable laminate wood (finish) flooring, in
plank form, is one which has a four-ply construction and which is
used where there is high personnel traffic, for example. The top
(first) ply is a clear translucent layer and is a durable wear and
stain resistant, resilient finish. The next (second) ply is an
image design layer upon which product patterns, such as, wood,
marble or granite patterns are printed. The third ply is a moisture
resistant, high-density core material that maintains the structural
integrity of each precision engineered plank. The bottom (fourth)
ply is composed of melamine for structural stability and seals the
bottom of each laminate wood plank flooring for additional
stability and moisture resistance. The four-ply construction is
fused together under tremendous heat and pressure to form a single
plank.
[0041] When installing a wood laminate floor over a concrete slab,
the installer first lays down a vapor-barrier of integral
polyethylene melted portion, and then apply a closed-cell
polyethylene foam sheet for both cushioning and sound reduction.
The vapor-barrier is not necessary, however, when installing over a
wood sub-floor such as plywood, or a preexisting wood floor. The
teachings replaces the separate integral polyethylene melted
portion and the separate polyethylene foam sheet with the teachings
laminate composition of a polyethylene foam sheet layered with a
integral polyethylene melted portion. Thereby, installation is less
complicated, quicker, more reliable and less costly.
[0042] The laminate composition 10 is positioned on reinforced
concrete subflooring 15 (with steel reinforcing rods 16) in a
free-lying manner. Laminate composition 10 is in the form of
layers, two adjacent layers. Laminate composition 10 is not adhered
to concrete subflooring 15. Bottom melted portion 11 contacts the
top surface of concrete subflooring 15. Planks 17 of laminate wood
flooring are positioned on laminate composition 10 in a free-lying
manner. Planks 17 fit together by means of tongue-in-groove
arrangement and are glued together. Laminate composition 10 is not
adhered to laminate wood flooring 17. Top sheet 12 contacts the
bottom surface of laminate wood flooring 17.
[0043] Example embodiments are provided so that this disclosure
will be thorough, and will fully convey the scope to those who are
skilled in the art. Numerous specific details are set forth such as
examples of specific components, devices, and methods, to provide a
thorough understanding of embodiments of the present disclosure. It
will be apparent to those skilled in the art that specific details
need not be employed, that example embodiments may be embodied in
many different forms and that neither should be construed to limit
the scope of the disclosure. In some example embodiments,
well-known processes, well-known device structures, and well-known
technologies are not described in detail.
[0044] The terminology used herein is for the purpose of describing
particular example embodiments only and is not intended to be
limiting. As used herein, the singular forms "a," "an," and "the"
may be intended to include the plural forms as well, unless the
context clearly indicates otherwise. The terms "comprises,"
"comprising," "including," and "having," are inclusive and
therefore specify the presence of stated features, integers, steps,
operations, elements, and/or components, but do not preclude the
presence or addition of one or more other features, integers,
steps, operations, elements, components, and/or groups thereof. The
method steps, processes, and operations described herein are not to
be construed as necessarily requiring their performance in the
particular order discussed or illustrated, unless specifically
identified as an order of performance. It is also to be understood
that additional or alternative steps may be employed.
[0045] When an element or layer is referred to as being "on,"
"engaged to," "connected to," or "coupled to" another element or
layer, it may be directly on, engaged, connected or coupled to the
other element or layer, or intervening elements or layers may be
present. In contrast, when an element is referred to as being
"directly on," "directly engaged to," "directly connected to," or
"directly coupled to" another element or layer, there may be no
intervening elements or layers present. Other words used to
describe the relationship between elements should be interpreted in
a like fashion (e.g., "between" versus "directly between,"
"adjacent" versus "directly adjacent," etc.). As used herein, the
term "and/or" includes any and all combinations of one or more of
the associated listed items.
[0046] Although the terms first, second, third, etc. may be used
herein to describe various elements, components, regions, layers
and/or sections, these elements, components, regions, layers and/or
sections should not be limited by these terms. These terms may be
only used to distinguish one element, component, region, layer or
section from another region, layer or section. Terms such as
"first," "second," and other numerical terms when used herein do
not imply a sequence or order unless clearly indicated by the
context. Thus, a first element, component, region, layer or section
discussed below could be termed a second element, component,
region, layer or section without departing from the teachings of
the example embodiments.
[0047] Spatially relative terms, such as "inner," "outer,"
"beneath," "below," "lower," "above," "upper," and the like, may be
used herein for ease of description to describe one element or
feature's relationship to another element(s) or feature(s) as
illustrated in the figures. Spatially relative terms may be
intended to encompass different orientations of the device in use
or operation in addition to the orientation depicted in the
figures. For example, if the device in the figures is turned over,
elements described as "below" or "beneath" other elements or
features would then be oriented "above" the other elements or
features. Thus, the example term "below" can encompass both an
orientation of above and below. The device may be otherwise
oriented (rotated 90 degrees or at other orientations) and the
spatially relative descriptors used herein interpreted
accordingly.
[0048] The foregoing description of the embodiments has been
provided for purposes of illustration and description. It is not
intended to be exhaustive or to limit the disclosure. Individual
elements or features of a particular embodiment are generally not
limited to that particular embodiment, but, where applicable, are
interchangeable and can be used in a selected embodiment, even if
not specifically shown or described. The same may also be varied in
many ways. Such variations are not to be regarded as a departure
from the disclosure, and all such modifications are intended to be
included within the scope of the disclosure.
* * * * *