Floor underlayment elements and flooring laminates

Abstract

The present disclosure relates to an underlayment element (1) configured to be installed between a flooring plank (10) and a subfloor (12). The underlayment element includes a substrate matrix (2) and a plurality of restricting members (3) at least partially embedded in the substrate matrix. The substrate matrix includes a compressible, preferably foamed, first material. The restricting members include a second material, each of which has a size greater than 0.25 mm in at least one direction. The restricting members are configured to restrict compression of the underlayment element. The disclosure also relates to a flooring laminate (20) including the flooring plank and the underlayment element.

Description

[Technical Field]

[0001] This disclosure generally relates to underlay elements for floors. More specifically, this disclosure relates to underlay elements configured to be installed between flooring boards and a subfloor. The underlay elements may be loosely installed on the subfloor, or the flooring boards may be suspended above the underlay elements. Alternatively, the underlay elements may be glued to the flooring boards and / or the subfloor. The underlay elements may be used with thermoplastic-based flooring boards or thin-layer flooring boards, but other flooring boards are also envisioned. This disclosure also relates to laminated flooring comprising flooring boards and underlay elements. [Background technology]

[0002] Underlays, such as foam, are used to separate flooring from the subfloor. The underlay fills in irregularities in the subfloor, reducing the risk of damage to flooring components such as floor tiles. Furthermore, underlays can improve the comfort and / or acoustic properties of the flooring, such as the reflection of footsteps and / or impact sounds. Some underlays also offer moisture-proofing properties.

[0003] Certain types of floor tiles, when installed on an underlayment, tend to deform or be damaged, especially when subjected to loads or stresses that can be localized to large forces, such as in caster chair tests, particularly over long periods. Mechanical fastening systems to the floor tiles can have a negative impact. This type of problem is particularly likely to occur with thin floor tiles and / or floor tiles with a low modulus of elasticity. Examples include plastic flooring and thin-layer flooring. The displacement of specific parts of the floor tile during load or stress can become extremely large. In fact, a 2mm thick foam can displace a floor tile by up to 2mm.

[0004] Furthermore, underlays typically compress over time, sometimes losing their original function.

[0005] Attempts have been made to improve at least some of the characteristics of the above-mentioned underlay. For example, the underlay can be made stronger or thinner by making it harder or denser. With a thinner underlay, the compressibility can be reduced to at least a certain extent.

[0006] However, any modification of the underlay may compromise one or more of the above-mentioned advantages. In addition, the underlay may become extremely expensive and / or extremely heavy. Furthermore, the comfort or heat insulation of such an underlay may be insufficient. Also, the heat insulation may be insufficient even for specific applications. Other problems may arise, such as the underlay losing its elasticity and / or shape over time.

[0007] Considering the above discussion, it is clear that there is a desire for an improved framework that preferably retains at least some of the advantages mentioned above while solving at least some of the problems mentioned above. [Overview of the project]

[0008] Accordingly, an object of at least one embodiment of the present disclosure is to provide an underlay element for flooring boards with a lower degree of compression.

[0009] Another object of at least one embodiment of the present disclosure is to provide an underlayment element that is preferably resistant to compression over long periods of time. For example, a limited compression may be maintained even after being subjected to prolonged pressure from the flooring board induced by daily use, and this pressure may include pressure from sustained static loads (e.g., pressure from the flooring itself and / or pressure from furniture) and / or dynamic pressure fluctuations (e.g., pressure from people walking on the flooring).

[0010] An object of at least one embodiment of this disclosure is to provide an underlay element configured to reduce during use the deterioration of at least a portion of the flooring board installed on the underlay element, particularly the deterioration of the fixing mechanism provided at the edge of the floor panel of the flooring board. It can also reduce the occurrence of cupping or curling of the floor panel (preferably in width and / or length, and surface flatness).

[0011] A further other object of at least one embodiment of the present disclosure is to provide the above-mentioned underlay element while maintaining or further improving at least some of the typical properties of known underlay elements, such as the ability to fill in irregularities in the subfloor, cushioning effect, sound-absorbing properties, cost-effectiveness, or thermal insulation effect.

[0012] An additional object of at least one embodiment of the present disclosure is to provide a laminated flooring material comprising flooring boards and underlayment elements in accordance with any of the above objects.

[0013] The above and other objectives and advantages that will become apparent from this description are achieved by the following various aspects, embodiments and examples.

[0014] According to a first aspect of this disclosure, an underlayment element is provided which is configured to be placed between a flooring board and a subfloor. The underlayment element comprises a base material matrix and a plurality of limiting members, at least a portion of which are embedded in the base material matrix. The base material matrix has a first material, which is compressible and preferably foamed. The limiting members have a second material, and in at least one direction, such as the thickness direction of the underlayment element, the size of each limiting member is greater than 0.25 mm. The underlayment element is configured such that compression is limited by the limiting members in at least a portion of the underlayment element, such as the entire underlayment element.

[0015] A portion of the underlayment element may be compressed in the thickness direction over time. However, the second material has the effect of mitigating the compression to a certain extent. This makes it possible to limit the compression of the underlayment element, for example, at a certain moment or over a long period of time.

[0016] Furthermore, when used in conjunction with a flooring board placed on top of the underlayment element, the underlayment element can reduce deformation of at least a portion of the flooring board placed on top of it (for example, the edge of the floor panel of the flooring board where the fixing mechanism is located). This reduces deformation of at least a portion of the flooring board.

[0017] The second material can reinforce the underlayment element. Furthermore, the second material can control the compressibility and / or degree of compression of the underlayment element. However, it is preferable that the underlayment element has a certain degree of elasticity, such as being able to fill in unevenness in the subfloor and / or provide a cushioning effect. Optionally, the second material may improve thermal insulation and / or moisture resistance.

[0018] By providing a low-cost base material matrix and / or low-cost limiting members, a cost-effective underlay element can be provided while maintaining or further improving at least some of the typical characteristics of known underlays (see above).

[0019] The incompressible thickness may mean the maximum thickness of at least a portion of the underlying elements.

[0020] There may be an embodiment in which the degree of compression when a pressure of 1.90 MPa is applied is 0.60 mm or less, preferably 0.30 mm or less. The degree of compression can be expressed as an absolute numerical range of compression. Regarding these parameters, it has been found that, particularly when the thickness of the underlying element is 1.0 to 3.0 mm (but not limited thereto), at least partial deterioration of the flooring plate provided on the underlying element can be significantly reduced. This is particularly applicable to the fixing mechanism provided at the edge of the floor panel included in the flooring plate. Furthermore, it is particularly applicable to the thermoplastic flooring plate and the thin-layer flooring plate disclosed in this specification.

