Building floor lining

Abstract

A fiber structure comprises: one or more vertically laid layers having a first surface and a second surface; and a finishing layer attached to the first surface of the vertically laid layers. The fiber structure is suitable for flooring assemblies. The fiber structure may include a mesh and / or a backing layer on the second surface of the vertically laid layers. Compared to conventional materials of the same thickness, the fiber structure exhibits improved performance in under-room and / or indoor testing.

Description

Technical Field

[0001] This teaching relates in general to a composite material and methods for forming the composite material, particularly a composite material for flooring applications. Background Technology

[0002] Common flooring systems consist of a subfloor made of cast concrete or plywood and finished flooring, typically made of wood, tile, laminate, vinyl, etc. Various components are positioned between the subfloor and the finished flooring to reduce sound transmission. These components typically include one or more of the following: foam, fiberglass insulation, polymer padding, liquid adhesives, and / or solvents. Installation of such components can be time-consuming and labor-intensive. Some may also result in undesirable thickness increases. For these and other reasons, the industry has been searching for alternative flooring systems or components that provide damping and / or reduce audible noise from the floor.

[0003] Furthermore, flooring products that minimize floor deformation remain necessary, especially after prolonged use. Reduction of fatigue stress and / or strain within or beneath sheets, boards, tiles, or wood panels remains essential. Reduction of tile vibration or noise radiation due to vibration is also required. Flooring components or parts thereof are also needed to withstand the pressure of chairs, furniture, or other items applying consistent and / or concentrated pressure to the floor. Summary of the Invention

[0004] This teaching addresses one or more of the aforementioned needs through the improved articles and methods described herein. This teaching provides a fiber structure or composite material in which combinations of layers and their materials produce unique properties through fiber-based solutions, such as improved noise reduction under the floor, prevention of floor cracking, or both.

[0005] This teaching includes multi-layered fiber structures. A fiber structure may include one or more lay-up layers and one or more finish layers. The finish layer may be a floor contact layer suitable for contacting a floor surface. At least one of the lay-up layers may be a vertical lay-up layer. The finish layer may be attached to the surface of the vertical lay-up layer. The fibers of the vertical lay-up layer may be generally vertically oriented in an uncompressed state. The vertical lay-up layer may be a compressed vertical lay-up layer.

[0006] The fiber structure may include a second facing layer that acts as a backing layer and / or a layer in contact with the underlying flooring, cement board, etc. The fiber structure may include one or more loosely woven fabric layers. The fiber structure may include one or more web layers. One or more layers of the fiber structure may be formed of, or may include, one or more of spunbond (S) materials, spunbond meltblown (SM) materials, or spunbond+meltblown+spunbond (SMS) nonwoven materials. For example, the facing layer may include polypropylene SMS material. The backing layer may include spunbond PET material.

[0007] The fiber structure can have a thickness of about 5 mm or less, or about 3.5 mm or less. The fiber structure can, for example, have a thickness of about 1.5 mm or more and about 5 mm or less. The fiber structure can, for example, have a thickness of about 1.5 mm or more and about 3.5 mm or less.

[0008] Compared to traditional materials, improved performance (e.g., acoustic performance, durability) can be achieved through underfloor testing, indoor testing, or both. The fiber structure retains its loft after undergoing 25,000 cycles of castorchair testing at 90 kg.

[0009] This teaching also envisions a flooring assembly comprising a fiber structure and a flooring surface. Exemplary flooring surfaces include vinyl tiles, luxury vinyl tiles, laminates, profiles, wood panels, linoleum, engineered wood, cork, hardwood, bamboo, stone, or combinations thereof. Fiber flooring surfaces, such as carpets, are also considered. This flooring assembly may be suitable for installation on a subfloor or on a concrete or cement surface. Attached Figure Description

[0010] Figure 1 An exemplary fiber structure according to this teaching is illustrated.

[0011] Figure 2 An exemplary fiber structure according to this teaching is illustrated.

[0012] Figure 3 An exemplary floor assembly including an exemplary fiber structure is illustrated in accordance with this teaching.

[0013] Figure 4 The test locations for the floor components are shown in the example.

[0014] Figure 5A and 5B Performance data for various materials in both under-room and indoor testing are shown.

[0015] Figure 6A and 6B Performance data are shown in both indoor and outdoor tests to assess the effect of AFR finishes on combed / cross-laid materials.

[0016] Figure 7A and 7B Performance data are shown in both under-chamber and indoor tests to assess the effect of AFR finishes on needled materials.

[0017] Figure 8A and 8BPerformance data are shown in both indoor and indoor tests to assess the effect of AFR finishes on vertically laid-out materials.

[0018] Figure 9 Performance data for a test sample with an 18-inch hollow truss bottom floor are shown.

[0019] Figure 10 Performance data for a test sample with a 6-inch concrete slab subfloor are shown. Detailed Implementation

[0020] The explanations and descriptions provided herein are intended to familiarize others skilled in the art with the teachings, their principles, and their practical applications. Those skilled in the art may modify and apply the teachings in various forms most likely suitable for the specific application requirements. Therefore, the specific embodiments of the teachings set forth are not intended to be exhaustive or limiting. Consequently, the scope of the teachings should not be determined by reference to the description herein, but rather by reference to the appended claims and the full scope of their equivalents. All publications and references, including patent applications and publications, are incorporated by reference for all purposes. Other combinations that may be derived from the following claims are also hereby incorporated by reference in this written description.

[0021] The flooring components and fiber structures described herein can be positioned such that these layers provide sufficient sound damping and / or isolation. Components can be provided as part of a subfloor, directly beneath the finished flooring, on a concrete subfloor, or any combination thereof. The subfloor, as defined herein, can include, but is not limited to, concrete, cement, wood, or other materials. The fiber structure can be located beneath the flooring material. The flooring components and / or fiber structures can include any number of layers described herein, and each layer can be included only once, or can be included in multiple locations throughout the component. Although referred to as layers herein, it is not necessarily required that each layer be a discrete, separately formed sheet or material. It is possible that different portions of the fiber structure within a single sheet may have different fibers, materials, properties, densities, weights, etc. These portions with different fibers, materials, properties, densities, weights, etc., even if formed integrally, can still be considered layers of the fiber structure. The use of the term layer does not necessarily imply co-linearity with the immediately adjacent layer, although it can be co-linear. Components can include one or more adhesive layers or adhesive portions. Flooring components and / or one or more fiber structures can include one or more moisture-impermeable layers to protect the fiber material layers from the moisture present on the concrete subfloor.

