Flooring underlayment with dimple endcaps and related methods

Abstract

An underlayment for installation between a base surface and a flooring material includes (a) a structural membrane formed of a structural material and including a panel and a plurality of dimples projecting from an underside surface of the panel. Each dimple has a dimple tip spaced apart from the underside surface. The underlayment further includes (b) a plurality of discrete dimple endcaps comprising a resilient material. Each endcap is fixed relative to, and covers at least a portion of, the dimple tip of a respective dimple. The endcaps support the dimples above the base surface when the underlayment is installed.

1 . An underlayment for installation between a base surface and a flooring material, the underlayment comprising:
 a) a structural membrane formed of a structural material and including a panel having a panel top surface and a panel underside surface opposite the panel top surface, the structural membrane further including a plurality of dimples projecting from the panel underside surface for supporting the panel above the base surface, each dimple having a dimple tip spaced apart from the panel underside surface and a dimple outer surface extending from the panel underside surface to the dimple tip; and   b) a plurality of discrete dimple endcaps comprising a resilient material, each dimple endcap fixed to the dimple outer surface and covering the dimple tip of a respective dimple, the endcaps supporting the dimple tips above the base surface when the underlayment is installed.   
     
     
         2 . The underlayment of  claim 1 , wherein the resilient material comprises an elastomeric material. 
     
     
         3 . The underlayment of  claim 1 , wherein the resilient material comprises a thermoplastic elastomer. 
     
     
         4 . The underlayment of  claim 1 , wherein the panel underside surface is generally free of and unobstructed by the resilient material. 
     
     
         5 . The underlayment of  claim 1 , wherein each endcap has an endcap peripheral edge spaced apart from the panel underside surface. 
     
     
         6 . The underlayment of  claim 1 , wherein the dimple includes an end wall comprising the dimple tip and a sidewall extending from the panel to the endwall, each dimple endcap covering the endwall, and wherein at least a portion of the sidewall is generally free of and unobstructed by the resilient material. 
     
     
         7 . The underlayment of  claim 1 , wherein each dimple endcap has an endcap thickness measured normal to the dimple outer surface, and the thickness is between about 0.5 mm and 1 mm. 
     
     
         8 . The underlayment of  claim 1 , wherein the endcap covers less than 90% of the dimple outer surface. 
     
     
         9 . The underlayment of  claim 8 , wherein the dimple endcap covers less than 60% of the dimple outer surface. 
     
     
         10 . The underlayment of  claim 9 , wherein the dimple endcap covers less than 30% of the dimple outer surface. 
     
     
         11 . An underlayment for installation between a base surface and a flooring material, the underlayment comprising:
 a) a structural membrane formed of a first material and including a panel and a plurality of dimples projecting from an underside surface of the panel, each dimple having a dimple tip spaced apart from the underside surface and a dimple outer surface extending from the panel underside surface to the dimple tip; and   b) a plurality of dimple endcaps formed of a second material different than the first material, each endcap fixed to the dimple outer surface and covering the dimple tip of a respective dimple, the endcaps supporting the dimple tips above the base surface when the underlayment is installed.   
     
     
         12 . The underlayment of  claim 11 , wherein the second material comprises a thermoplastic elastomer. 
     
     
         13 . A method of producing an underlayment for installation between a base surface and a flooring material, the method comprising:
 a) providing a structural membrane having a panel and a plurality of dimples extending from the panel for supporting the panel above the base surface;   b) heating a thermoplastic elastomer to above a glass transition temperature to form an elastomer melt;   c) applying the elastomer melt to a tip of each dimple; and   d) cooling the elastomer melt to below the glass transition temperature to form a plurality of discrete dimple endcaps, each dimple endcap fixed to the dimple and covering the dimple tip, the endcaps supporting the dimple tips above the base surface when the underlayment is installed.   
     
     
         14 . The method of  claim 13 , wherein step (c) includes passing a roller over each dimple tip, the roller holding the elastomer melt. 
     
     
         15 . The method of  claim 13 , wherein the dimple endcaps are formed with a peripheral edge spaced apart from the panel. 
     
     
         16 . The method of  claim 13 , wherein the panel is generally free of the elastomer melt during steps (c) and (d). 
     
     
         17 . The method of  claim 13 , further including (d), after step (c), rolling up the underlayment into a roll with at least some of the endcaps directed toward and exposed to the panel top surface.