# US 2014/0335315 A1 · Method for manufacturing an underlay material, and underlay material

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- Number: US 2014/0335315 A1
- Document ID: US20140335315A1
- Status: Published application
- Kind: A1
- Application number: 14/363,936
- Filed: 2012-12-07
- Published: 2014-11-13
- Earliest claimed: 2011-12-07
- Inventors: Thomas Virtanen
- Web page: https://patentgrep.com/patent/US20140335315A1

## CPC

- B32B 37/04: characterised by the partial melting of at least one layer
- B29C 65/18: using heated tools
- B29C 66/1122: {Single lap to lap joints, i.e. overlap joints (B29C66/45, B29C66/472, B29C66/52272 take precedence)}
- B29C 66/45: {Joining of substantially the whole surface of the articles (methods or apparatus for laminating B32B37/00)}
- B29C 66/727: {being porous, e.g. foam}
- B29C 66/81433: {being toothed, i.e. comprising several teeth or pins (comprising a single tooth B29C66/81429), or being patterned}
- B29C 66/83413: {cooperating rollers, cylinders or drums}
- B32B 5/18: characterised by features of a layer {of} foamed material
- B32B 37/0076: {characterised in that the layers are not bonded on the totality of their surfaces}
- B32B 37/0084: {Point bonding}
- B32B 37/06: characterised by the heating method
- B32B 37/203: {One or more of the layers being plastic}
- B32B 38/06: Embossing
- E04F 15/00: Flooring (stair treads E04F11/104; coverings not specially adapted for floors E04F13/00; borders, skirtings E04F19/02; {implements for laying flooring E04F21/20;} gratings for cleaning soles of footwear A47L23/24; {built-in gratings E04F19/10; removing floor coverings E04G23/00; carpets A47G27/00;} of similar materials to roads E01C; basic or rough floors {, structural floors} E04B5/00)
- E04F 15/18: Separately-laid insulating layers; Other additional insulating measures; Floating floors (insulating of buildings in general E04B1/62)
- E04F 15/185: {Underlayers in the form of studded or ribbed plates}
- E04F 15/186: {Underlayers covered with a mesh or the like}
- B29C 59/04: using rollers or endless belts
- B29C 66/221: {being in the form of a sinusoidal wave (B29C66/2272 takes precedence)}
- B29C 66/71: {characterised by the composition of the plastics material of the parts to be joined (welding bar compositions B29C65/125)}
- B29C 66/73521: {of different thickness, i.e. the thickness of one of the parts to be joined being different from the thickness of the other part}
- B29C 66/7486: {Paper, e.g. cardboard}
- B32B 37/08: characterised by the cooling method
- B32B 2305/022: Foam
- B32B 2309/02: Temperature
- B32B 2471/00: Floor coverings (B32B2419/04 takes precedence)
- Y10T 156/1021: Treating material of corrugated lamina or dry adhesive thereon to render tacky
- Y10T 428/24504: Component comprises a polymer [e.g., rubber, etc.]
- B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B29C: SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00)
- E04F: FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS (windows, doors E06B)
- Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION

## Abstract

A method for manufacturing an underlay material (8) to be set under parquet or a laminate, the underlay material including a sheet material layer (1) and a flexible cellular plastic material layer (3) bonded under the sheet material layer, and a bottom surface of the cellular plastic layer being processed for providing an air space, whereby the bottom surface of the cellular plastic material layer (3) is processed by melting the cellular plastic material locally for providing an air space (9) and for simultaneously bonding the cellular plastic material layer to the sheet material layer (1). An underlay material manufactured by such a method is also described.

## Claims

### Claim 1

A method for manufacturing an underlay material (8) to be set under parquet or a laminate, said underlay material consisting of a sheet material layer (1) and a flexible cellular plastic material layer (3) bonded under the sheet material layer, and a bottom surface of said cellular plastic layer being processed for providing an air space, characterized in that the bottom surface of the cellular plastic material layer (3) is processed by melting the cellular plastic material locally for providing an air space (9) and for simultaneously bonding the cellular plastic material layer to the sheet material layer (1).

### Claim 2 (depends on 1)

A method according to claim 1, characterized in that the melting and bonding of the cellular plastic material layer (3) to the sheet material layer (1) is conducted by conveying the material layers through between rolls 5 and 6 set in opposition to each other, whereby the roll (6) placing itself against the cellular plastic material has its surface formed with uniform protrusions (7, 7′), the roll placing itself against the cellular plastic material layer having at least its protrusions heated.

### Claim 3 (depends on 1)

A method according to claim 1, characterized in that the cellular plastic material layer (3) is by melting formed with at least two sets of continuous and parallel grooves (9), the grooves of various sets crossing each other to make up a pattern of squares or lozenges on the surface of the cellular plastic material layer.

### Claim 4 (depends on 1)

A method according to claim 1, characterized in that the sheet material layer (1) is made of plastic, paper or cardboard and is preferably in the form of a material web.

### Claim 5 (depends on 1)

A method according to claim 1, characterized in that the cellular plastic material layer (3) is made of a foamed polymer or polymer blend and is preferably in the form of a material web.

### Claim 6

An underlay material (8) to be placed under parquet or a laminate, said underlay material consisting of a sheet material layer (1) and a flexible cellular plastic material layer (3) bonded under the sheet material layer, and said cellular plastic having recesses on its bottom surface for providing an air space (9), characterized in that the cellular plastic material layer (3) is bonded to the sheet material layer (1) only by melting the plastic material at the recesses (9) formed in the cellular plastic material layer.

### Claim 7 (depends on 6)

An underlay material (8) according to claim 6, characterized in that the recesses of the cellular plastic material layer (3) consist of at least two sets of continuous and parallel grooves (9), the grooves of various sets crossing each other to make up a pattern of squares or lozenges.

### Claim 8 (depends on 6)

An underlay material (8) according to claim 6, characterized in that the sheet material layer (1) is made of plastic, paper or cardboard.

### Claim 9 (depends on 6)

An underlay material (8) according to claim 6, characterized in that the cellular plastic material layer (3) is made of a foamed polymer or polymer blend.

### Claim 10 (depends on 6)

An underlay material (8) according to claim 6, characterized in that the underlay material (8) is in the form of a material web.

### Claim 11 (depends on 2)

A method according to claim 2, characterized in that the cellular plastic material layer (3) is by melting formed with at least two sets of continuous and parallel grooves (9), the grooves of various sets crossing each other to make up a pattern of squares or lozenges on the surface of the cellular plastic material layer.

### Claim 12 (depends on 7)

An underlay material (8) according to claim 7, characterized in that the sheet material layer (1) is made of plastic, paper or cardboard.

### Claim 13 (depends on 7)

An underlay material (8) according to claim 7, characterized in that the cellular plastic material layer (3) is made of a foamed polymer or polymer blend.

### Claim 14 (depends on 8)

An underlay material (8) according to claim 8, characterized in that the cellular plastic material layer (3) is made of a foamed polymer or polymer blend.