Low relflected-sound-pressure-level, low moisture-vapor-transmission-rate flooring system
A flooring system having a top floor layer, a sub-floor, and an underlayment material disposed between the sub-floor and the top floor layer is disclosed. The underlayment material may include a cross-linked, polyolefin foam having a moisture vapor transmission rate of less than about 3.0 lb/1000 ft 2 /24 hr, and an average sound pressure level of less than about 15 dB over a range of about 300 Hz to about 1000 Hz. The foam may have a compressive strength of at least about 0.85 kg/cm 2 . Foam density, gel fraction, and resin blend may combine to provide an underlayment material having such reflective sound and moisture vapor barrier properties.
1. A flooring system, comprising:
a top floor layer;
a sub-floor; and
an underlayment material comprising a cross-linked, polyolefin foam comprising 80-90% polypropylene and having a gel fraction of 40-60% and a density of 40-60 kg/m 3 disposed between the sub-floor and the top floor layer,
wherein the flooring system produces an average reflected sound pressure level of less than about 13.5 dB over a range of about 300 Hz to about 1000 Hz.
2. The flooring system of claim 1 , wherein the foam has a compressive strength of at least about 0.8 kg/cm 2 .
3. The flooring system of claim 1 , wherein the cross-linked, polyolefin foam includes a blend of polyethylene and polypropylene copolymer.
4. The flooring system of claim 3 , wherein the underlayment material has a thickness of about 1.5 mm and about 2.5 mm.
5. The flooring system of claim 1 , wherein the underlayment material includes at least one of an anti-microbial additive, a flame retardant additive, and an adhesion promoter.
6. The flooring system according to claim 1 ,
wherein the cross-linked, polyolefin foam has a moisture vapor transmission rate of less than about 3.0 lb/1000 ft 2 /24 hr.
7. The flooring system of claim 1 , wherein the foam has a fine cell structure with cells having diameters between about 0.1 millimeter and about 1 millimeter.
8. The flooring system of claim 1 , further comprising a vapor barrier layer disposed between the top floor layer and the sub-floor.
9. The flooring system of claim 1 , wherein the foam is laminated to a layer comprising at least one of a non-woven, a film, and another foam.
10. The flooring system of claim 1 , wherein the foam is at least one of embossed, textured, or molded.
11. A flooring system, comprising:
a top floor layer;
a sub-floor; and
an underlayment material comprising a cross-linked, polyolefin foam comprising 80-90% polypropylene and having a degree of cross-linking of 40-60% and a density of 40-60 kg/m 3 disposed between the sub-floor and the top floor layer,
wherein the flooring system produces an average reflected sound pressure level of less than about 13.5 dB over a range of about 300 Hz to about 1000 Hz.
12. The flooring system of claim 11 , wherein the foam has a compressive strength of at least about 0.8 kg/cm 2 .
13. The flooring system of claim 11 , wherein the cross-inked, polyolefin foam includes a blend of polyethylene and polypropylene copolymer.
14. The flooring system of claim 13 , wherein the underlayment material has a thickness of about 1.5 mm and about 2.5 mm.
15. The flooring system of claim 11 , wherein the underlayment material includes at least one of an anti-microbial additive, a flame retardant additive, and an adhesion promoter.
16. The flooring system according to claim 11 , wherein the cross-linked, polyolefin foam has a moisture vapor transmission rate of less than about 3.0 lb/1000 ft 2 /24 hr.
17. The flooring system of claim 11 , wherein the foam has a fine cell structure with cells having diameters between about 0.1 millimeter and about 1 millimeter.
18. The flooring system of claim 11 , further comprising a vapor barrier layer disposed between the top floor layer and the sub-floor.
19. The flooring system of claim 11 , wherein the foam is laminated to a layer comprising at least one of a non-woven, a film, and another foam.
20. The flooring system of claim 11 , wherein the foam is at least one of embossed, textured, or molded.