[0022] The materials described herein can provide cushioning for flooring components. These materials can reduce or prevent damage to flooring materials, such as cracking. They can provide additional beneficial effects such as compression resilience and puncture resistance, protection, filling, odor suppression, cooling effects, insulation, flame retardancy (e.g., meeting specific regulations, such as in residential or commercial buildings, and / or for heated floors), water resistance, breathability, or combinations thereof. The materials can be molded to fit the area where they will be installed or used.

[0023] The materials described herein can reduce audible noise and / or vibration of components within a floor assembly. The floor assembly described herein includes a fiber structure to achieve these beneficial effects. The fiber structure may include multiple layers, thereby forming a layered material. One or more layers may be flexible and / or provide softness. One or more layers may be rigid or provide strength to the fiber structure.

[0024] Layered materials may include one or more fiber layers. Although referred to herein as “layer” for convenience, any discussion of layers in the plural form is also intended to refer to the singular number of layers. For example, if a fiber structure comprises multiple fiber layers, not all fiber layers are expected to have the same properties, composition, or structure. Fiber layers can provide cushioning or protection. Fiber layers can provide such cushioning or protection with a relatively light weight. One or more of the fiber layers may have a high loft (or thickness), at least in part due to the orientation of the fibers in the layer (e.g., generally transverse to the longitudinal axis of the layer) and / or the method of forming the layer. Fiber layers may exhibit good resilience and / or compressive strength. Fiber layers may refer to, for example, but not limited to, one or more bulky layers, one or more loosely woven fabric layers, one or more mesh layers, one or more finishing layers, one or more backing layers, etc., or combinations thereof.

[0025] The fiber layer can be tailored to the desired characteristics. It can be adjusted to provide the required weight, thickness, compressive strength, or other physical properties. The fiber layer can be formed from nonwoven fibers. The fiber layer can be a nonwoven structure. The fiber layer can be thermoformable, allowing it to be molded or otherwise manufactured into the desired shape to meet one or more application requirements. The fiber layer can be a bulky material. The fiber layer can be a layup (e.g., a vertical layup).

[0026] The tunable properties of fiber layers may be a result of the fibers used within them. Shape, size, type, diameter, modulus, stiffness, denier, crimp level, polymer properties, etc., can affect the material's properties.

[0027] The fibers constituting the fiber layer (or any other layer of the material) may have an average linear mass density of about 0.5 denier or greater, about 1 denier or greater, or about 5 denier or greater. The material fibers constituting the fiber layer may have an average linear mass density of about 25 denier or less, about 20 denier or less, or about 15 denier or less. Fibers may be selected based on considerations such as cost, resilience, and desired hygroscopicity / moisture resistance. For example, coarser fiber blends (e.g., fiber blends with an average denier of about 12 denier) can help provide resilience to the fiber layer. For example, if a softer material is required, finer blends (e.g., with deniers of about 10 denier or less, or about 5 denier or less) may be used. Fibers may have short fiber lengths of about 1.5 mm or greater, or even about 70 mm or greater (e.g., in terms of a carded fiber web). For example, fiber lengths may range from about 30 mm to about 65 mm. Fibers can have an average or typical length of about 50 to 60 millimeters, or any length typical of those used in fiber carding processes. Short fibers can be used (e.g., alone or in combination with other fibers) in any nonwoven process. For example, some or all of the fibers can be in powder form (e.g., fiber lengths of about 3 millimeters or less, about 2 millimeters or less, or even smaller, such as about 200 micrometers or more, or about 500 micrometers or more). Fibers of different lengths can be combined to provide desired properties. Fiber lengths may vary depending on the application, desired moisture properties, type, size, and / or properties of the fiber material (e.g., density, porosity, desired airflow resistance, thickness, size, shape, etc. of the fiber layers and / or any other layers of a layered material), or any combination thereof. Adding shorter fibers alone or in combination with longer fibers can provide more efficient fiber filling, which can allow for easier control of pore size to achieve desired properties (e.g., moisture interaction properties).

[0028] The fiber layer may include fiber blends. The fiber layer (or any other material layer) may include fibers blended with inorganic fibers. The fiber layer may include natural fibers, manufactured fibers, synthetic fibers, or combinations thereof. Suitable natural fibers may include cotton, jute, wool, flax, silk, cellulose, glass, fibers derived from shells or husks (e.g., fruit shells and / or nut shells, such as coconut shells or fibers thereon, hazelnut shells, etc.), and ceramic fibers. The fiber layer may include eco-fibers, such as bamboo fiber or eucalyptus fiber. Suitable manufactured fibers may include those formed from cellulose or proteins. Suitable synthetic fibers may include polyester, polypropylene, polyethylene, nylon, aramid, imide, acrylate fibers, or combinations thereof. The fiber layer material may include polyester fibers. Fibers may include polymer fibers. The melting and / or softening temperature of the fibers may be selected. Fibers may include mineral fibers or ceramic fibers. Fibers may be or may include elastic fibers or elastomer fibers. These fibers may provide cushioning properties and / or compressibility and recovery characteristics. Fibers may provide fire resistance or flame retardancy. Fibers may be formed from any material capable of being combed and laid up into a three-dimensional structure. The fiber can be up to 100% virgin fiber. The fiber can be recycled from post-consumer waste (e.g., up to about 90% of the fiber is recycled from post-consumer waste, or even up to 100% of the fiber is recycled from post-consumer waste).

[0029] The fibers may have or provide improved thermal insulation properties. The fibers may have relatively low thermal conductivity. Such fibers can be used to retain heat or slow the rate of heat transfer (e.g., to keep the floor warm). The fibers may have or provide high thermal conductivity, thereby increasing the rate of heat transfer. Such fibers can be used to extract heat from the floor surface (e.g., to cool the floor). The fiber layer may include or incorporate an engineered aerogel structure to impart additional thermal insulation benefits.

[0030] At least some of the fibers can be inorganic materials. Inorganic materials can be any material capable of withstanding temperatures of about 250°C or higher, about 500°C or higher, about 750°C or higher, or about 1000°C or higher. The inorganic material can be a material capable of withstanding temperatures up to about 1200°C (e.g., up to about 1150°C). Fibers can include combinations of fibers with different melting points. Inorganic fibers can have a limiting oxygen index (LOI) indicating low flame or smoke, for example, according to ASTM D2836 or ISO 4589-2. The LOI of inorganic fibers can be higher than that of standard bonded fibers. The LOI of inorganic fibers can be about 23 or greater. Inorganic fibers can have an LOI of about 25 or greater.

[0031] The fiber layer may include one or more elastic fiber materials. The elastic fiber material can be used as a binder. The elastic fiber material can provide resilience to the fiber layer. Exemplary elastic fibers include polyester materials, such as high-performance polyester materials.