[0021] The compression rate of at least a part of the underlying element, such as the entire underlying element, may be limited to 50% or less, 30% or less, or 20% or less with respect to the thickness of the underlying element when not compressed, preferably the maximum thickness of the underlying element. It should be noted that any of these numerical ranges can be expressed as a relative numerical range of compression and there are embodiments that can be combined with the absolute degree of compression numerical range disclosed in this specification.

[0022] The thickness of the underlying element and / or the substrate matrix may be 0.4 to 3.0 mm, for example 1.0 to 2.5 mm.

[0023] When the thickness of the underlying element is 0.4 to 0.6 mm, the degree of compression when a pressure of 1.90 MPa is applied may be 0.20 mm or less.

[0024] The underlying element preferably has an original uniform thickness. For example, the underlying element, preferably the substrate matrix, may include a sheet laminate including at least one sheet such as a single-layer sheet. The limiting member may be at least partially embedded in the sheet laminate. As will be described in detail below, the sheet may optionally have a cavity for accommodating the limiting member. There may be embodiments in which the thickness of the underlying element varies slightly. For example, embodiments having a protruding pattern such as a wave shape or a rib shape on the upper surface and / or the bottom surface may be included.

[0025] The underlayment element may be flexible. For example, the underlayment element may be configured to be placed on a roll, or to be configured to be folded into a folding section. The underlayment element may be configured to be cut to the appropriate size with a knife or scissors. This allows for the creation of underlayment elements with dimensions suitable for installation on a given base floor.

[0026] The underlayment element can be used in combination with a flooring board, which preferably comprises at least one floor panel, such as multiple floor panels.

[0027] The size of the limiting member in at least one direction, such as the thickness direction of the underlay element, may be greater than 0.30 mm or greater than 0.40 mm. There may also be embodiments in which the size of the limiting member in at least one direction, such as the thickness direction of the underlay element, is greater than 1.00 mm.

[0028] Embodiments may exist in which the size of the limiting members in two or three orthogonal directions exceeds 0.25 mm. Embodiments may also exist in which the size of the limiting members in two or three orthogonal directions exceeds 0.30 mm, 0.40 mm, or even 1.00 mm. In any embodiment, one of these directions may be parallel to the thickness direction. Obviously, the size of the limiting member in one direction is limited by the thickness of the underlayment element along the thickness direction.

[0029] The limiting members may have substantially the same size and / or shape. However, there may be embodiments in which the limiting members have various sizes and / or shapes.

[0030] The limiting member, for example, the outer surface of the limiting member, may have a shape such as a sphere, cylinder, rectangular parallelepiped, or uneven surface.

[0031] The base material matrix and / or underlayment elements are preferably extruded and / or gloss-finished, but molding by a mold, such as injection molding, is also conceivable.

[0032] Here, generally, the second material may contain recycled raw materials. This can reduce the cost of the underlay element.

[0033] The restricting member may have particles such as granules or flakes, and / or elongated pieces such as threads, strings or yarns. The elongated pieces may have a longitudinal direction, and its length may be more than 5 mm, for example more than 10 mm or equivalent to 20 mm.

[0034] The restricting member may be basically uniformly distributed throughout the base matrix. This is preferable when the restricting members have substantially the same size and / or shape. However, embodiments in which the restricting members are non-uniformly distributed throughout the base matrix are equally envisioned.

[0035] The density of the second material may be greater than the density of the first material. For example, the restricting member and / or the second material may be solid. However, there may be embodiments in which the density of the second material is less than the density of the first material. For example, the restricting member and / or the second material may be hollow.

[0036] Generally, the density of the first material is less than 700 kg / m 3 or less than 600 kg / m 3 and may be less. When the density of the first material is less than 500 kg / m 3 for example 20 - 350 kg / m 3 or 70 - 250 kg / m 3 embodiments may exist. This can reduce the weight and / or material cost of the underlay element.

[0037] Generally, the density of the second material may be 200 - 2700 kg / m 3 and may preferably be 800 - 1200 kg / m 3 When the density of the second material includes a polymer material such as rubber or consists entirely of polymer materials, it may be 400 - 2100 kg / m 3 and may be 800 - 1500 kg / m 3It is preferable that the second material has at least one of the fillers described elsewhere in this specification.

[0038] The elastic modulus or Young's modulus E of the second material may be greater than the elastic modulus of the first material.

[0039] Hereinafter, thermoplastic materials can be distinguished from crosslinked thermoplastic materials. Thermoplastic materials are thermoplastic plastic materials, while crosslinked thermoplastic materials include crosslinked polymers and may optionally include thermoplastic plastic materials. For example, they may be crosslinked by chemical reaction or radiation.

[0040] The first material may include a polymer material such as a thermoplastic or a crosslinked thermoplastic. The thermoplastic can impart improved rebound elasticity to a softer and more flexible substrate matrix. The crosslinked thermoplastic may be harder and can impart a higher glass transition temperature and / or chemical resistance. For example, the substrate matrix or underlayment element may as a whole contain a crosslinked thermoplastic with a degree of crosslinking between 40% and 80%, or embodiments may consist entirely of a crosslinked thermoplastic with a degree of crosslinking between 40% and 80%.

[0041] The polymer material of the first material is preferably foamed with a foaming agent or the like. For example, the first material may include polyethylene (PE), preferably radiation-crosslinked PE (IXPE), ethylene vinyl acetate (EVA), polyethylene terephthalate (PET), polypropylene (PP), preferably extruded PP (XPP) or crosslinked PP (IXPP), polystyrene (PS), preferably extruded PS (XPS) or foamed PS (EPS), or polyolefin (PO), preferably crosslinked PO (XPO).

[0042] The first material may include a porous foam. For example, the size of the bubbles or pores may be in the range of 10 to 1300 microns. The porous foam may be a closed-cell porous foam that can provide a rigid substrate matrix and impart improved thermal insulation and / or moisture resistance. However, a continuous-cell porous foam is also conceivable, which can provide a lighter substrate matrix and impart improved sound insulation. It can also reduce the amount of material required for the substrate matrix.

[0043] The first material may contain at least one filler. The filler may include an organic filler and / or an inorganic filler. Any of these fillers can increase the bending strength and / or stiffness of the underlayment element. The organic filler may also provide a lightweight material that can reduce the weight of the underlayment element. For example, the organic filler may include cork particles and / or wood-based particles, such as wood fibers or wood powder. The maximum cut diameter of the wood-based particles, e.g., particle size D98, may be 1000 μm. Alternatively, the particle size, which is preferable according to ASTM E11-17, may be less than 1000 μm. For example, the particle size may be 0 to 250 μm, and for example, 40% of the particle size may be greater than 75 μm. The packing density of the wood-based particles is 100 to 250 kg / m³. 3 But that's fine. Cork particles have a compressive modulus of 8-20 MPa and / or 55-320 kg / m³. 3 For example, 55-240 kg / m 3 It may have a packing density of . The first material may contain up to 70% by weight of cork particles. For example, the inorganic filler may contain mineral materials such as calcium carbonate (CaCO3), barium sulfate, wollastonite, and talc, sand materials, clay materials such as bentonite, or glass fibers.

