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Underlayment for surface coverings and methods of making the same

a technology of surface coverings and underlayments, which is applied in the field of underlayment for surface coverings, can solve the problems of high sound transmission of laminate flooring, undesirable to many users, and achieve the effect of improving impact sound transmission and/or airborne sound transmission

Inactive Publication Date: 2002-02-28
MANNINGTON MILLS
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  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

AI Technical Summary

Benefits of technology

[0004] A feature of the present invention is an underlayment which preferably has improved impact sound transmission and / or airborne sound transmission when used as an underlayment for surface coverings such as flooring products.
[0006] Another feature of the present invention is to provide a method for reducing or controlling sound transmission in surface coverings like flooring products.

Problems solved by technology

This concern has especially been prevalent with laminate flooring due to the core of the laminate flooring being made of particle board which has the ability to result in sound transmissions which are undesirable to many users.
While laminate flooring has many benefits and has become a popular product in the United States based on many favorable properties, one of the weaknesses of laminate flooring in addition to the problem of moisture resistance, is that laminate flooring creates high sound transmission due to foot traffic on the hard top surface.
These paddings have been made in the past with wood fibers, which have been pressed together along with binder to form a rigid sheet or have been made of a polyurethane foam layer which is very expensive.

Method used

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  • Underlayment for surface coverings and methods of making the same
  • Underlayment for surface coverings and methods of making the same

Examples

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example 1

[0035] A underlayment according to the present invention was made and tested for sound transmission properties. In particular, a backing felt layer having a relatively flat thickness of about 0.025 inch was obtained from, Cascades Lupel, wherein the felt layer was a cellulosic fiber material impregnated with styrenebutadiene resin latex, calcium carbonate. This felt layer was then coated uniformly to a wet thickness of from about 0.018 inch with a foamable PVC plastisol having the composition set forth below. The foamable PVC plastisol composition was then fused by placing the coated felt layer in a heated oven at a temperature of about 400.degree. F. for a period of about 1.5 minutes. This temperature was sufficient to decompose or activate the azodicarbonamide-blowing agent and form a foam thickness of about 0.06 inch.

1 Formula PHR Polyvinyl chloride, dispersion grade, I.V.1.0 30 VC-433; polyvinyl chloride, dispersion grade, 16.67 Polyvinyl chloride, dispersion grade; I.V. -0.91 2...

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Abstract

An underlayment for surface covering, such as flooring, is described wherein the underlayment includes at least one polymeric foam layer having a top surface and a bottom surface and at least one felt layer located on either the top surface or bottom surface of the polymeric foam layer. Methods to reduce or control sound transmission and / or sound reflection of surface coverings like flooring products is also described wherein the underlayment is installed beneath the surface covering.

Description

[0001] The present invention relates to a product for surface coverings and preferably a product for flooring products such as laminate flooring. More particularly, the present invention relates to an underlayment for use with surface coverings which preferably provide improved control of sound transmission.[0002] It has always been the goal of manufacturers who develop hard floor surfaces such as laminate flooring and solid wood flooring to ensure that the sound transmission from foot traffic is held to acceptable levels. This concern has especially been prevalent with laminate flooring due to the core of the laminate flooring being made of particle board which has the ability to result in sound transmissions which are undesirable to many users. While laminate flooring has many benefits and has become a popular product in the United States based on many favorable properties, one of the weaknesses of laminate flooring in addition to the problem of moisture resistance, is that lamina...

Claims

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Application Information

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Patent Type & Authority Applications(United States)
IPC IPC(8): B32B5/18B32B27/12E04F15/20
CPCB32B5/18B32B27/12E04F15/20Y10T442/56Y10T442/51Y10T442/50B32B2266/0221B32B2471/00B32B2307/102B32B5/245
Inventor CHEN, HAO A.ZEREBECKI, NICHOLAS
Owner MANNINGTON MILLS
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