Static structures (e.g. – buildings) – Underlying compressible layer or pad
Utility Patent
1999-01-08
2001-01-02
Kent, Christopher T. (Department: 3635)
Static structures (e.g., buildings)
Underlying compressible layer or pad
C052S409000, C052S741410, C052S742140, C052S746100, C052S747110, C052S749110
Utility Patent
active
06167668
ABSTRACT:
FIELD OF THE INVENTION
This invention relates generally to an underlayment for installation of finished flooring over a substrate or subfloor which is unsuitable for the application of finished flooring and, more particularly, to an underlayment mat for use with such subfloors. The invention further relates to a method of making an underlayment upon which finished flooring is to be installed.
BACKGROUND OF THE INVENTION
Heretofore, the installation of ceramic tiles, marble and thin stone required a sound, clean floor surface which is crack-free, free from excess deflection, and having a smooth surface suitable for application of finished flooring by an adhesive method.
Known methods of preparing these “problem” floor surfaces include the application of a 2 inch Portland cement thin concrete topping, or alternatively, the use of one or two layers of plywood, securely fastened to the floor surface and/or the application of prefabricated cement fiberboard or the application of cement backerboard (which is a composition of Portland cement with light weight aggregate) having two skins of cement rich slurry impregnated with a glass fiber mesh.
The use of these composition boards require cutting, sawing and fitting, which takes considerable time and labor and incurs wastage of sheet goods which normally are supplied in sizes 4′×4′, 3′×5′ and 4′×8′. The alternative of supplying a 2 inch thick Portland cement composition has the disadvantage of adding some 25-30 pounds per square foot to the floors, and raising the floor elevation a minimum of two inches. In remodeling work, the addition of two inches to a floor may make it unsuitable for existing buildings, and/or the addition of 25 pounds per square foot may exceed the design characteristics or the ability of the existing floor structures to support the finished floor with the normal “dead” load and traffic load that will later be applied.
OBJECTS OF THE INVENTION
A principal object of this invention is to provide a new and improved finished flooring underlayment and a new and improved method of installing such an underlayment that provides strength, reinforcement and crack suppression for the installation of ceramic tile, marble, thin stone, parquet flooring or resilient flooring over subfloors that are not suitable for the direct application of these finished surfaces.
Another object of this invention is to provide a new and improved finished flooring underlayment and a quick and easy installation method which eliminates heretofore costly and labor intensive techniques conventionally used in installing a finished floor over a subfloor unsuited for such an installation.
A further object of this invention is to provide a new and improved finished flooring underlayment and method of installing that underlayment which effectively isolates the underlayment from imperfections of the underlying subfloor so as to eliminate undesired transmittal of shrinkage cracks in the subfloor, for example, to the underlayment and ultimately to the finished flooring.
Other objects will be in part obvious and in part pointed out more in detail hereinafter.
SUMMARY OF THE INVENTION
This invention discloses a composite underlayment mat for use in installing finished flooring over a subfloor unsuitable for direct application of such finished flooring. The mat features a flexible fabric membrane and a flexible mesh. The mesh overlies the membrane and is formed of filaments. The filaments are intertwined in a form-sustaining unitary body for mortar reinforcement and having a generally uniform height preselected to correspond to a desired underlayment thickness.
This invention also discloses a method of making an underlayment for installing finished flooring over a subfloor unsuitable for direct application of finished flooring. Steps of the method include supplying a mat of the type noted in the preceding paragraph, laying the mat over the subfloor, pouring a hydraulic cement composition onto the mat, and measuring the amount of composition being poured by the height of the mesh filaments which serve as gauges to provide a predetermined slab thickness corresponding to the preselected height of the mesh of the mat.
REFERENCES:
patent: 4590731 (1986-05-01), DeGooyer
patent: 5942300 (1999-08-01), Kukowski, Sr.
patent: 5956921 (1999-09-01), Fleck et al.
Fine Steve B.
Quinn Francis X.
Kent Christopher T.
Laticrete International, Inc.
Murtha Cullina LLP
Reinsmith R. William
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