[0044] Herein, throughout this disclosure, the average size of fillers, preferably inorganic fillers, in particular in the first and / or second material, preferably in two or three orthogonal directions, is preferably 0.106 mm or less, for example, 0.10 mm or less. Preferably, the size of organic fillers in the first and / or second material in two or three orthogonal directions is less than 0.25 mm. Herein, there may be embodiments in which the particle size of inorganic and / or organic fillers in the first and / or second material can be determined according to ASTM E11-17.

[0045] However, there are embodiments in which the first material does not contain cork and / or wood-based materials. Furthermore, there are embodiments in which the second material does not contain cork and / or wood-based materials.

[0046] The second material may be compressible.

[0047] The compressive strength of the second material may be greater than that of the first material. This makes it possible to increase the compressive strength (CS) of at least a portion of the underlayment element, preferably the compressive strength of the entire underlayment element, compared to, for example, the substrate matrix itself which contains only the first material.

[0048] The compressive strength of the first material may be 20 to 800 kPa, for example, 60 to 250 kPa. It is preferable to use the standard CEN / TS 16354:2013 (see SS-EN 826:2013), which is a method for measuring compressive strength when deformed by 0.5 mm.

[0049] The second material may include a polymer material such as a thermoplastic material or a crosslinked thermoplastic material, and optionally include at least one filler and / or a mineral material such as calcium carbonate (CaCO3) or a sand material. For example, the filler may include an organic filler and / or an inorganic filler, or a functional filler and / or a bulking agent. The inorganic filler may similarly include a mineral material such as calcium carbonate or a sand material such as sand powder. The organic filler may include organic fibers, such as cork particles, wood fibers or wood powder, or rice husks. The particle size, compressive modulus, density, and grade of the cork particles and / or wood particles are not limited, and this may also apply to the first material described above, and is referred to herein. There may be embodiments in which the filler includes a clay material such as kaolin. For example, the amount of filler in the second material may be 5 to 20% by weight or 20 to 90% by weight, for example, 40 to 80% by weight.

[0050] Embodiments may include a second material that is a vulcanizing adhesive or a curing adhesive.

[0051] The second material and / or limiting member may be solid. Preferably, the second material is not foam. However, there may be embodiments in which the second material and / or limiting member is hollow, for purposes such as reducing the weight of the underlay element.

[0052] The material compositions of the first and second materials may be different. For example, the first and second materials may contain different types of polymer materials, such as different types of thermoplastic materials.

[0053] There may be embodiments in which the material composition of the first and second materials is substantially identical. For example, the first and second materials may contain the same type of polymer material, such as the same type of thermoplastic material. However, the polymer material may differ in at least one element selected from the group consisting of grade, density, miscibility, degree of crosslinking, amount of filler, and amount of additives.

[0054] The first and second materials are based on the same type of thermoplastic material, and the first material may be a thermoplastic material while the second material is a crosslinked thermoplastic material. For example, the second material may be crosslinked by a chemical reaction or radiation to a selected portion of the thermoplastic material of the first material. The first and second materials may be PE and IXPE, respectively, or PP and IXPP, respectively, but are not limited to these.

[0055] Embodiments may include a cork component, preferably embodied as particles, of the second material. This means the limiting member may contain a cork component or consist entirely of a cork component. For example, in at least one direction, preferably two or three orthogonal directions, as described elsewhere in this specification, the cork component may be 0.25 to 3.0 mm, for example, 0.25 to 0.40 mm.

[0056] The limiting member may be entirely embedded within the base matrix.

[0057] There may be embodiments in which at least some of the restricting members are partially exposed, or for example, all of the restricting members may be partially exposed.

[0058] In general, the limiting member may be formed separately from the base matrix. The base matrix may have a cavity, and the limiting member may be provided within the cavity. In the first example, the cavity is a through hole, so it completely penetrates the base element. In the second example, the cavity is a blind hole, so it does not completely penetrate the base element.

[0059] The limiting member may be bonded to the base matrix by an adhesive or the like. Alternatively, the limiting member may be bonded to the base matrix by press-fitting, such as when it is placed in a cavity. Alternatively, the second material may be encapsulated within the first material. For example, the second material may be mixed with the first material when forming the underlayment element by extrusion molding or the like. The first material and / or the second material preferably contain polymer materials such as thermoplastic or thermosetting materials, and preferably contain rubber materials, PU, ​​polyester resin, epoxy resin, silicone resin, melamine resin, or furan resin, and preferably contain at least one filler if desired. The second material may have a higher melting point than the first material, and it is preferable that the second material does not melt at any temperature when forming the underlayment element by extrusion molding or the like. Alternatively, or optionally, when the first and second materials are supplied at the same temperature, preferably at a temperature exceeding the glass transition temperature of the first material, the second material may have a higher viscosity than the first material.

[0060] There may be embodiments in which the base matrix comprises multiple base materials, such as beaded, spherical, or rectangular parallelepiped shapes, and the multiple base materials have a first material, preferably a polymer material, and the multiple restricting members are formed separately. It is preferable that the base material containing the first material contains a polymer material. The underlay element may further comprise a first sheet and a second sheet, such as foil, surrounding at least a portion of the base materials and restricting members. It is preferable that the base materials and restricting members are attached to the first and second sheets with an adhesive or the like. The sheets may hold the separately formed base materials and restricting members in place. An advantage of this embodiment is that the manufacture of the underlay element can be simplified and / or made less expensive, preferably lightweight. A moisture-proof layer may also be incorporated.

[0061] In some embodiments, it is preferable that the limiting member is integrally formed with the base matrix and provided as a sheet laminate, such as a single sheet. The first and second materials may be based on the same material, and are preferably based on a thermoplastic material such as PP, PE, or PVC. For example, the first material may be a thermoplastic material and the second material may be a crosslinked thermoplastic material. The second material may be crosslinked in a sheet immediately after extrusion molding containing the first material, for example, by a chemical reaction or selective radiation of the first material.

[0062] According to a second aspect of this disclosure, a laminated flooring material can be provided that is configured to be installed on a subfloor. The laminated flooring material comprises a flooring board and preferably comprises at least one floor panel and an underlayment element. The underlayment element and / or flooring board can be embodied as any embodiment described in relation to the first aspect, and thereby referenced herein. Further embodiments are also possible.

[0063] The floor panels may be interconnected vertically and / or horizontally by a fixing mechanism. The fixing mechanism may be a mechanical fixing mechanism comprising, for example, a vertical fixing arrangement having protrusions and grooves and / or a horizontal fixing arrangement having fixing elements and fixing grooves.