[0032] The fiber can be a high-temperature thermoplastic material.

[0033] At least a portion of the fibers constituting the fiber layer may have a low melting temperature. The amount of low-melting-temperature fibers can affect the strength of the layer. For example, improved properties of the fiber layer and / or the overall fiber structure can be achieved by using fiber blends with fibers having low melting temperatures. Such properties can be measured using the Castor Chair Test, where the results can be measured using, for example, ISO 4918:2016.

[0034] The fiber can have a melting point of about 70°C or higher, about 100°C or higher, about 110°C or higher, about 130°C or higher, 180°C or higher, about 200°C or higher, about 225°C or higher, about 230°C or higher, or even about 250°C or higher.

[0035] One or more fiber layers (or any other material layers) may comprise bicomponent fibers. The bicomponent fibers may be thermoplastic, low-melting-point bicomponent fibers. The bicomponent fibers may have a lower melting temperature than other fibers in the mixture (e.g., a lower melting temperature than ordinary fibers or short fibers). The bicomponent fibers may be air-laid or mechanically combed, laid up, and spatially fused into a network so that the layered material can have a structure and body, and can be processed, laminated, manufactured, and mounted as cut or molded parts to provide desired properties. The bicomponent fibers may comprise a core material and a sheath material surrounding the core material. The sheath material may have a lower melting point than the core material. The web of fiber material may be formed at least partially by heating the material to a temperature that softens the sheath material of at least some of the bicomponent fibers.

[0036] The fiber layer (or any other layer of the layered material) may include an adhesive or adhesive fibers. The adhesive may be present in the fiber layer in amounts of about 100% by weight or less, about 80% by weight or less, about 60% by weight or less, about 50% by weight or less, about 40% by weight or less, about 30% by weight or less, about 25% by weight or less, or about 15% by weight or less. The fiber layer may be substantially free of adhesive. The fiber layer may be completely free of adhesive.

[0037] Although referred to herein as fibers, the binder is also contemplated to be in generally powdery, spherical, or any shape capable of being contained within the interstitial spaces between other fibers and capable of bonding the fiber layers together. The binder may have a softening temperature and / or melting temperature of about 70°C or higher, about 100°C or higher, about 110°C or higher, about 130°C or higher, 180°C or higher, about 200°C or higher, about 225°C or higher, about 230°C or higher, or even about 250°C or higher.

[0038] The fiber layer may include a multi-adhesive system. The fiber layer may include one or more sacrificial adhesive materials and / or adhesive materials having a lower melting temperature than the other fibers within the layer. The melting and / or softening temperatures of the fibers can be selected.

[0039] The fibers in the fiber layer may be blended with or otherwise combined with suitable additives, such as other forms of recycled waste, virgin (non-recycled) materials, binders, fillers (e.g., mineral fillers), adhesives, powders, thermosetting resins, colorants, flame retardants, longer and shorter fibers, etc., but not limited to these. Any, some, or all of the fibers used in the matrix may be of low flame and / or smoke emission type (e.g., to meet flame and smoke standards for transport). Powders or liquids may be incorporated into the matrix, imparting additional properties such as adhesion, flame retardancy / smoke suppression expansion, and expansion of the polymer under heat, induction, or radiation, which improves acoustic, physical, thermal, and fire-resistant properties.

[0040] The fibers and binders discussed in this article in the context of fiber layers can also be used to form any other layer of a layered material. The fibers and binders discussed in this article can be used to form finishing layers, lay-up layers, mesh layers, loose fabric layers, backing layers, or any combination thereof.

[0041] The fiber layer may include one or more lay-up layers. The lay-up layers can be formed by one or more lay-up processes, including cross-layup, perpendicular lay-up, rotational lay-up, etc., or combinations thereof. The lay-up layers may have a generally perpendicular fiber orientation (e.g., generally transverse to the longitudinal axis of the layer, or forming an angle of about 60 to about 90 degrees relative to the longitudinal axis of the layer). The generally perpendicular orientation may be before compression or when the lay-up layer is uncompressed. The fibers may be a unique mixture of fibers with a generally perpendicular or near-perpendicular orientation. The fiber layer may be compressed. After compression, the fibers may retain a generally perpendicular or near-perpendicular orientation. After compression, the fiber orientation may change. The fibers may be a unique mixture of fibers having a generally Z-shaped, C-shaped, or S-shaped or other non-linear shape, which can be formed by compressing fibers with a perpendicular or near-perpendicular orientation. The fibers may be in the form of a three-dimensional ring structure. The rings may extend through the thickness direction from one surface of the matrix to an opposite surface of the matrix. The fibers may have an orientation of about ±60 degrees, about ±50 degrees, or about ±45 degrees perpendicular to the vertical. Vertical can be understood as relative to a plane that extends substantially laterally from the longitudinal axis of the composite structure (e.g., in the thickness direction). Therefore, vertical fiber orientation means that the fibers are substantially perpendicular to the length of the composite structure (e.g., fibers extending in the thickness direction). It is also anticipated that the fibers may be substantially horizontally oriented (e.g., fibers extending in the length and / or width directions).

[0042] The layup can have a weight of about 100 grams per square meter (gsm) or more, about 105 gsm or more, or about 110 gsm or more. The layup can have a weight of about 200 gsm or less, about 185 gsm or less, or about 175 gsm or less. In one example, without limitation, the layup can have a weight of about 115 gsm to about 125 gsm (e.g., about 120 gsm) and be formed from up to 100% by weight PET fibers.

[0043] Nonwoven processes can be used to form a nonwoven web from fibers that make up one or more fiber layers. These processes include, for example, fiber blending, carding, lay-up, air-laid web formation, mechanical forming, or combinations thereof. Through these processes, the fibers can be oriented in a generally vertical or near-vertical direction (e.g., generally perpendicular to the longitudinal axis of the fiber layer). Conventional processes can be used to open and blend the fibers. The resulting structure can be a bulky fiber layer. The bulky fiber layer can be designed for optimal weight, thickness, physical properties, thermal conductivity, insulation properties, moisture absorption, or combinations thereof.

[0044] One or more fiber layers can be formed, at least partially, through a carding process. The carding process separates clustered material into individual fibers. During the carding process, the fibers can be aligned with each other in a substantially parallel orientation, and a carding machine can be used to produce a fiber web.

