Energy Absorptive/Moisture Resistive Underlayment Formed using Recycled Materials and a Hard Flooring System Incorporating the Same

Abstract

A recycled energy absorptive/moisture resistive underlayment includes a recycled energy absorbing layer comprised of either a nonwoven fiber batt formed from shoddy fibers or a foam pad formed from bonded foam. To protect the recycled energy absorbing layer from moisture, a moisture barrier is laminated on either one or preferably both side surfaces of the recycled energy absorbing layer. The moisture barrier laminated on a lower side surface of the recycled energy absorbing layer has a projecting flap which projects from first and second edge surfaces of the recycled energy absorbing layer to which the moisture barrier is laminated to the lower side surface thereof. The projecting flap enhances protection of the recycled energy absorbing layer from moisture by preventing moisture from migrating through seams and/or other exposed portions of the recycled energy absorbing layer.

1 . A flooring underlayment configured for installation between hard flooring and a subfloor, said flooring underlayment comprising: 
 an energy absorbing layer formed from a recycled material; and    a moisture barrier affixed to a first side surface of said energy absorbing layer;    wherein said energy absorbing layer absorbs acoustic energy produced by said hard flooring in response to an application of mechanical energy thereto.    
   
   
       2 . The flooring underlayment of  claim 1 , wherein said energy absorbing layer is a nonwoven fiber batt.  
   
   
       3 . The flooring underlayment of  claim 2 , wherein said nonwoven fiber batt is formed from shoddy fiber.  
   
   
       4 . The flooring underlayment of  claim 1 , wherein said energy absorbing layer is a foam pad.  
   
   
       5 . The flooring underlayment of  claim 4 , wherein said foam pad is formed from bonded foam.  
   
   
       6 . The flooring underlayment of  claim 1 , wherein said moisture barrier further comprises a moisture impermeable film laminated to said first side surface of said energy absorbing layer.  
   
   
       7 . The flooring underlayment of  claim 6 , wherein: 
 said first moisture barrier engages said subfloor;    said flooring underlayment further comprises a second moisture barrier laminated onto a second side surface of said energy absorbing layer; and    said second moisture barrier engages said hard flooring.    
   
   
       8 . The flooring underlayment of  claim 7 , wherein said energy absorbing layer is a nonwoven fiber batt formed from shoddy fibers.  
   
   
       9 . The flooring underlayment of  claim 7 , wherein said energy absorbing layer is a foam pad formed from bonded foam.  
   
   
       10 . The flooring underlayment of  claim 1 , wherein said first moisture barrier attached to said first side surface of said energy absorbing layer is formed from a closed cell foam.  
   
   
       11 . The flooring underlayment of  claim 10 , wherein: 
 said first moisture barrier engages said subfloor;    said underlayment further comprises a second moisture barrier attached to a second side surface of said energy absorbing layer and formed from a closed cell foam; and    said second moisture barrier engaging said hard flooring.    
   
   
       12 . The flooring underlayment of  claim 11 , wherein said energy absorbing layer is a nonwoven fiber batt formed from shoddy fibers.  
   
   
       13 . The flooring underlayment of  claim 11 , wherein said energy absorbing layer is a foam pad formed from bonded foam.  
   
   
       14 . A flooring underlayment configured for installation between hard flooring and a subfloor, said flooring underlayment comprising: 
 an energy absorbing layer formed from a recycled material, said energy absorbing layer having a first side surface, a second side surface and a plurality of edge surfaces;    a first moisture barrier for engaging a subfloor, said first moisture barrier laminated to said first side surface of said energy absorbing layer, said first moisture barrier having at least one edge surface laying flush with a corresponding one of said plurality of edge surface of said energy absorbing layer and at least one edge surface projecting past a corresponding one of said plurality of edge surfaces of said energy absorbing layer; and    a second moisture barrier for engaging hard flooring, said second moisture barrier laminated to said second side surface of said energy absorbing layer, said second moisture barrier having a plurality of edge surfaces, each of which corresponds to and lays flush with one of said plurality of edge surfaces of said energy absorbing layer;    wherein said energy absorbing layer absorbs acoustic energy produced by said hard flooring in response to an application of mechanical energy thereto.    
   
   
       15 . The flooring underlayment of  claim 14 , wherein said energy absorbing layer is a nonwoven fiber batt formed from shoddy fibers.  
   
   
       16 . The flooring underlayment of  claim 14 , wherein said energy absorbing layer is a foam pad formed from bonded foam.  
   
   
       17 . A hard flooring system configured for installation in a space defined by a subfloor, a first wall and a second wall, said hard flooring system comprising: 
 a first energy absorptive/moisture resistive underlayment section;    a second energy absorptive/moisture resistive underlayment section;    a hard flooring;    each of said first and second energy absorptive/moisture resistive underlayment sections comprising: 
 an energy absorbing layer formed from a recycled material, said energy absorbing layer having a first side surface, a second side surface and a plurality of edge surfaces;  
 a first moisture barrier for engaging a subfloor, said first moisture barrier laminated to said first side surface of said energy absorbing layer, said first moisture barrier having at least one edge surface laying flush with a corresponding one of said plurality of edge surface of said energy absorbing layer and at least one edge surface projecting past a corresponding one of said plurality of edge surfaces of said energy absorbing layer; and  
 a second moisture barrier engaging said hard flooring, said second moisture barrier laminated to said second side surface of said energy absorbing layer, said second moisture barrier having a plurality of edge surfaces, each of which corresponds to and lays flush with one of said plurality of edge surfaces of said energy absorbing layer;  
   said projecting edge surface of said first moisture barrier laminated to said energy absorbing layer of said first energy absorptive/moisture resistive underlayment section engaging a portion of said first wall;    said projecting edge surface of said first moisture barrier laminated to said energy absorbing layer of said second energy absorptive/moisture resistive underlayment positioned underneath a portion of said first moisture barrier laminated to said energy absorbing layer of said first energy absorptive/moisture resistive underlayment section; and    a moisture resistive section engaging said second wall and an edge surface of said energy absorbing layer of said second energy absorptive/moisture resistive underlayment section which abuts said second wall.    
   
   
       18 . The hard flooring system of  claim 17 , wherein said moisture resistive section extends underneath a portion of said first moisture barrier laminated to said energy absorbing layer of said second energy absorptive/moisture resistive underlayment section.  
   
   
       19 . The hard flooring system of  claim 18 , wherein said energy absorbing layer of each of said first and second energy absorptive/moisture resistive underlayment sections is a nonwoven fiber batt formed from shoddy fibers.  
   
   
       20 . The hard flooring system of  claim 18 , wherein said energy absorbing layer of each of said first and second energy absorptive/moisture resistive underlayment sections is a foam pad formed from bonded foam.