[0064] The flooring boards may comprise a first floor panel and a second floor panel, and the underlayment element may be provided at least along the edge of the joint between the first floor panel and the second floor panel. This reduces the phenomenon of the flooring boards shifting along the edge of the joint, for example, where a (mechanical) fixing mechanism is provided. It also reduces vertical displacement, such as in the thickness direction of the underlayment element and / or the flooring boards.

[0065] The underlayment element may be attached to the flooring board with adhesive or the like, for example, as a preliminary attachment. Preferably, the underlayment element is attached to the rear side of the flooring board. However, there may be embodiments in which the flooring board is loosely positioned so as to float on the underlayment element. Furthermore, there may be embodiments in which the underlayment element is equipped with a friction member that can be partially attached to the underlayment element. For example, the friction member can reduce the sliding of the flooring board relative to the underlayment element.

[0066] The embodiments of this disclosure have been described above, primarily by reference to a few embodiments. However, as will be readily apparent to those skilled in the art, other embodiments not described above are similarly possible within the scope of the embodiments of this disclosure.

[0067] In general, all terms used in the claims and reference numerals in the following sections of embodiments shall be interpreted according to the general meaning of the art unless otherwise expressly defined herein. All references to [elements, apparatus, components, means, processes, etc.] shall be broadly interpreted as referring to at least one example of such elements, apparatus, components, means, processes, etc., unless otherwise expressly stated herein. References to one, two, or more “at least one element,” etc., may simply be referred to as “elements.” [Brief explanation of the drawing]

[0068] The present disclosure will be described in more detail below with reference to typical drawings, relating to typical embodiments.

[0069] [Figure 1a-1b] Figure 1a and Figure 1b schematically show a typical embodiment of laminated flooring material comprising flooring boards and underlayment elements. [Figure 1c-1g] Figures 1c and 1d, 1e, and 1f schematically show a typical embodiment of the underlay element, as well as a 1g schematic side view showing a partial embodiment of the underlay element. [Figure 2a-2f] A typical embodiment of the underlay element is schematically shown, for example, in the side cross-sectional view along lines AA and / or BB in Figure 1a. [Figures 3a-3d] A schematic plan view or bottom view showing a typical embodiment of the underlay element, and / or a plan cross-sectional view along line CC in, for example, Figure 1b. [Figure 4a-4b] This is a schematic perspective view showing a typical embodiment of the limiting member. [Figures 4c-4f] Figure 4c is a schematic perspective view illustrating a typical embodiment of the underlay element, and Figures 4d-4f are, for example, side cross-sectional views along lines AA and / or BB in Figure 4c. [Figure 4g] This is a schematic side view showing a typical embodiment of a substrate equipped with a limiting member. [Figures 5a-5e] These figures schematically show a typical embodiment of compression of the underlay element: a side view or side cross-sectional view (Figures 5a-5b and 5e) and a plan view (Figure 5c), as well as a bottom view (Figure 5d) schematically showing a typical embodiment of the pressurizing device. [Figures 6a-6d] These schematic side cross-sectional views (Figures 6a-6c) and plan view (Figure 6d) show a typical embodiment of a floor panel equipped with a mechanical fixing mechanism used when testing a sample of the underlying element, and are conceivable in any embodiment described herein. [Figure 6e] This diagram schematically shows a typical circular shape of interlocking floor panels on a sample of the underlay element used when testing cupping. [Figure 6f] This figure schematically shows a typical pressure-compression graph obtained from testing a sample of the underlay element. [Modes for carrying out the invention]

[0070] Next, various aspects of this disclosure will be described with reference to, for example, Figures 1a-1g, 2a-2f, 3a-3d, 4a-4g, 5a-5e, and 6a-6d. These figures show embodiments of the underlayment element 1, embodiments of the flooring laminated timber 20 comprising the flooring board 10 and the underlayment element 1, and embodiments of the compression of the underlayment element.

[0071] The underlayment element 1 is preferably suitable for indoor use and is configured to be installed between the flooring board 10 and the subfloor 12, and is preferably in contact with either or both of the flooring board 10 and the subfloor 12 during use. The underlayment element may be loosely installed on the subfloor, and the flooring board may float above the underlayment element. However, there may be embodiments in which the underlayment element is attached to the flooring board and / or subfloor, preferably with adhesive. For example, the underlayment element may be used in combination with a thermoplastic flooring board, for example, having a thickness of 2.0 to 8.0 mm, preferably 4.0 to 6.0 mm, or a laminated thin flooring board, for example, having a thickness of 6.0 to 8.0 mm, but other flooring boards and thicknesses are also conceivable. For example, the thermoplastic flooring board may include so-called luxury vinyl tiles (LVT tiles), stone-plastic (polymer) composite panels (SPC panels), or expanded polymer core panels (EPC panels), also known as waterproof core panels (WPC panels). Embodiments may include flooring boards containing a thermosetting resin such as polyurethane (PU), or embodiments in which the thickness of the flooring boards is, for example, 2.0 to 8.0 mm, preferably 4.0 to 6.0 mm. As shown in Figures 1a-1b and later in Figures 6a-6d, in any of the above examples, the flooring boards may be provided with floor panels such as a first floor panel 11 and a second floor panel 11', and the edges of the floor panels may be interconnected by a fixing mechanism 13. The fixing mechanism may be a mechanical fixing mechanism, for example, a vertical fixing arrangement having a protrusion 13a and a groove 13b, and / or a horizontal fixing arrangement having a fixing element 13c and a fixing groove 13d. The protrusion 13a may be separate, preferably flexible, and may be a protrusion incorporated so as to be movable in a movable groove 13e (see, for example, Figures 1a-1b). Alternatively, the protrusion 13a may be formed integrally with the floor panel (see, for example, Figures 6a-6d). A base layer element 1 may be provided at least along the edges 11a and 11a' of the panel joint, and the edges of the joint may be, for example, the long side 15 and / or the short side 16.

[0072] As shown in Figures 1c and 1d, the underlay element 1 may be flexible. In a preferred embodiment, as shown in Figure 1d, the underlay element may be adapted to be provided in a roll shape. In other embodiments, as also shown in Figures 1e to 1f, the underlay element may be adapted to be folded into a plurality of folding sections 1' along the fold 1''. The underlay element preferably has a uniform thickness T0 and may be provided as a sheet composite material 6 such as a single-layer sheet 6a or a multi-layer sheet 6a, 6b. The thickness T0 of the underlay element is preferably 0.4 to 3.0 mm, for example, 1.0 to 2.5 mm. The underlay element can be compressed along the thickness direction TD, which is parallel to the surrounding vertical direction Z, when in use. Due to its flexibility and / or compressibility, the underlay element can adapt its shape and / or external form to the base floor 12.