[0045] Carded fiber webs can undergo a lay-up process to create fiber layers. Carded webs can be rotated, cross-laid, or perpendicularly laid up to form bulky or fluffy nonwoven materials. Carded webs can be perpendicularly laid up, for example, according to processes such as "Struto" or "V-Lap." This configuration provides a web with relatively high structural integrity in the fiber layer thickness direction, minimizing the likelihood of the web detaching during application or use, and / or providing compressive strength to the layered material. Carding and lay-up processes can produce nonwoven fiber layers with good compressive strength throughout the vertical cross-section (e.g., throughout the thickness of the layered material) and can produce lower-quality fiber layers, especially fluffy to higher thickness fiber layers without adding a large amount of fiber to the matrix. Hollow conjugated fibers are expected to improve bulkiness and resilience to enhance physical integrity. This arrangement also provides the ability to obtain low-density fiber webs with relatively low packing density.

[0046] When viewed in cross-section, the layup process can produce a wrinkled or wavy appearance in the fiber. The frequency of these wrinkles or undulations can be varied during the layup process. For example, increasing the number of wrinkles or undulations per unit area can increase the density and / or stiffness of one or more layers of the material. Reducing the number of wrinkles or undulations per unit area can increase the flexibility of one or more layers and / or decrease the density. The ability to change the frequency of wrinkles or undulations during the layup process allows for alteration or control of the material's properties. The expected frequency of wrinkles or undulations can vary throughout the material. The wrinkle frequency can be dynamically controlled and / or adjusted during the layup process. Adjustments can be made during the laying of one layer of material. For example, some portions of the layer may have an increased frequency, while other portions may have a lower frequency. Adjustments can be made during the laying of different layers of material. Different layers can be made to have different properties with different wrinkle frequencies. For example, one layer may have a wrinkle frequency greater or less than that of another layer of the layered material.

[0047] Fiber layers or lay-up layers may undergo additional processes during their formation. Fibers (e.g., surface fibers) can be mechanically entangled to bind them together. For example, the top surface of the fiber layer, the bottom surface of the fiber layer, or both surfaces can undergo mechanical entanglement. Mechanical entanglement can be used, for example, to hold fiber layers or lay-up layers together by binding the peaks of three-dimensional rings together. Mechanical entanglement processes can also allow fabrics or finishes to be mechanically bound to the top and / or bottom surfaces of the lay-up fiber layer. Alternatively, or in addition to mechanical entanglement, the surface of the material can be melted, for example, by an IR heating system, a hot air stream, or a laser beam to form a surface layer. Fibers within the surface or layer can be hydroentangled.

[0048] A fiber structure may include one or more additional layers. A fiber structure may include multiple layers, some or all of which may serve different functions or provide different properties to the fiber structure (when compared to other layers in the fiber structure). The ability to combine layers of materials with different properties allows for application-specific customization of the fiber structure. One or more additional layers within the fiber structure may provide structural properties or physical strength to the fiber structure. One or more additional layers may repel water, moisture, fluids, and / or particles. Layers may be permeable membranes to allow air permeability while preventing fluids or moisture from penetrating downwards into the fiber structure, such as fiber layers. One or more layers may be provided to encapsulate the system. One or more layers may have a damping effect. One or more layers may have airflow resistance characteristics. The layer may provide compressive strength, resilience, or both. The layer or the entire fiber structure may provide insulating properties. The layer or the entire fiber structure may be tailored to provide the desired heat resistance. The layer or the entire fiber structure may be tailored to provide the desired thermal conductivity. The layer or the entire fiber structure may be tailored to provide desired properties such as flame retardancy or fire resistance, smoke resistance, reduced toxicity, etc. This layer may be able to withstand exposure to elevated temperatures.

[0049] These layers may include one or more of the following: a finish layer, a backing layer, one or more intermediate layers, a mesh layer, a sparse fabric layer, a top layer, etc. The layer may be a floor contact layer. A finish layer, backing layer, mesh, sparse fabric, or a combination thereof may be applied to the fiber layer or layup. Additional functional layers may be applied to the fiber structure or layup. Another layup or structure may be attached to the layup. Another intermediate layer formed of any of the materials or structures described herein may be located between two layups. Any combination of layers is contemplated herein.

[0050] For example, a fiber structure may include a finishing layer and a backing layer, with a layer having fibers that are generally vertically oriented in an uncompressed state sandwiched between them. One or more finishing layers and / or backing layers may be airflow resistance (AFR) layers. For example, a fiber structure may include a finishing layer, a layup layer, a web layer, and a backing layer. These layers may be arranged in this order. One or more adhesive or bonding agent layers may be located between some of the layers. For example, an adhesive or bonding agent layer may be located between the finishing layer and the layup layer. The adhesive or bonding agent layer may be applied to or part of the finishing layer before the finishing layer is attached to the layup layer. An adhesive or bonding agent layer may be located between the backing layer and the layup layer. The adhesive or bonding agent layer may be part of or applied to the backing layer before the backing layer is attached to the layup layer. A web layer may be sandwiched between the layup layer and the backing layer. The web layer may be open enough that an adhesive or bonding agent bonds the backing layer and the layup layer together.

[0051] One or more additional layers may be formed of different materials. One or more additional layers may be formed of the same material. One or more additional layers may be formed of fibers and / or binders, as described herein with respect to fiber layers. Fiber structures may include needle-punched layers, one or more spunbond layers, one or more meltblown layers, one or more hydroentangled layers, one or more air-laid layers, or combinations thereof. Layers may be formed of spunbond (S) materials, spunbond meltblown (SM) materials, or spunbond + meltblown + spunbond (SMS) nonwoven materials. For example, the finishing layer may be an SMS material. The finishing layer may be a polypropylene SMS material. For example, the backing layer may be a spunbond layer. The backing may be a PET spunbond layer. Layers may be hydroentangled and / or hydroentangled.

[0052] One or more additional layers may include a sparse fabric and / or a mesh. A layer may be a sparse fabric. A layer may be a needle-punched layer, such as a needle-punched sparse fabric. A layer may be a mesh layer. A layer may be a reinforcing mesh. A layer may be a generally open mesh. A layer may be a sparse mesh (e.g., glass, metal, polymers such as PET or polyethylene (e.g., high-density polyethylene (HDPE)), or combinations thereof). For example, a mesh layer may be an HDPE mesh. The sparse mesh may be embedded within one or more other layers of a fibrous structure. The mesh layer may have sufficient openness to allow an adhesive to bond two layers with the mesh sandwiched within it. For example, the mesh may be open enough to allow an adhesive on the backing layer to be used to secure the backing layer and the mesh layer to the layup. The mesh layer may have sufficient openness to allow other attachment methods to be used between the two layers with the mesh sandwiched within it (e.g., allowing a reaction between the materials of one layer and another, heating one or more layers so that when one or more components soften or melt, the softened or melted material can flow through the mesh to the other layer). The mesh layer can have a weight of about 15 gsm or more, about 20 gsm or more, or about 22 gsm or more. The mesh layer can have a weight of about 35 gsm or less, about 30 gsm or less, or about 28 gsm or less.

