Solid self-leveling underlayment

Abstract

Described are flooring systems which include an underlayment material that compresses over projecting irregularities in a subfloor to provide a level surface for a top flooring layer. Such flooring systems may include a top flooring layer, a subfloor, and an underlayment material disposed between the subfloor and the top flooring layer. The underlayment material may comprise a cross-linked polyolefin foam and a compressible foam. Methods for a self-leveling underlayment are disclosed herein, as well as methods of manufacture of the same.

1 . A flooring system, comprising:
 a top flooring layer;   a subfloor; and   an underlayment material disposed between the subfloor and the top flooring layer, wherein the underlayment material comprises:
 a cross-linked polyolefin foam; and 
 a foam selected to compresses over projecting irregularities in the subfloor to provide a level surface for the top flooring layer. 
   
     
     
         2 . The flooring system of  claim 1 , wherein the underlayment material bridges voids in the subfloor to provide a level surface for the top flooring layer. 
     
     
         3 . The flooring system of  claim 1 , wherein the cross-linked polyolefin foam is produced from a resin composition comprising a blend of polyethylene and polypropylene. 
     
     
         4 . The flooring system of  claim 1 , wherein the foam selected to compresses over projecting irregularities in the subfloor to provide a level surface for the top flooring layer is a non-cross-linked foam. 
     
     
         5 . The flooring system of  claim 4 , wherein the non-cross-linked foam is a polyolefin foam. 
     
     
         6 . The flooring system of  claim 4 , wherein the non-cross-linked foam consists essentially of polyethylene. 
     
     
         7 . The flooring system of  claim 1 , wherein the cross-linked polyolefin foam has a fine cell structure with cells having diameters between about 0.1 millimeter and about 0.5 millimeter. 
     
     
         8 . The flooring system of  claim 5 , wherein the non-cross-linked polyolefin foam has an open cell structure with cells having diameters between about 0.5 millimeter and about 4 millimeter. 
     
     
         9 . A flooring system, comprising:
 a top flooring layer;   a subfloor; and   an underlayment material disposed between the subfloor and the top flooring layer, wherein the underlayment material comprises:
 a cross-linked polyolefin foam; and 
 a non-cross-linked polyolefin foam; 
   wherein the underlayment material compresses over projecting irregularities in the subfloor to provide a level surface for the top flooring layer.   
     
     
         10 . The flooring system of  claim 9 , wherein the underlayment material bridges voids in the subfloor to provide a level surface for the top flooring layer. 
     
     
         11 . The flooring system of  claim 9 , wherein the cross-linked polyolefin foam comprises a blend of polyethylene and polypropylene. 
     
     
         12 . The flooring system of  claim 9 , wherein the non-cross-linked polyolefin foam consists essentially of polyethylene. 
     
     
         13 . The flooring system of  claim 9 , wherein the underlayment material includes at least one of an anti-microbial additive, a flame retardant additive, and an adhesion promoter. 
     
     
         14 . The flooring system of  claim 9 , further comprising a vapor barrier layer disposed between the top flooring layer and the subfloor. 
     
     
         15 . The flooring system of  claim 9 , wherein the cross-linked polyolefin foam is laminated to the non-cross-linked polyolefin foam. 
     
     
         16 . The flooring system of  claim 15 , wherein the underlayment material is laminated to a layer comprising at least one of a non-woven, a film, a foil, or another foam. 
     
     
         17 . The flooring system of  claim 9 , wherein the cross-linked polyolefin foam has a fine cell structure with cells having diameters between about 0.1 millimeter and about 0.5 millimeter. 
     
     
         18 . The flooring system of  claim 9 , wherein the non-cross-linked polyolefin foam has an open cell structure with cells having diameters between about 0.5 millimeter and about 4 millimeter. 
     
     
         19 . A method, comprising:
 placing an underlayment material between a subfloor and a top flooring layer, wherein the underlayment material comprises:
 a cross-linked polyolefin foam; and 
 a foam selected to compresses over projecting irregularities in the subfloor to provide a level surface for the top flooring layer. 
   
     
     
         20 . The method of  claim 19  wherein the foam that compresses over projecting irregularities in the subfloor to provide a level surface for the top flooring layer is a non-cross-linked polyolefin foam. 
     
     
         21 . The method of  claim 19  wherein the foam that compresses over projecting irregularities in the subfloor to provide a level surface for the top flooring layer is another cross-linked polyolefin foam, provided that the polyolefin foams do not have identical properties.