[0073] In any embodiment of this specification, such as the embodiments shown in Figures 1a-1g, 2a-2f, 3a-3d, and 5a-5e, the base matrix 2 may be provided as a sheet composite material 6 comprising at least one sheet 6a having a single-layer structure, preferably a foamed sheet 6a as shown in Figure 2a, or as a sheet composite material 6 comprising a first sheet 6a and a second sheet 6b as shown in Figure 1g. The first sheet 6a and / or the second sheet 6b may be foamed. It is preferable that the first sheet 6a and the second sheet 6b are bonded to each other. The limiting member 3 may be at least partially embedded in the sheet composite material 6, such as the sheets 6a and 6b.

[0074] The underlayment element 1 comprises a base material matrix 2 and a plurality of limiting members 3 at least partially embedded in the base material matrix. Figures 2a-2f and 3a-3d show side cross-sectional views and plan views of such an embodiment. The base material matrix 2 has a first material, and the limiting members 3 have a second material. The compression of at least a portion of the underlayment element 1 is configured to be limited by the limiting members 3.

[0075] When the underlayment element 1 is provided beneath a flooring board 10 that includes a floor panel, at least one, preferably more, limiting members 3 may be located beneath the edge of the floor panel, and a fixing mechanism 13 may be provided at the edge of the floor panel (see Figures 1a-1b and 6a-6d). However, it is preferable that the entire underlayment element 1 is configured to be restricted by the limiting members 3.

[0076] During use, as shown in Figure 1a, a pressure Q acts on the upper surface of the flooring board in the direction toward the underlayment element.

[0077] The first material is compressible and preferably contains a polymer material such as a thermoplastic or crosslinked thermoplastic. For example, the first material may contain PE, IXPE, EVA, PET, PP, XPP, PS, XPS, PS, EPS, PO, or XPO. As described above, the first material is preferably foamed, thereby having closed-cell or open-cell structured cells or holes 4. The density of the first material is 700 kg / m³. 3 Preferably less than 500 kg / m 3 Less than is preferable.

[0078] Part or all of the underlay element 1 may be compressed along the thickness direction TD. In a preferred embodiment, when the thickness T0 is 1.0 to 3.0 mm, the degree of compression, such as the maximum degree of compression Zm when a pressure P of 1.90 MPa is applied, is 0.60 mm or less, preferably 0.30 mm or less. Figures 5a to 5b show embodiments of compression of the underlay element along lines AA and / or BB in analogy to, for example, Figure 1a or Figures 2a to 2f, and Figure 5c is a plan view showing the compression in Figures 5a to 5b. The pressurizing device 30 can move along direction D, which is preferably parallel to the thickness direction TD when the pressurizing device is in use, and it is shown that the pressurizing device applies pressure to the upper surface 1a via the pressure plate 31, and the pressure plate may have any shape, such as a rectangle or a circle as shown in Figure 5d. For example, when a force of 9.5 kN is applied at a preferably speed of 0.1 mm / min, a rectangular pressure plate with dimensions of 5 cm × 10 cm can supply a pressure P of 1.90 MPa. The degree of compression, such as the maximum degree of compression Zm, may be the distance from the uncompressed upper surface 1a to preferably the innermost compressed portion 1a' of the compressed underlay element 1 (see, for example, Figure 5a). Figure 5e is a side cross-sectional view of the embodiment in Figure 5b, showing how the underlay element is further compressed when, for example, several restricting members 3 come into contact with each other, thereby further restricting the compression. There are also embodiments in which the compression is restricted overall.

[0079] In one embodiment, the thickness T0 of the underlay element 1 is 0.4 to 0.6 mm, and the compressibility, such as the maximum compressibility Zm when a pressure P of 1.90 MPa is applied, is 0.20 mm or less.

[0080] For example, as shown in the embodiments of Figures 2a to 2c, the limiting member 3 may be embedded entirely within the base matrix 2. The limiting member may be formed separately from the base matrix. Alternatively, the limiting member may be formed integrally with the base matrix, for example, by a chemical reaction, or by selectively emitting the first material to form the second material.

[0081] For example, as shown in the embodiments of Figures 2d-2f and 3a-3d, it is preferable that the separately formed limiting member 3 is partially embedded in the base matrix 2. A portion of the limiting member 3 may be exposed. This means that at least one surface of the limiting member 3 may face the first material, such as facing the top surface 1a and / or bottom surface 1b of the base element, or facing away from the first material. For example, as shown in Figures 2d-2f, there may be embodiments in which the base matrix 2 has a cavity 5 and the limiting member 3 is provided inside the cavity. The limiting member may be bonded to the base matrix. Figures 2d, 2f and 2e show the cavity 5 in the form of a through hole and a blind hole, respectively. Parts 3', 3'' of the limiting member may be provided along horizontal planes HP' and / or HP'' along the top surface 1a and / or bottom surface 1b (see, for example, Figures 2d-2f). In Figure 2f, at least some cavities, such as all of them, are not completely filled with the limiting member. For example, the bottom of the cavity may have space 5a. However, there may also be embodiments in which the upper part of the cavity has space 5a, as can be seen by turning Figure 2f inverted.

[0082] For example, as shown in Figures 2d and 3a, the horizontal dimensions Xc and Yc of each cavity may be less than 5 mm, for example less than 2 mm, which is possible in any of the embodiments shown in Figures 2a-2f and 3a-3d. For example, in at least one direction along the horizontal plane HP parallel to the top surface 1a and / or bottom surface 1b, for example two orthogonal directions, the horizontal dimension of the cavity may be 1 to 5 mm, for example 1 to 2 mm (see Figure 2d). Clearly, the height Zc of each cavity is limited by the thickness T0 (see Figure 2e).

[0083] In at least one direction, for example, in two or three orthogonal directions, the size of each limiting member is greater than 0.25 mm. There are embodiments in which, in at least one direction, for example, in two or three orthogonal directions, the size of each limiting member is greater than 0.30 mm, greater than 0.40 mm, or even greater than 1.00 mm. In any of these cases, one direction may be parallel to the thickness direction TD of the base element 1. The other two directions may extend along the first horizontal direction X and the second horizontal direction Y of the base element and may be parallel to a pair of sides of the base element, for example, the short sides 1c, 1d and the long sides 1e, 1f.

[0084] For example, as shown in Figures 2a and 2d-2f, the restricting members 3 may have substantially the same size and / or shape. For example, as shown in Figures 2b-2c, the restricting members 3 may have various sizes and / or shapes. For example, the shape and / or size may be irregular. In any embodiment, the restricting members may be uniformly dispersed throughout the base matrix 2.

