Underlay element for flooring and floor assembly

Patent metadata

Field	Value
Publication number	US-12084871-B2
Application number	US-202117645082-A
Country	US
Kind code	B2
Filing date	Dec 20, 2021
Priority date	Dec 21, 2020
Publication date	Sep 10, 2024
Grant date	Sep 10, 2024

Abstract

An underlay element configured to be provided between a floor covering and a subfloor. The underlay element includes a base matrix and a plurality of restriction members at least partly embedded in the base matrix. The base matrix includes a first material which is compressible and, preferably, foamed. The restriction members include a second material, wherein a size of each of the restriction members exceeds 0.25 mm in at least one direction. A compression of the underlay element is configured to be restricted by the restriction members. Also, a corresponding floor assembly including a floor covering and an underlay element.

First claim

The invention claimed is:

1. Underlay element configured to be provided between a floor covering and a subfloor, the underlay element comprising a base matrix and a plurality of restriction members at least partly embedded in said base matrix,
wherein the base matrix comprises a first material comprising a polymeric material, the first material being foamed, the first material being compressible, and the first material having a density of less than 700 kg/m 3 ,
wherein the restriction members comprise a second material, a size of each of the restriction members exceeding 0.25 mm in two or three perpendicular directions, wherein one of these directions is parallel with a thickness direction of the underlay element,
wherein a compression of at least a portion of the underlay element is configured to be restricted by the restriction members, and
wherein the base matrix comprising the first material overlaps the restriction members above and/or below the restriction members in the thickness direction of the underlay element.

2. The underlay element according to claim 1 , wherein said compression does not exceed 0.60 mm, at an applied pressure of 1.90 MPa.

3. The underlay element according to claim 1 , wherein a thickness of the underlay element is 0.4-3.0 mm.

4. The underlay element according to claim 1 , wherein the size of the restriction members exceeds 1.00 mm in at least one direction.

5. The underlay element according to claim 1 , wherein the size of the restriction members exceeds 1.00 mm in the two or three perpendicular directions, wherein one of these directions is parallel with said thickness direction.

6. The underlay element according to claim 1 , wherein the restriction members have about the same sizes and/or shapes.

7. The underlay element according to claim 1 , wherein the restriction members have varying sizes and/or shapes.

8. The underlay element according to claim 1 , wherein the restriction members comprise particles and/or strips.

9. The underlay element according to claim 1 , wherein a density of the second material is greater than a density of the first material.

10. The underlay element according to claim 1 , wherein a density of the first material is less than 500 kg/m 3 .

11. The underlay element according to claim 1 , wherein the first material comprises a thermoplastic material or a cross-linked thermoplastic material.

12. The underlay element according to claim 1 , wherein the second material is compressible, a compressive strength of the second material being greater than a compressive strength of the first material.

13. The underlay element according to claim 1 , wherein the second material comprises a polymeric material and/or a mineral-based material.

14. The underlay element according to claim 1 , wherein the restriction members are entirely embedded in said base matrix.

15. The underlay element according to claim 1 , wherein the base matrix comprises cavities and wherein the restriction members are provided in the cavities.

16. The underlay element according to claim 1 , wherein the base matrix comprises a plurality of base members, wherein the plurality of restriction members are separately formed, and wherein the underlay element further comprises a first and a second sheet at least partly enclosing the base members and the restriction members.

17. The underlay element according to claim 1 , wherein the first material comprises an organic filler and/or an inorganic filler.

18. A floor assembly configured to be provided on a subfloor, the floor assembly comprising:
a floor covering, the floor covering comprising at least one floor panel; and
the underlay element according to claim 1 ;
wherein the underlay element is configured to be disposed between the floor covering and the subfloor.

19. The floor assembly according to claim 18 , wherein the floor covering is a thermoplastic floor covering including floor tiles or panels.

Assignees

• Ceraloc Innovation Ab

Inventors

• Josefsson Per
• Olofsson Richard
• Bjeremyr Martin

Classifications

• E04F15/18

  Separately-laid insulating layers; Other additional insulating measures; Floating floors (insulating of buildings in general E04B1/62) · CPC title

• B32B27/304

  comprising vinyl halide (co)polymers, e.g. PVC, PVDC, PVF, PVDF · CPC title

• B32B2307/732

  Dimensional properties · CPC title

• B32B2307/7242

  Non-permeable · CPC title

• B32B2307/7265

  Non-permeable · CPC title