Architectural flooring underlayment

Patent metadata

Field	Value
Publication number	US-12442199-B2
Application number	US-202117792244-A
Country	US
Kind code	B2
Filing date	Jan 27, 2021
Priority date	Jan 27, 2020
Publication date	Oct 14, 2025
Grant date	Oct 14, 2025

Abstract

A fibrous structure having one or more vertically lapped layers having a first surface and a second surface and a facing layer secured to the first surface of the vertically lapped layer. The fibrous structure is adapted to be used in a flooring assembly. The fibrous structure may include a mesh and/or a backing layer on the second surface of a vertically lapped layer. The fibrous structure exhibits improved performance in below room testing and/or in-room testing as compared with traditional materials of the same thickness.

First claim

What is claimed is:

1. A fibrous structure comprising:
a. a vertically lapped layer having a first surface and a second surface, wherein the vertically lapped layer has a weight of about 110 gsm to about 175 gsm;
b. a facing layer secured to the first surface of the vertically lapped layer, wherein the facing layer includes one or more of a spunbond (S) material, a spunbond and meltblown (SM) material spunbond+meltblown+spunbond (SMS) nonwoven material;
c. a backing layer secured directly or indirectly to the second surface of the vertically lapped layer, wherein the backing layer comprises a spunbond PET material having a weight of about 8 gsm to about 22 gsm;
wherein the fibrous structure has a thickness of about 5 mm or less; and
wherein the fibrous structure is a flooring subassembly adapted to be used in a flooring assembly.

2. The fibrous structure of claim 1 , wherein the facing layer is an air flow resistive facing layer.

3. The fibrous structure of claim 1 , wherein the facing layer is a flooring contact layer adapted to contact a flooring surface, a subfloor, or both.

4. The fibrous structure of claim 1 , wherein the facing layer comprises the SMS nonwoven material.

5. The fibrous structure of claim 4 , wherein the SMS nonwoven material of the facing layer comprises a polypropylene SMS material.

6. The fibrous structure of claim 1 , wherein the fibrous structure comprises a scrim or mesh.

7. The fibrous structure of claim 6 , wherein the scrim or mesh is located between the second surface of the vertically lapped layer and the backing layer.

8. The fibrous structure of claim 6 , wherein the scrim or mesh has a weight of about 20 gsm to about 30 gsm.

9. The fibrous structure of claim 1 , wherein fibers of the vertically lapped layer are oriented generally vertically in an uncompressed state.

10. The fibrous structure of claim 1 , wherein the vertically lapped layer is a compressed vertically lapped layer.

11. The fibrous structure of claim 1 , wherein the facing layer has a weight of about 50 gsm to about 60 gsm.

12. The fibrous structure of claim 1 , wherein the weight of the backing layer is about 10 gsm to about 20 gsm.

13. The fibrous structure of claim 1 , wherein one or more of the layers includes an adhesive for bonding to an adjacent layer.

14. The fibrous structure of claim 1 , wherein the fibrous structure has a thickness of about 1.5 mm or greater and about 3.5 mm or less.

15. The fibrous structure of claim 1 , wherein the fibrous structure maintains its loft after a castor chair test at 25,000 cycles at 90 kg.

16. A fibrous structure comprising:
a. a vertically lapped layer having a first surface and a second surface, wherein the vertically lapped layer comprises PET fibers and has a weight of about 110 gsm to about 175 gsm;
b. a facing layer secured to the first surface of the vertically lapped layer, wherein the facing layer is formed of a polypropylene SMS material and has a weight of about 50 gsm to about 60 gsm;
c. a backing layer comprising a spunbond PET material having a weight of about 10 gsm to about 20 gsm; and
d. a scrim or a mesh sandwiched between the second surface of the vertically lapped layer and the backing layer, wherein the scrim or mesh has a weight of about 20 gsm to about 30 gsm;
wherein one or more of the layers includes an adhesive secured thereto for binding to an adjacent layer; and
wherein the fibrous structure is a flooring subassembly adapted to be used in a flooring assembly.

17. The fibrous structure of claim 16 , wherein the fibrous structure includes one or more pressure sensitive adhesive layers for bonding a flooring surface to the fibrous structure, bonding the fibrous structure to a subfloor, or both.

18. A flooring assembly comprising a flooring surface and the fibrous structure of claim 1 .

19. The flooring assembly of claim 18 , wherein the flooring surface is vinyl, luxury vinyl tile, laminate, type, wood planks, linoleum, engineered wood, cork, hardwood, bamboo, stone, or a combination thereof.

20. The flooring assembly of claim 18 , wherein the flooring assembly includes one or more pressure sensitive adhesive layers for bonding the flooring surface to the fibrous structure, bonding the fibrous structure to a subfloor, or both.

Assignees

• Zephyros Inc
• Pak Lite Inc

Inventors

• Mohan Varun
• Chaut Christophe
• Bush Kendall
• Thompson Greg
• Boring William Desmond

Classifications

• D04H11/04

  formed by zig-zag folding of a fleece or layer of staple fibres, filaments, or yarns, strengthened or consolidated at the folds · CPC title

• E04F15/186

  Underlayers covered with a mesh or the like · CPC title

• E04F15/182

  Underlayers coated with adhesive or mortar to receive the flooring · CPC title

• B32B2307/732

  Dimensional properties · CPC title

• B32B2307/7242

  Non-permeable · CPC title