[0085] There are embodiments in which the second material is compressible. The second material may include a polymer material such as a thermoplastic material or a crosslinked thermoplastic material, and may optionally include at least one filler. For example, the second material may include PVC and a filler, or a rubber material.

[0086] The density and / or modulus E and / or compressive strength CS of the second material are preferably greater than those of the first material.

[0087] There are embodiments in which the second material is sufficiently hard and / or incompressible. For example, the second material may include a mineral-based material such as CaCO3 or sand.

[0088] Figures 3a to 3d are schematic plan views or bottom views and / or plan cross-sectional views along the CC line (see Figure 1b) illustrating embodiments of the underlay element. The underlay elements in Figures 3a, 3b, 3c, and 3d may correspond to any of the underlay elements in Figures 2a to 2f, and therefore any combination of these embodiments may be used. In Figure 3c, the limiting member 3 extends between a pair of sides of the underlay element, for example, between a pair of short sides 1c and 1d. In Figures 3a, 3b, and 3d, the limiting member 3 is separated from the sides, for example, from all four sides 1c, 1d, 1e, and 1f. Sides 1e and 1f may be long sides.

[0089] For example, as can be seen in any of Figures 3a to 3d, there may be embodiments in which the size of the limiting member 3 is less than or equal to the thickness T0 of the base element 1 and / or the base matrix 2 in at least two orthogonal directions, preferably three orthogonal directions X, Y, and Z as shown in Figures 3a to 3b. For example, the limiting member may have particles 3a such as granules or flakes, and / or elongated pieces 3b such as threads, strings, or twisted yarns. Embodiments of particles 3a and elongated pieces 3b extending in three orthogonal directions are shown in Figures 4a and 4b, respectively.

[0090] For example, as can be seen in any of the embodiments shown in Figures 3a to 3d, there may be embodiments in which the limiting member 3 is greater than the thickness T0 in one direction or in two orthogonal directions X and Y. For example, the limiting member may have particles 3a such as granules or flakes, and / or elongated pieces 3b such as threads, strings or twisted yarns.

[0091] The underlay element 1 may have a second material in an amount greater than 0.01 volume%, preferably 75 volume%, or less. For example, if the restricting member 3, such as a spherical shape, is entirely embedded in the base matrix 2, the underlay element may have a second material in an amount from 0.03 to 50 volume%. Also, if, as desired, the embodiment of Figure 3c or 3d is combined, as in any of the embodiments of Figures 2d to 2f, and at least a portion of the restricting member 3 is exposed, the underlay element may have a second material in an amount from 38 volume%, or less. Hereinafter, volume% means a percentage of the total volume of the underlay element.

[0092] As described above, there may be embodiments in which the limiting member 3 is integrally formed with the base matrix 2, and it is preferable that the integrally formed product is provided as a sheet laminated material 6 such as a single sheet 6a. For example, the embodiments shown in Figures 2a to 2f and 3a to 3d may all correspond to integrally formed limiting members 3. As a result, the underlay element 1 does not have any cavities or holes for providing the limiting member 3 other than the possibility of foaming, and may be substantially continuous. For example, the first material may be a thermoplastic material, and the second material may be a crosslinked thermoplastic material, and it is preferable that the first and second materials are based on the same type of thermoplastic material, such as PP, PE, or PVC.

[0093] For example, as shown in Figures 4c to 4g, the base element 1 comprises a base matrix 2 having a plurality of base materials 2' such as beaded, spherical, or rectangular parallelepipeds, and the base materials 2' have a first material, preferably a polymer material such as EPS, and may be foamed. The base materials 2' are preferably formed separately. The base element preferably further comprises a plurality of separately formed restricting members 3, for example, beaded or spherical. The restricting members 3 are at least partially embedded in the base matrix 2 by being at least partially surrounded by the base materials 2' and / or placed alongside the base materials 2'. There may be at least one restricting member and base material that are adjacent to each other, if desired. The size of the restricting member 3 may be greater than 0.25 mm in at least one direction, for example two directions, or preferably three orthogonal directions X, Y, Z. The size may be greater than 0.30 mm or 0.40 mm, or greater than 1.00 mm, in at least one direction, for example two or three orthogonal directions X, Y, Z. For example, the size of the limiting member 3 may be between 0.35 and 2.95 mm.

[0094] In the first example, the size and / or shape of the base material 2' and the limiting member 3 may be substantially the same. In the second example, the size and / or shape of the base material 2' and the limiting member 3 may be different. In either example, the size of the base material 2' may be 0.35 to 2.95 mm. If the sizes are different, a reinforcing effect may occur at different stages of compression of the underlayment element, preferably along the thickness direction TD, which may improve the cushioning effect. The underlayment element comprises a laminated sheet material 6 having a first sheet 6a and a second sheet 6b, such as a first foil and a second foil. The thickness of the first sheet and the second sheet may be 0.025 to 0.20 mm. The first foil and the second foil may be thermoplastic foils, for example, containing PE, PET, or PP. At least a portion of the first sheet 6a and the second sheet 6b may be spaced apart from each other. The base material 2' and the limiting member 3 are at least partially, for example, completely, surrounded by the first sheet 6a and the second sheet 6b. For example, the base material 2' and the limiting member 3 may be attached to sheets 6a and 6b with adhesive.

[0095] For example, the thickness T0 of the underlay element 1 in Figures 4c to 4g may be 0.4 to 3.0 mm, but is preferably 0.4 to 2.0 mm.

[0096] In Figures 4d-4e, the thickness T0 of the underlay element 1 is substantially constant. In the first example, sheets 6a and 6b may be rigid and remain undeformed to a noticeable degree under pressure, for example, from the flooring board 10. In the second example, sheets 6a and 6b are soft. The sheets may be stretched in order to obtain a substantially constant thickness.

[0097] As shown in Figure 4d, there may be embodiments in which the vertical ranges of the base material 2' and the limiting member 3 are substantially the same. As shown in Figure 4e, there may be embodiments in which the vertical range of the limiting member 3 is smaller than the vertical range of the base material 2'. This allows the base material 2' to be compressed in the first stage, and then the limiting member and optionally the base material 2' to be compressed in the second stage.

[0098] In Figure 4f, the thickness of the underlay element 1 varies between a thickness T0, which is preferably an external thickness, and an internal thickness T0'. For example, sheets 6a and 6b may be flexible, and the shape of at least a portion of sheets 6a and 6b may conform to the shape of a portion of the base material 2' and the limiting member 3. Sheets 6a and 6b may be formed separately, or they may be formed integrally as a single sheet 6a.

[0099] It is preferable that the separately formed limiting members 3 and base materials 2' are uniformly dispersed between sheets 6a and 6b.