[0053] The layers of the fibrous structure can be non-airflow-resistant layers (e.g., non-airflow-resistant loose fabric). Layers can be woven, non-woven, or both. Layers can be felt materials. Layers can be formed from hardened or expanded (e.g., upon activation) materials to provide stiffness or additional structural properties to the fibrous structure. The layer can be polymeric, where crystallinity can be tuned to alter the structural properties of the fibrous structure. For example, crystallinity can be tuned during any heating and / or cooling process in the fibrous structure formation process. Layers can be formed from polymeric, copolymeric, elastic, elastomeric, rubbery, thermoplastic, thermosetting, and other materials. Layers can be laminates. These materials, or one or more layers formed from these materials, can provide cushioning and / or resilience to the fibrous structure. Layers can include or can be formed from powders.

[0054] The fiber structure layer can have high infrared reflectivity or low emissivity. At least a portion of the layer can be metallized to provide infrared (IR) radiation thermal reflection. The layer can be perforated. The layer can be permeable. The layer can be designed to be selectively permeable. The layer can be inherently permeable. To provide thermal reflective properties to other layers of the structure and / or protect other layers of the structure, the layer (e.g., its fibers, the surface of the layer, or the layer itself) can be metallized.

[0055] Where one or more layers of a fibrous structure may be exposed to high temperatures, the layers may include solid films, perforated films, solid foils, perforated foils, woven or nonwoven loose fabrics, selectively permeable films or foils, or other materials. Any layer may have heat resistance capable of withstanding the temperatures to which these layers will be exposed. However, these materials are not limited to use in high-temperature applications. Such materials are also intended for use, for example, in finishing layers of fibrous structures.

[0056] The layer may provide other beneficial effects, such as odor control and / or antimicrobial properties. For example, the layer may be an activated carbon film or other nonwoven layer. The layer may include copper, steel (e.g., stainless steel), silver, or other metallic materials or be treated with them. Other layers of the fibrous structure (e.g., a carding layer) may include these components to achieve odor control and / or antimicrobial properties.

[0057] One or more additional layers may be generally hydrophobic. One or more additional layers may be generally hydrophilic. Corrosion-resistant coatings may be applied to reduce or prevent oxidation and / or loss of reflectivity of metals (e.g., aluminum). IR-reflective coatings not based on metallization techniques may be added. One or more coatings may be applied to fibers to form additional layers, or applied to the surface of the layer itself. Oleophobic and / or hydrophobic treatments may be added. Flame retardants may be added. One or more additional layers may be porous or perforated. One or more layers may be permeable or at least partially permeable. One or more additional layers may be solid (e.g., non-porous or non-perforated). One or more additional layers may be generally flexible. One or more additional layers may be generally rigid.

[0058] For example, the fiber structure may include one or more finishing layers. The finishing layer may be the outermost layer of the fiber structure. The finishing layer may be adapted to contact the underside plane of the floor layer. Therefore, the finishing layer can act as a floor contact layer. The finishing layer may have airflow resistance properties. The finishing layer may be formed of a polymeric material. The finishing layer may be formed of, for example, polypropylene or polyester, or may include such materials. The finishing layer may be formed of spunbond (S) material, spunbond meltblown (SM) material, or spunbond + meltblown + spunbond (SMS) nonwoven material. For example, the finishing layer serving as a floor contact layer may be a polypropylene SMS layer.

[0059] One or more finishing layers of a fiber structure may have a weight of about 45 gsm or more, about 48 gsm or more, or about 50 gsm or more. One or more finishing layers of a fiber structure may have a weight of about 65 gsm or less, about 62 gsm or less, or about 60 gsm or less.

[0060] One or more finishing layers can be bonded to adjacent layers (e.g., lay-up layers) using an adhesive material. The adhesive material can be applied to the finishing layers. The adhesive material can be integrally formed with the finishing layers. Adhesive properties can be attributed to one or more components forming the finishing layers (e.g., one or more components soften and / or melt upon application of heat to bond to adjacent layers, or one or more components of one layer react with one or more components of an adjacent layer to create adhesion upon contact). The adhesive material can be present on the finishing layers before positioning them onto adjacent layers (e.g., lay-up layers). For example, the adhesive material can be ethylene vinyl acetate (EVA) adhesive, but other adhesives are also considered.

[0061] The adhesive material between the finishing layer and the adjacent layer can have a weight of about 4 gsm or more, about 5 gsm or more, or about 6 gsm or more. The adhesive material can have a weight of about 16 gsm or less, about 15 gsm or less, or about 14 gsm or less.

[0062] The fiber structure may include a backing layer. Although referred to herein as a backing layer, it can be considered as another facing layer. It is also contemplated that the fiber structure can be flipped so that the facing layer (e.g., the layer facing the flooring material) becomes the backing layer (e.g., the layer facing the subfloor), and the backing layer becomes the facing layer. The backing layer may be formed of polypropylene or polyester. The backing layer may be formed of spunbond (S), spunbond meltblown (SM), or spunbond+meltblown+spunbond (SMS) nonwoven material. For example, the backing layer may be a PET spunbond layer. The backing layer may be the bottom layer of the fiber structure. The backing layer may be adapted to contact the subfloor plane to which the fiber structure is to be positioned. It is also contemplated that the fiber structure does not contain a backing layer. The backing layer may be a loosely woven fabric.

[0063] The backing layer may have a weight of about 8 gsm or more, about 9 gsm or more, or about 10 gsm or more. The backing layer may have a weight of about 22 gsm or less, about 21 gsm or less, or about 20 gsm or less.

[0064] One or more backing layers can be bonded to one or more adjacent layers using an adhesive material. The adhesive material can be applied to the backing layers. The adhesive material can be integrally formed with the backing layers. Adhesive properties can be attributed to one or more components forming the backing layers (e.g., one or more components soften and / or melt upon application of heat to bond to adjacent layers, or one or more components of one layer react with one or more components of an adjacent layer to create adhesion upon contact). The adhesive material can be present on the backing layers before positioning the backing layers onto adjacent layers (e.g., lay-up layers and / or web layers). For example, the adhesive material can be ethylene vinyl acetate (EVA) adhesive, but other adhesives are also considered. In an example where the web layer is sandwiched between the backing layer and the lay-up layer, the adhesive material can be used to encapsulate the web layer within the fiber structure. The adhesive material can flow through openings in the web layer to bond the backing layer to layers on opposite sides of the web layer (e.g., lay-up layer).

