IP Library Granted Patent US 11,448,405
Granted Patent B2
US 11,448,405 · App. 17/365,180 · Granted Sep 20, 2022

Floor heating system including membranes that are configured to be joined together to house a heating cable, and flooring underlayment including such membranes

Inventors: Chase Warneke (Pierce, NE); Alan B. Collison (Pierce, NE); Reid Borgman (Norfolk, NE)
Assignee: MP Global Products, L.L.C.
F24D3/142E04F15/182E04F15/185F24D3/141F24D3/144F28D7/082F28D7/087F24D3/12F28D7/08H05B3/28
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Quick Facts
Patent No.
US 11,448,405
App. No.
17/365,180
Granted
Sep 20, 2022
Kind
B2
Abstract

A flooring underlayment includes a base membrane and a cover membrane. The base membrane is configured to be installed between a subfloor and floor tiles to allow movement of the floor tiles relative to the subfloor. The cover membrane is configured to be coupled to the base membrane to form a flat surface for supporting the floor tiles. The cover membrane is configured to be coupled to the base membrane using at least one of a snug fit and a snap fit.

Claims (54)

1. A flooring underlayment comprising:

a base membrane configured to be installed between a subfloor and floor tiles to allow movement of the floor tiles relative to the subfloor; and

a cover membrane configured to be coupled to the base membrane to form an uninterrupted flat surface for supporting the floor tiles and to cover the base membrane to prevent tile adhesive from reaching the base membrane, wherein the cover membrane is configured to be coupled to the base membrane using at least one of a snug fit and a snap fit.

2. The flooring underlayment of claim 1 wherein the base membrane includes a base layer and a plurality of studs projecting from the base layer.

3. The flooring underlayment of claim 2 wherein the cover membrane includes a cover layer and a plurality of studs projecting from the cover layer.

4. The flooring underlayment of claim 3 wherein the plurality of studs on the cover membrane are configured to engage the plurality of studs on the base membrane to couple the cover membrane to the base membrane.

5. The flooring underlayment of claim 1 wherein the base and cover membranes are made of at least one of a plastic and a rubber.

6. A flooring underlayment comprising:

a base membrane configured to be installed between a subfloor and floor tiles to allow movement of the floor tiles relative to the subfloor, the base membrane including a base layer and a plurality of studs projecting from the base layer; and

a cover membrane configured to be coupled to the base membrane to form an uninterrupted flat surface for supporting the floor tiles, the cover membrane including a cover layer and a plurality of studs projecting from the cover layer, wherein:

the cover membrane is configured to be coupled to the base membrane using at least one of a snug fit and a snap fit;

the plurality of studs on the cover membrane are configured to engage the plurality of studs on the base membrane to couple the cover membrane to the base membrane;

the plurality of studs on one of the base and cover membranes have free ends that define pockets therein; and

the plurality of studs on the other one the base and cover membranes are configured to fit within the pockets in the plurality of studs on the one of the base and cover membranes to couple the cover membrane to the base membrane.

7. A flooring underlayment comprising:

a base membrane configured to be installed between a subfloor and floor tiles to allow movement of the floor tiles relative to the subfloor; and

a cover membrane configured to be coupled to the base membrane to form a flat surface for supporting the floor tiles and to cover the base membrane to prevent tile adhesive from reaching the base membrane, wherein the cover membrane is configured to be coupled to the base membrane using at least one of a snug fit and a snap fit, wherein the base and cover membranes are made of a material having a flexibility that enables the base and cover membranes to be rolled.

8. A floor structure comprising:

a subfloor;

floor tiles;

a base membrane configured to be installed between the subfloor and the floor tiles to allow movement of the floor tiles relative to the subfloor; and

a cover membrane configured to be coupled to the base membrane using at least one of a snug fit and a snap fit and to cover the base membrane to prevent tile adhesive from reaching the base membrane, the cover membrane forming an uninterrupted flat surface for supporting the floor tiles.

9. The floor structure of claim 8 wherein:

the base membrane includes a base layer and a plurality of studs projecting from the base layer;

the cover membrane includes a cover layer and a plurality of studs projecting from the cover layer; and

the plurality of studs on the cover membrane are configured to engage the plurality of studs on the base membrane to couple the cover membrane to the base membrane.

10. The floor structure of claim 9 wherein the base and cover membranes are made of at least one of a plastic and a rubber.

11. The floor structure of claim 9 wherein the floor structure is free of any heating cable.

12. The floor structure of claim 9 further comprising a detent mechanism configured to couple the cover membrane to the base membrane.

13. A floor structure comprising:

a subfloor;

floor tiles;

a base membrane configured to be installed between the subfloor and the floor tiles to allow movement of the floor tiles relative to the subfloor, the base membrane including a base layer and a plurality of studs projecting from the base layer; and

a cover membrane configured to be coupled to the base membrane using at least one of a snug fit and a snap fit, the cover membrane including a cover layer and a plurality of studs projecting from the cover layer, wherein:

the plurality of studs on the cover membrane are configured to engage the plurality of studs on the base membrane to couple the cover membrane to the base membrane;

the plurality of studs on one of the base and cover membranes have free ends that define pockets therein;

the plurality of studs on the other one the base and cover membranes are configured to fit within the pockets in the plurality of studs on the one of the base and cover membranes to couple the cover membrane to the base membrane; and

adjacent ones of the plurality of studs on the base membrane are configured to hold a heating cable therebetween.

14. A method of installing a floor structure, the method comprising:

placing a base membrane onto a subfloor;

positioning a heating cable between adjacent ones of a plurality of studs on the base membrane such that the heating cable is held between the adjacent studs;

coupling a cover membrane to the base membrane using at least one of a snug fit and a snap fit;

applying tile adhesive to the cover membrane without applying tile adhesive to the base membrane; and

installing floor tiles on the cover membrane.

15. The method of claim 14 further comprising coupling the cover membrane to the base membrane by engaging a plurality of studs on the cover membrane with the plurality of studs on the base membrane.

16. The method of claim 15 further comprising coupling the cover membrane to the base membrane by inserting the plurality of studs on one of the base and cover membranes into a plurality of pockets defined in the plurality of studs on the other one of the base and cover membranes and engaging the plurality of studs on the cover membrane with the plurality of studs on the base membrane.

17. The method of claim 14 further comprising:

applying a first layer of thinset between the subfloor and the base membrane; and

applying a second layer of thinset between the cover membrane and the floor tiles.

18. The method of claim 14 further comprising installing the floor tiles without applying thinset directly to a top surface of the base membrane.

19. A method of replacing the floor tiles after installing the floor structure according to the method of claim 14 , the method of replacing the floor tiles comprising:

pulling up on the cover membrane by hand to remove the cover membrane and the floor tiles;

reinstalling the cover membrane or installing a new one of the cover membrane; and

installing new ones of the floor tiles.

Assignments (1)
ASSIGNMENT OF ASSIGNOR'S INTEREST Recorded Mar 31, 2025
From: WARNEKE, CHASE; COLLISON, ALAN B.; BORGMAN, REID
To: MP GLOBAL PRODUCTS, L.L.C.
Reel/Frame 070679/0502 →
Continuity (3)
Continuation 17093610 · Nov 9, 2020
Continuation 16885782 · May 28, 2020
Related Publication 20210372632A1 · Dec 2, 2021