[0100] There may be embodiments in which the limiting member 3 is provided at least partially, for example, entirely within the base material 2'. For example, some or all of the base materials and / or limiting members in any of Figures 4c to 4f may be replaced with a base material having a limiting member, and several embodiments are schematically shown in Figure 4g, for example.

[0101] Furthermore, for the underlay elements in particular in Figures 4c to 4f, the compressive strength of the second material in the separately formed limiting member 3 may be at least 1.5 times, preferably at least 2 times, the compressive strength of the first material in the base material 2'. For example, the compressive properties of other embodiments of the underlay elements in Figures 4c to 4g may be the same as the compressive properties of the embodiments described in relation to, for example, Figures 1a to 1g, 2a to 2f, 3a to 3d, 4a to 4b and 5a to 5e, thereby referring to each embodiment. In the first example, the compressibility when a pressure of 1.90 MPa is applied may be 0.60 mm or less, preferably 0.30 mm or less. In the second example, the compressibility of the separately formed limiting member 3 when a pressure of 1.90 MPa is applied may be 0.60 mm or less, preferably 0.30 mm or less.

[0102] For example, with respect to the first and / or second material, density, or modulus of elasticity, the examples of other embodiments and the embodiments in Figures 4c-4g may be the same as those of the embodiments in Figures 1a-1g, 2a-2f, 3a-3d, 4a-4b, and 5a-5e, and each embodiment will be referred to accordingly.

[0103] In general, in any of the embodiments shown in Figures 1a-1g, 2a-2f, 3a-3d, 4a-4g, and 5a-5e, the compression ratio may be limited to 50% or less of the thickness of the uncompressible underlay element, preferably the maximum thickness of the underlay element, for example, 30% or less or 20% or less.

[0104] As described above, the underlayment element 1 may be attached to the flooring board 10 by adhesive or the like. For example, such laminated flooring 20 may be materialized as shown in Figures 1a to 1b. The underlayment element 1 and / or the flooring board 20 may be materialized as shown in any of Figures 1a to 1g, 2a to 2f, 3a to 3d, 4a to 4g, 5a to 5b, and 6a to 6d, respectively, to refer to each embodiment.

[0105] As shown in Figure 1b, there may be embodiments in which each floor panel 11, 11' has a groove 14, preferably on the rear side of the floor panel. For example, the floor panel and / or groove may be embodied in the plate elements or panels and / or grooves described on pages 44, lines 7-19 and 49, line 21 to 51, line 2 of International Publication No. 2020 / 180237, and in Figures 13a-13d and 14a-14g, all of which are incorporated by reference. [Examples]

[0106] Example 1 The following embodiments further describe and demonstrate embodiments within the scope of this disclosure. The embodiments are provided for illustrative purposes only and should not be construed as limiting this disclosure so that many modifications are possible without departing from the spirit and scope of the embodiments described herein.

[0107] Flooring boards placed on top of the underlayment elements from three groups, samples S1(j), S2(j), and S3(j) (j=0, 1, 2, ...), were subjected to a caster chair (CC) test according to ISO standard 4918:2016 (replacing the casters and recommended underlayment with those of type W). Each group's sample contained the same type of base material matrix (BM) 2 but had different configurations of limiting members 3. Each group Si(j) (i=1, 2, 3) had a reference sample Si(0) with the same type of base material matrix as the other samples in the group, but the reference sample did not have a limiting member. S1(j), S2(j), and S3(j) contained base material matrices BM1, BM2, and BM3 in the form of EVA-based foamed sheets, foamed XPS sheets, and foamed PO sheets, respectively. At a deformation of 0.5 mm, their CS values ​​were 160, 500, and 60 kPa, respectively, and their densities were 160 kg / m³. 3 , 110 kg / m 3 and 85 kg / m 3 Table 1 discloses the maximum thickness T0 of the sample.

[0108] S1(1) and S2(1) are concrete embodiments of the embodiments shown in Figures 3c and 3d and Figure 2f, respectively. The limiting member has a rectangular parallelepiped LVT elongated piece with a width of 7 mm and a height of 1.3 mm, and contains PVC, a plasticizer, additives and inorganic fillers, with a bending strength of 7.1 MPa, an elastic modulus of 397 MPa and a density of 1970 kg / m³. 3The LVT elongated pieces of S1(1) were separated by substrate matrix elongated pieces that were 20 mm wide and 1.5 mm high. The LVT elongated pieces and substrate matrix elongated pieces extended adjacent to each other between a pair of opposite sides of the base element. The LVT elongated piece of S2(1) was 50 mm long and was inserted into a cavity provided in the substrate matrix. Each cavity was substantially the same size as the corresponding LVT elongated piece, except that there was a space 5a of about 0.2 mm in the upward-facing S2(1). The LVT elongated pieces were separated from each other by distances of Xs = 50 mm and Ys = 20 mm (see Figure 3d). The LVT elongated pieces and substrate matrix (fragments) of S1(1) and S2(1) were secured by adhesive tape provided along the top surface 1a or the bottom surface 1b.

[0109] S3(j) (when j>0) is a concrete implementation of the embodiments shown in Figures 2f and 3a, respectively. BM3 had cylindrical cavities in the form of through holes with a diameter of 2.5 mm, arranged in a square grid pattern, with limiting members provided inside. The cavities were spaced 8.2 mm apart. The limiting members of S3(1) and S3(3) contained woodworking adhesive and PU-based adhesive, respectively, and each limiting member was placed inside the cavity. The woodworking adhesive was a white, one-component PVAc adhesive with a solid content of 46 volume%. After the adhesive cured, a small space 5a was formed. The limiting member of S3(2) had a cylindrical polylactic acid (PLA) pellet with a height of approximately 1.8 mm and a radius of 1.75 mm.

[0110] During the test, a 4mm flooring board with a thermoplastic panel was placed on top of the sample. More specifically, it contained PVC and inorganic filler, with a flexural strength of 27.2 MPa, an elastic modulus of 6320 MPa, and a density of 2000 kg / m³. 3 The flooring board used in S1(j) is of the first type of SPC panel form, containing PVC and inorganic filler, with a bending strength of 30.0 MPa, an elastic modulus of 6022 MPa, and a density of 2008 kg / m³. 3For S2(j) and S3(j), the second type of flooring board in the form of an SPC panel was used. Panels 11, 11', and 11'' were equipped with an integrally formed mechanical fixing mechanism 13 at their edges, which was a means of interlocking the panels horizontally and vertically. The long side 15 of the panel (see Figure 6a) was configured to be fixed by the diagonal movement A of panels 11 and 11', and had not only fixing elements 13c and fixing grooves 13d but also protrusions 13a and grooves 13b. The short side 16 (see Figures 6b-6c) was configured to be fixed by the vertical overlap V of panel 11'' with respect to panel 11, and had fixing elements 13c and fixing grooves 13d for horizontal fixing. As shown in Figure 6b, the short side of the first type of flooring board was fixed vertically by contact slopes 13f and 13g on the fixing elements and fixing grooves, and the slopes also fixed horizontally. As shown in Figure 6c, the short side of the second type of flooring board was fixed vertically by a small protrusion 13a and a small groove 13b, and was able to be folded vertically. The contact surfaces 13f and 13g were positioned substantially vertically. Figure 6d shows a plan view of the panel 11 in Figures 6a-6c. As schematically shown in Figure 6e, the panels interlocked in the circle 17 containing the sample of the underlay element described above.