[0065] The adhesive material between the backing layer and the adjacent layer may have a weight of about 1 gsm or more, about 2 gsm or more, or about 4 gsm or more. The adhesive material may have a weight of about 10 gsm or less, about 8 gsm or less, or about 6 gsm or less.

[0066] One or more finishing layers (including backing layers) may have a thickness of about 1 mm or less, about 0.5 mm or less, or about 0.2 mm or less.

[0067] One or more intermediate layers may be located between the finish layer or flooring contact layer and the fiber layer. The intermediate layer can be any of the possible layers described herein.

[0068] The adhesive can be placed on or between any layers of the fiber structure. The adhesive allows the fiber structure to adhere to the desired substrate (e.g., floor surface, subfloor, or cement floor, or both). The fiber structure may be provided with a pressure-sensitive adhesive (PSA). The PSA can be applied by rollers and laminated to the surface of the fiber structure. A release liner may be provided with the PSA. The release liner can be removed from the pressure-sensitive adhesive before installing the fiber structure to allow adhesion to the substrate or surface. For some applications, it may be advantageous to provide an easily removable release liner with high tear strength.

[0069] While any configuration of the layers is possible, exemplary configurations include a layup having a finishing layer and a backing layer on one surface. A loosely woven mesh, such as glass or PET mesh, can be positioned on or within the fiber layers. The loosely woven mesh can be laid on or beneath the layup. After heating and / or lamination, the mesh can be embedded within the fiber structure. Such meshes can provide increased stability, compressive strength, strength, stiffness, product life, etc., or a combination thereof.

[0070] A non-limiting configuration may sequentially include a finishing layer, a lay-up layer, a mesh layer, and a backing layer. An adhesive may be disposed between the finishing layer and the lay-up layer. An adhesive may be disposed between the backing layer and the lay-up layer. The adhesive may be allowed to flow through openings in the mesh layer to secure the backing layer to the lay-up layer.

[0071] Fiber structure layers can be bonded together to produce the final fiber structure. One or more layers can be bonded together by elements present in the layers. For example, bonding fibers in the layers can be used to bond the layers together. The outer layer (i.e., sheath) of the bicomponent fibers in one or more layers can soften and / or melt upon application of heat, which allows the fibers of the individual layers to adhere to each other and / or to the fibers of other layers. Fiber structures or portions thereof can be formed or assembled using lamination processes. For example, a fiber structure can be constructed by carding and laying one or more thicker nonwoven layers and applying heat via lamination. Lamination can be performed to compress one or more layers (e.g., one or more lay-up layers). Layers can be joined by one or more lamination processes. These layers can be laminated to another layer during nonwoven production and lamination, or in a separate process. Additional layers can be laminated in the same manner. One or more adhesives can be used to bond two or more layers together. The adhesive can be a powder or can be applied, for example, in strip, sheet form, or as a liquid. The adhesive may not impede airflow through the material (e.g., it will not block openings, perforations, pores, etc.).

[0072] The finished fiber structure can have a thickness of about 10 mm or less, about 7 mm or less, or about 5 mm or less. The fiber structure can have a thickness of about 1 mm or more, about 1.25 mm or more, or about 1.5 mm or more. For example, the finished structure can have a thickness of about 1.5 mm or more and about 5 mm or less. The finished structure can have a thickness of about 1.5 mm or more and about 3.5 mm or less.

[0073] The acoustic properties of a fiber structure (and / or its layers) can be affected by the shape of the fiber structure. One or more of the fiber structure or its layers can be generally flat. Finished fiber composites can be made into cut-to-print two-dimensional planar parts for installation into components of end users, installers, or customers. Fiber structures can be formed into any shape. For example, fiber structures can be molded (e.g., into three-dimensional shapes) to generally match the shape of the area where they will be installed. Finished fiber composites can be molded into three-dimensional shapes for installation into components of end users, installers, or customers. The three-dimensional geometry of molded products can provide additional sound absorption. Three-dimensional shapes can provide structural stiffness and air space.

[0074] This teaching also includes flooring assemblies. Flooring assemblies may include a fiber structure and one or more flooring surfaces. Exemplary flooring surfaces include vinyl tiles, luxury vinyl tiles, laminates, ceramic tiles, wood panels, linoleum, engineered wood, cork, hardwood, bamboo, and stone. Fiber flooring surfaces, such as carpet, are also considered. Therefore, a flooring assembly may include a fiber structure positioned on a subfloor or cement board. Flooring surfaces can then be positioned on the fiber structure. The fiber structure described herein is used to separate the floor from concrete or cement board or wood subfloor to provide excellent noise reduction.

[0075] Fiber structures can be used to provide improved indoor acoustic performance. Indoor acoustic performance refers to the sound absorption and / or sound damping within a room where the fiber structure is located. One or more layers, such as a finish layer, can create microcavities or air gaps between the finish and the floor, which helps improve performance. The combination of a finish layer with a layup (such as a compressed vertical layup) can further improve performance in a room.

[0076] Fiber structures can be used to provide improved acoustic performance beneath a room. For example, in multi-story structures (e.g., multi-story buildings), this may be desirable to reduce audible noise between floors. Fiber structures can, for example, reduce audible noise from people upstairs or prevent someone from hearing footsteps from people upstairs. Layup fiber layers, alone or in combination with other layers of material, can be used to provide a resilient effect between the floor layer and the underlying concrete or subfloor. When testing performance beneath a room, the lower the spring stiffness of the material, the lower the noise level inside the room.

[0077] Fiber structures can provide improved acoustic performance at a lower thickness. Equivalent or similar acoustic performance can be achieved with thicker products, such as approximately 5mm or greater. However, materials of this thickness often affect the durability of the flooring. This teaching achieves the desired acoustic performance with a thinner material than conventional materials.

[0078] Compared to other conventional materials, fiber structures offer superior acoustic performance. When tested with wheelchairs, fiber structures provide increased durability compared to other conventional materials. After durability testing, the fiber structure retains its bulkiness. This is because other conventional materials, such as foam, would be crushed during wheelchair tests at 90 kg for 25,000 cycles, thus maintaining proper structure preserves acoustic performance.

[0079] Now turn to the attached image. Figure 1This is an exemplary fiber structure 10. As shown, the fiber structure 10 includes a layup layer 12. A finishing layer 16 is located on one side of the layup layer 12. The finishing layer can serve as a floor contact layer, thereby contacting the floor surface during installation. A backing layer 18 is located on the opposite side of the layup layer 12. The backing layer 18 is adapted to contact the subfloor or cement during installation. It is anticipated that the backing layer can be omitted.

