Floor underlayment
The invention relates to a floor underlayment comprising a first layer, a second layer, and an inner layer between the first layer and the second layer, wherein the inner layer has one layer of foam beads, and the floor underlayment has a thickness from 0.8 mm to 1.5 mm. The invention further relates to a method for manufacturing a floor underlayment, a flooring system and a use of a floor underlayment.
1. A floor underlayment comprising:
a first layer,
a second layer, and
an inner layer between the first layer and the second layer,
wherein:
the inner layer has one layer of foam beads,
the floor underlayment has a thickness from 0.8 mm to 1.5 mm,
the foam beads have a diameter of less than 1.3 mm, and
at least wt. 90% of the foam beads have a diameter in a range between 0.95 mm and 1.3 mm.
2. The floor underlayment according to claim 1 , wherein
at least one of the first layer and the second layer is a plastic film layer, and/or
the floor underlayment further comprises at least one adhesive layer between the first layer and the second layer, and/or
the foam beads are expanded polystyrene (EPS) beads.
3. The floor underlayment according to claim 1 , wherein
the foam beads have a density equal to or more than 28 kg/m 3 ,
and equal to or less than 41 kg/m 3 .
4. The floor underlayment according to claim 1 , wherein the foam beads have a diameter equal to or less than 1.1 mm.
5. The floor underlayment according to claim 4 , wherein at least 95 wt. % of the foam beads have a diameter in a range between 0.95 mm and 1.1 mm.
6. The floor underlayment according to claim 1 , wherein
the first layer comprises polyolefin, and/or
the second layer comprises polyolefin.
7. The floor underlayment according to claim 1 , wherein
the inner layer comprises gaps between adjacent foam beads, thereby forming pathways for moisture.
8. The floor underlayment according to claim 1 , wherein
the first layer has a thickness in a range between 0.02 mm and 0.09 mm, and/or
the second layer has a thickness in a range between 0.02 mm and 0.09 mm.
9. The floor underlayment according to claim 1 , wherein
a total amount of an adhesive in the floor underlayment is in a range between 20 g/m 2 and 32 g/m 2 , and/or
a basis weight of the floor underlayment is in a range between 105 g/m 2 and 135 g/m 2 .
10. The floor underlayment according to claim 1 , wherein the floor underlayment comprises:
an adhesive in a range between 3 wt. % and 10 wt. % based on a total weight of the floor underlayment, and/or
the foam beads in a range between 23 wt. % and 31 wt. % based on a total weight of the floor underlayment, and/or
materials of the first and the second layer in a range between 58 wt. % and 78 wt. % based on a total weight of the floor underlayment.
11. A flooring system comprising a floor underlayment according to claim 1 , and a floor.
12. A floor underlayment comprising:
a first layer,
a second layer, and
an inner layer between the first layer and the second layer,
wherein:
the inner layer has one layer of foam beads,
the floor underlayment has a thickness from 0.8 mm to 1.5 mm, and
a compressive strength of the floor underlayment is equal to or more than 150 kPa.
13. A floor underlayment comprising:
a first layer,
a second layer, and
an inner layer between the first layer and the second layer,
wherein:
the inner layer has one layer of foam beads,
the floor underlayment has a thickness from 0.8 mm to 1.5 mm, and
the number of the foam beads is in a range between 300000 pieces/m 2 and 800000 pieces/m 2 .