Flooring underlayment with dimple endcaps and related methods
AssigneeDmx Plastics Limited
InventorSundeepan Sennik
Life of this patent
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Abstract
An underlayment for installation between a base surface and a flooring material includes (a) a structural membrane formed of a structural material and including a panel and a plurality of dimples projecting from an underside surface of the panel. Each dimple has a dimple tip spaced apart from the underside surface. The underlayment further includes (b) a plurality of discrete dimple endcaps comprising a resilient material. Each endcap is fixed relative to, and covers at least a portion of, the dimple tip of a respective dimple. The endcaps support the dimples above the base surface when the underlayment is installed.
Claims17
An underlayment for installation between a base surface and a flooring material, the underlayment comprising:
- a) a structural membrane formed of a structural material and including a panel having a panel top surface and a panel underside surface opposite the panel top surface, the structural membrane further including a plurality of dimples projecting from the panel underside surface for supporting the panel above the base surface, each dimple having a dimple tip spaced apart from the panel underside surface and a dimple outer surface extending from the panel underside surface to the dimple tip;
- and
- b) a plurality of discrete dimple endcaps comprising a resilient material, each dimple endcap fixed to the dimple outer surface and covering the dimple tip of a respective dimple, the endcaps supporting the dimple tips above the base surface when the underlayment is installed.
An underlayment for installation between a base surface and a flooring material, the underlayment comprising:
- a) a structural membrane formed of a first material and including a panel and a plurality of dimples projecting from an underside surface of the panel, each dimple having a dimple tip spaced apart from the underside surface and a dimple outer surface extending from the panel underside surface to the dimple tip;
- and
- b) a plurality of dimple endcaps formed of a second material different than the first material, each endcap fixed to the dimple outer surface and covering the dimple tip of a respective dimple, the endcaps supporting the dimple tips above the base surface when the underlayment is installed.
A method of producing an underlayment for installation between a base surface and a flooring material, the method comprising:
- a) providing a structural membrane having a panel and a plurality of dimples extending from the panel for supporting the panel above the base surface;
- b) heating a thermoplastic elastomer to above a glass transition temperature to form an elastomer melt;
- c) applying the elastomer melt to a tip of each dimple;
- and
- d) cooling the elastomer melt to below the glass transition temperature to form a plurality of discrete dimple endcaps, each dimple endcap fixed to the dimple and covering the dimple tip, the endcaps supporting the dimple tips above the base surface when the underlayment is installed.
Dependencies are inferred from the claim text.