[0080] Figure 2 This is an exemplary fiber structure 10. As shown, the fiber structure 10 includes a layup layer 12. A finishing layer 16 is located on one side of the layup layer 12. A mesh layer 14 is located on the opposite side of the layup layer 12. A backing layer 18 is located on the opposite side of the layup layer 12. The backing layer 18 is adapted to contact the subfloor or cement during installation.

[0081] Figure 3 An exemplary fiber structure 10 is included as part of flooring assembly 20. Fiber structure 10 includes a layup layer 12 supporting a finish layer 16. An optional backing layer 18 is located on the opposite side. A mesh layer 14 is located between the backing layer 18 and the layup layer 12. As shown herein, the finish layer 16 forms a planar contact with the underside of the flooring surface 22. The backing layer 18 rests on the subfloor 24 of the flooring assembly 20. For clarity, gaps between each layer are shown in the figures. It is anticipated that any or all layers will have direct planar contact with the layers directly adjacent to them.

[0082] The facing layer and backing layer can be formed from the same material or different materials. The facing layer, backing layer, or both can be formed from the same material as the fibers in the layup layer. One or more of the facing layer, backing layer, and layup layer can include polyester material. The facing layer and / or backing layer can include polypropylene material, polyester (e.g., PET) material, or combinations thereof. The facing layer and / or backing layer can include spunbond, spunbond + meltblown, or spunbond + meltblown + spunbond (SMS) material. The facing layer can, for example, include polypropylene SMS material. The backing layer can be formed from polyester such as PET. For example, the backing layer can include spunbond PET material.

[0083] Illustrative example

[0084] Tests were conducted to compare the performance of various materials both indoors and below ground. Figure 4The test area is illustrated. Fiber structure 10 is located between floor surface 22 and subfloor 24. The tests performed measure the performance of the interior 26 and the subfloor 28. Impact insulation class (IIC) ASTM E1007 testing is conducted to test sound propagation through the entire floor / ceiling assembly (e.g., from a higher living area to a lower living area). IIC testing targets impact noise such as footsteps, moving furniture, clinking sounds from objects falling on the floor, etc. Interior testing is conducted according to ISO 523B. Testing is performed using a 6-inch concrete subfloor and a 5.5 luxury vinyl tile (LVT) / wood-plastic composite (WPC) type flooring.

[0085] Figure 5A and 5B Comparative data are shown for vertically laid materials (data points: triangles), combed and cross-laid materials (data points: x), needle-punched materials (data points: *), and foam materials (data points: rhombuses) based on the teaching content. All these materials have the same top-facing (i.e., facing the floor layer) finish layer. Figure 5A The results of the test below the chamber are shown, and Figure 5B The results of indoor testing are shown. All tested materials maintained the same thickness and GSM, except for the needle-punched material, which was 1 mm thinner. The same fiber blending, finishing, and lamination techniques were used for each material. The results show that the vertically laid materials, according to this teaching, outperform the carded / cross-laid materials by 2 IIC and outperform the foam materials by 4 IIC.

[0086] Figure 6A and 6B Comparative data are shown between combed / cross-laid layers with the finish layer facing upwards (i.e. towards the floor layer) (where data points are represented by x) and combed / cross-laid layers with the finish layer facing downwards (i.e. towards the subfloor or cement) (where data points are represented by a+). Figure 6A The results of the test below the chamber are shown, and Figure 6B The results of indoor testing are shown. The results indicate that the presence of a finish layer between the combed / cross-laid material and the flooring layer improves indoor performance, with the finish layer being an AFR finish.

[0087] Figure 7A and 7B Comparative data is shown between the needled layers with the finish layer facing upwards (i.e. towards the floor layer) (where data points are indicated by *) and the needled layers with the finish layer facing downwards (i.e. towards the subfloor or cement) (where data points are indicated by a-). Figure 7A The results of the test below the chamber are shown, and Figure 7B The results of indoor testing are shown. The results indicate that the presence of a finishing layer between the needled material and the floor layer, wherein the finishing layer is an AFR finish, improves indoor performance.

[0088] Figure 8A and 8B Comparative data is shown between vertical lay-up layers with the finish layer facing upwards (i.e. towards the floor layer) (where data points are represented by triangles) and vertical lay-up layers with the finish layer facing downwards (i.e. towards the subfloor or cement) (where data points are represented by circles). Figure 8A The results of the test below the chamber are shown, and Figure 8B The results of indoor testing are shown. The results indicate that the presence of a finish layer between the vertically laid material and the floor layer, where the finish layer is an AFR finish, improves indoor performance.

[0089] Therefore, the results show that the performance of materials with a finishing layer is improved. The results also indicate that the performance of vertically folded materials is improved compared to other types of materials. Combining vertically folded materials with AFR finishing layers may produce synergistic and / or additive effects. Acoustic performance can be improved more than the sum of the acoustic performance of each layer.

[0090] Samples of vertically laid layers with the finish layer facing upwards (i.e., towards the floor layer) were also tested using existing products—commercially available foam backing and commercially available recycled fiber-based backing. Tests were conducted on 18-inch open-web truss (OWT) subfloor floors and 6-inch concrete slab subfloor floors using 5.5mm LVT / WPC flooring. Impact sound propagation tests were performed according to ASTM E492. IIC values ​​and High-Frequency Impact Insulation Class (HIIC) values ​​were calculated according to ASTM E989 and ASTM E3222, respectively. These tests and calculations were performed by a certified third-party laboratory.

[0091] Figure 9 This is a graph showing the results of impact sound propagation tests on a test sample of a floor with an 18-inch open-web truss subfloor. Results for the finished vertical layup are shown as solid lines, while results for the commercially available foam underlayment are shown as dashed lines. Table 1 below includes calculated values ​​for IIC and HIIC for both the finished vertical layup and the commercially available foam underlayment. It can be seen that the finished vertical layup outperforms the commercially available foam underlayment in both IIC and HIIC.

[0092] Table 1.

[0093] <![CDATA[ sample ]]> <![CDATA[ IIC ]]> <![CDATA[ HIIC ]]> Vertical tiling with finish 60 79 Foam padding 55 67

[0094] Figure 10This is a graph showing the results of impact sound propagation tests on test samples with a 6-inch concrete subfloor. Results for finished vertical lay-up are shown as solid lines. Results for commercially available foam underlay are shown as dashed lines. Results for commercially available recycled fiber underlay are shown as dotted lines. Table 2 below includes calculated values ​​for IIC and HIIC for finished vertical lay-up, commercially available foam underlay materials, and commercially available recycled fiber underlay materials. It can be seen that, in terms of both IIC and HIIC, finished vertical lay-up is superior to both commercially available foam underlay and commercially available recycled fiber underlay.

[0095] Table 2.

