Underlayment for floor coverings

• US 6,576,577 B1
• Filed: 06/04/1999
• Issued: 06/10/2003
• Est. Priority Date: 12/03/1998
• Status: Expired due to Fees

• Current Assignee: Foam Products Corporation
• Original Assignee: Foam Products Corporation
• Inventors: Garner, Kenneth B.
• Primary Examiner(s): Cole, Elizabeth M.
• Assistant Examiner(s): JOHNSON, JENNA LEIGH
• Application Number:
  US09/326,383
• Time in Patent Office: 1,467 Days
• Field of Search: 442/370, 442/374, 442/401, 428/304.4, 524/031
• US Class Current: 442/374
• CPC Class Codes: B32B 27/12 next to a fibrous or filamentary layer
• CPC Class Codes: B32B 5/18 characterised by features of a layer of foamed material
• CPC Class Codes: D06N 3/0043 characterised by their foraminous structure; Characteristics of the foamed layer or of cellular layers foraminous structure obtained by stretching D06N3/0029
• CPC Class Codes: D06N 3/14 with polyurethanes
• CPC Class Codes: E04F 15/18 Separately-laid insulating layers; Other additional insulating measures; Floating floors insulating of buildings in general E04B1/62
• CPC Class Codes: E04F 15/186 Underlayers covered with a mesh or the like
• CPC Class Codes: E04F 15/203 Separately-laid layers for sound insulation
• CPC Class Codes: Y10T 428/249953 Composite having voids in a component [e.g., porous, cellular, etc.]
• CPC Class Codes: Y10T 442/647 Including a foamed layer or component
• CPC Class Codes: Y10T 442/652 Nonwoven fabric is coated, impregnated, or autogenously bonded
• CPC Class Codes: Y10T 442/681 Spun-bonded nonwoven fabric

Abstract

An underlayment material is disclosed for use as an underlayment in a non-textile flooring system. The underlayment material comprises a thin, flexible layer of polyurethane foam and a thin, flexible substrate layer bonded to one side of the layer of polyurethane foam. In a preferred embodiment, the underlayment material is a mechanically frothed polyurethane foam. In another preferred embodiment, the substrate layer is a layer of non-woven spun bonded polyester fibers. In another preferred embodiment, the underlayment material has a thickness of between about 0.05 and 0.125 inches, and most preferably, about 0.085 inches. In still another preferred embodiment, the foam has a fine cell structure and a density of between 10 and 30 pounds per cubic foot, and most preferably about 20 pounds per cubic foot. In still another preferred embodiment, the foam has a compression set of between about 5% and 25%, and most preferably about 10%.

Claims

1. An underlayment material for a non-textile flooring system, comprising:

(a) a flexible layer of frothed, polyurethane foam with an open cell structure and a density between 10 and 30 pounds per cubic foot;

(b) a flexible substrate layer bonded to one side of the layer of polyurethane foam to form a thin underlayment material that is between about 0.05 and 0.125 inches thick wherein in use the underlayment material provides at least one of (a) smoothing imperfections beneath the flooring system, (b) providing a cushioning effect for the flooring system, and (c) reducing sound transmission through the flooring system; and

(c) a non-textile flooring system.

2. The underlayment material of claim 1, wherein the substrate layer is a layer of non-woven spun bonded polyester fibers.

3. The underlayment material of claim 1, wherein the underlayment material has a thickness of about 0.085 inches.

4. The underlayment material of claim 1, wherein the foam has a density of about 20 pounds per cubic foot.

5. The underlayment material of claim 1, wherein the foam has a compression set of between about 5% and 25%.

6. The underlayment material of claim 1, wherein the foam has a compression set of about 10%.

7. A non-textile flooring system comprising (a) an underlayment material comprising a flexible layer of polyurethane foam and a flexible substrate layer bonded to one side of the layer of polyurethane foam, wherein the underpayment material has a thickness of between about 0.05 and 0.125 inches thick, the foam is mechanically frothed polyurethane foam having a density between 10 and 30 pounds per cubic foot, and the substrate layer is a layer of non-woven spun bonded polyester fibers and (b) a non-textile flooring system.

8. The underlayment material of claim 7, wherein the foam has a density of about 20 pounds per cubic foot.

9. The underlayment material of claim 7, wherein the foam has a compression set of between about 5% and 25%.

10. The underlayment material of claim 7, wherein the foam has a compression set of about 10%.

11. A flooring system, comprising:

(a) an underlayment material for a non-textile flooring system, the material comprising;

(i) a flexible layer of mechanically frothed polyurethane foam with an open cell structure, a density between 10 and 30 pounds per cubic foot; and

(ii) a flexible substrate layer bonded to one side of the layer of polyurethane foam to form an underlayment material that is between about 0.05 and 0.125 inches thick; and

(b) non-textile flooring material for installation above the underlayment material.