[0096] <![CDATA[ sample ]]> <![CDATA[ IIC ]]> <![CDATA[ HIIC ]]> Vertical tiling with finish 60 73 Foam padding 56 62 Recycled fiber liner 56 68

[0097] Unless otherwise stated, any numerical value described herein includes all values ​​increasing by one unit from the lower limit to the upper limit, provided that there is an interval of at least two units between any lower limit and any upper limit. For example, if the value describing the amount, characteristic, or process variable (such as temperature, pressure, time, etc.) of a component is, for example, 1 to 90, preferably 20 to 80, more preferably 30 to 70, then intermediate range values ​​(e.g., 15 to 85, 22 to 68, 43 to 51, 30 to 32, etc.) are intended to be within the teachings of this specification. Similarly, individual intermediate values ​​are also within the teachings. For values ​​less than 1, one unit is considered as 0.0001, 0.001, 0.01, or 0.1, as appropriate. These are merely examples of specific intent, and all possible combinations of numerical values ​​between the listed minimum and maximum values ​​will be explicitly stated in this application in a similar manner. It can be seen that the teachings of quantities expressed herein as “parts by weight” also cover the same range expressed as weight percentages. Therefore, the statement of the range of "at least 'x' parts by weight of the resulting composition" also covers the teachings of the range of the same enumerated amount of "x" in weight percentage of the resulting composition.

[0098] Unless otherwise stated, all ranges include both endpoints and all numbers in between. The use of “about” or “approximately” with respect to ranges applies to both endpoints of the range. Therefore, “about 20 to 30” is intended to encompass “about 20 to about 30”, including at least the specified endpoint.

[0099] All publications, including patent applications and publications, and all articles and references are incorporated by way of citation for all purposes. The term “consistently of” used to describe a combination shall include the identified elements, components, parts, or steps, as well as other elements, components, parts, or steps that do not substantially affect the fundamental and novel characteristics of the combination. The use of the terms “comprising” or “including” to describe combinations of elements, components, parts, or steps herein also considers embodiments consisting of or substantially consisting of said elements, components, parts, or steps.

[0100] Multiple elements, components, or steps may be provided as a single integrated element, ingredient, component, or step. Alternatively, a single integrated element, ingredient, component, or step may be divided into multiple separate elements, ingredients, components, or steps. The use of "a" or "an" to describe an element, ingredient, component, or step is not intended to exclude other elements, ingredients, components, or steps.

Claims

1. A fibrous structure comprising: a. One or more vertically stacked layers having a first surface and a second surface; b. A finishing layer, which is attached to the first surface of the vertically stacked layers; c. A backing layer, which is directly or indirectly attached to the second surface of the vertically laid-up layer; The finishing layer and backing layer each comprise one or more of spunbond (S) material, spunbond meltblown (SM) material, or spunbond + meltblown + spunbond (SMS) nonwoven material; The vertically laid-up layer is formed of 100% by weight PET fibers, and the backing layer contains spunbond PET material with a weight of 8 gsm to 22 gsm. The fiber structure described herein is suitable for flooring components.

2. The fiber structure of claim 1, wherein the finishing layer is an airflow resistance finishing layer.

3. The fiber structure as claimed in any of the preceding claims, wherein the finishing layer is a floor contact layer suitable for contacting the floor surface, the subfloor, and / or both.

4. The fiber structure as claimed in claim 1 or 2, wherein one or more layers of the fiber structure are a loosely woven fabric or a web.

5. The fiber structure of claim 4, wherein the loose fabric or web is located between the second surface of the vertically laid layer and the backing layer.

6. The fiber structure as claimed in claim 1 or 2, wherein the fibers of the vertically laid-up layers are generally vertically oriented in an uncompressed state.

7. The fiber structure as claimed in claim 1 or 2, wherein the vertical layup is a compressed vertical layup.

8. The fiber structure of claim 1, wherein the finishing layer comprises polypropylene SMS material.

9. The fiber structure as claimed in claim 1 or 2, wherein the finishing layer has a weight of 50 gsm to 60 gsm.

10. The fiber structure of claim 1 or 2, wherein the vertically laid-up layer has a weight of 110 gsm to 175 gsm.

11. The fiber structure of claim 1, wherein the backing layer has a weight of 10 gsm to 20 gsm.

12. The fiber structure of claim 4, wherein the loose fabric or web has a weight of 20 gsm to 30 gsm.

13. The fiber structure of claim 1 or 2, wherein one or more of the layers include an adhesive for bonding to adjacent layers.

14. The fiber structure as claimed in claim 1 or 2, wherein the fiber structure has a thickness of 5 mm or less.

15. The fiber structure as claimed in claim 1 or 2, wherein the fiber structure has a thickness of 3.5 mm or less.

16. The fiber structure as claimed in claim 1 or 2, wherein the fiber structure has a thickness of 1.5 mm or greater and 5 mm or less.

17. The fiber structure as claimed in claim 1 or 2, wherein the fiber structure has a thickness of 1.5 mm or greater and 3.5 mm or less.

18. The fiber structure as claimed in claim 1 or 2, wherein improved performance is achieved in under-chamber testing compared to conventional materials.

19. The fiber structure as claimed in claim 1 or 2, wherein improved performance was achieved in indoor testing compared to conventional materials.

20. The fiber structure of claim 1 or 2, wherein the fiber structure retains its fluffiness after 25,000 cycles of wheelchair testing at 90 kg.

21. The fiber structure as described in claim 1 or 2, comprising: a. A vertically stacked layer having a first surface and a second surface, wherein the vertically stacked layer has a weight of 110 gsm to 175 gsm; b. A finishing layer, which is fixed to the first surface of the vertically laid-up layer, wherein the finishing layer is formed of polypropylene SMS material and has a weight of 50 gsm to 60 gsm; c. A backing layer comprising spunbond PET material weighing 10 gsm to 20 gsm; and d. A loose fabric or mesh sandwiched between the second surface of the vertically laid layer and the backing layer, wherein the loose fabric or mesh has a weight of 20 gsm to 30 gsm.

22. A flooring assembly comprising a flooring surface and a fiber structure as described in any of the preceding claims.

23. The flooring assembly of claim 22, wherein the flooring surface is vinyl tile, luxury vinyl tile, laminate, profile, wood panel, linoleum, engineered wood, cork, hardwood, bamboo, stone, or a combination thereof.

24. The floor assembly of claim 22 or 23, wherein the floor assembly is adapted to be installed on the subfloor.

25. The flooring assembly of claim 22 or 23, wherein the flooring assembly includes one or more pressure-sensitive adhesive layers for bonding the flooring surface to the fiber structure, bonding the fiber structure to a subfloor, or both.

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