[0111] Table 1 summarizes the results of the CC test conducted according to ISO standard 4918:2016. The test was stopped when a portion of the flooring board delaminated (DL) and / or cracked (CR) on the surface of the flooring board. As shown in Table 1, all tests except S3(3), which was run to the maximum number of cycles, were stopped and therefore judged as "failure" according to the standard. The number of cycles performed before stopping the test was recorded. Compared to the reference sample Si(0), it can be seen that the number of cycles increased significantly in samples S1(j), S2(j), and S3(j) which were equipped with limiting members. In particular, the damage to the mechanical fixing mechanism provided at the edge of the panel was reduced in these samples due to the restriction of compression. It is also noteworthy that visual improvements were observed, for example, in the form of a reduction in the degree of delamination and / or a reduction in visible cracks on the flooring board.

[0112] [Table 1]

[0113] The same CC test was also performed on the second hybrid sample S1(2), which belonged to the first group. As can be seen from the plan view, half of S1(2) was materialized as S1(0) and the other half as S1(1), and the CC test was performed on the center of the sample. The test was stopped after 6000 cycles when cracks appeared in the half of S1(2) materialized as S1(0). In the half of S1(2) materialized as S1(1), no visible cracks or signs of delamination were observed because a limiting member was provided.

[0114] Furthermore, flooring boards positioned on a group of underlayment elements, sample T(j) (j=0, 1, 2), were subjected to a similar CC test in accordance with ISO standard 4918:2016. Sample T(j) included a reference sample T(0) and two forms (samples T(1) and T(2)) equipped with limiting member 3. T(j) had a base matrix BM of a foamed XPS sheet with a conventional water vapor barrier of 0.03 mm thickness, consisting of aluminum and PE foil. The base matrix BM had a CS value of 700 kPa and a density of 127 kg / m³ at a deformation of 0.5 mm. 3 The maximum thickness T0 was 1 mm.

[0115] T(1) and T(2) were formed by combining the embodiments shown in Figures 3a and 3c and Figure 2e (where the underlay element is shown upside down). T(1) had cylindrical cavities in the form of blind holes with a diameter of 3.4 mm and a height of 0.8 mm arranged in a square grid. The cavities were spaced 4.6 mm apart from each other. T(2) had continuous parallel cavities extending in the vertical direction, in the form of blind holes with a rectangular cross-section of 3.0 mm in width and a height of 0.8 mm. The cavities were spaced 4 mm apart in the horizontal direction from each other. The limiting members in T(1) and T(2) were formed by providing a PU-based adhesive containing 83.3% by weight of polyol and filler and 16.7% by mass of toluene diisocyanate in the cavities. The adhesive was cured for at least one week to obtain a hardness (Shore D) of 41.

[0116] During the test, a 4mm flooring board equipped with an SPC panel was placed on sample T(j). The SPC panel contained PVC and inorganic filler, with a flexural strength of 22.0 MPa, an elastic modulus of 6184 MPa, and a density of 1989 kg / m³. 3 As described above and in Figures 6a and 6b-6c, the panel was equipped with a mechanical fixing mechanism 13 integrally formed on both the long and short sides. In fact, it was a combination of not only the first type of flooring board having contact slopes 13f and 13g, but also the second type of flooring board having small protrusions 13a and small grooves 13b, with the short sides fixed vertically.

[0117] CC tests were conducted according to ISO standard 4918:2016. The test was stopped when a portion of the flooring board delaminated (DL). In all three tests, T(0), T(1), and T(2), a portion of the flooring board delaminated. The number of cycles performed up to the point when the test was stopped due to a "failure" according to the standard was recorded. The T(0) test was stopped at 3000 cycles, while the T(1) and T(2) tests were stopped at 7000 cycles, respectively. Therefore, compared to T(0), the number of cycles before "failure" was significantly higher for samples T(1) and T(2) which included limiting members.

[0118] Finally, after performing various cycle counts as specified in the CC test described above, numerous cupping tests were conducted on the flooring board located above sample T(j), as shown in Table 2. Following ISO 4918:2016, the eight SPC panels, including sample T(j), were interlocked in a circle 17 (see Figure 6e), and the test was conducted according to ISO standard 10582:2017 (Annex B). Measurements were consistently taken at position L1, 50 mm to the right from the short side 16 of panel 11 in the third row from the top, and at position L2, 50 mm to the left from the short side 16 of panel 11 in the second row from the top (see Figure 6e). The cupping (CE) at L1 and L2 was determined. CE is expressed as a percentage and is given by the formula... 100% × (C(W) - C(0)) / d This was normalized to zero cupping at 0 cycles. Here, C(W) is the surface flatness in the width direction at W cycles, and is defined as d=229 mm in Annex B. Table 2 shows that at a given number of cycles, CE decreased significantly in samples T(1) and T(2) compared to T(0). All panels were concave at cycles other than 0.

[0119] [Table 2]

[0120] Example 2 Three underlayment element 1 samples U(0), U(1), and U(2) were compressed using a pressurizing device 30 (described in detail in relation to Figures 5a-5d) equipped with a 5 x 10 cm rectangular pressure plate 31. Each sample U(j) (j=0, 1, 2) had a base matrix made of the same material as BM1 described above. U(0) was a reference sample without any limiting members. U(1) was a complete embodiment of S1(1), including the material composition and the characteristics of the LVT strips, except that the LVT strips were 15 mm wide and 1.3 mm high, and the base matrix strips were 15 mm wide and 1.5 mm high. U(2) was a complete embodiment of U(1), except that it instead had two nitrile rubber (NBR) strings with a hardness (Shore A) of 70 and a diameter of 1.6 mm as limiting members. The strings extended adjacent to each other and were sandwiched between the base matrix strips.

[0121] Figure 6f shows the results of instantaneous pressurization of sample U(j) to assess its compressive function. To obtain more accurate measurement results, the degree of compressibility was determined from a sample in a pre-compressed state obtained by applying a load of 5N with a pressure plate. In addition, a force that continuously increases from the pre-applied load up to 9.5kN was applied at a rate of 0.1mm / min. Compared with the reference sample U(0), it can be seen that the compression of samples U(1) and U(2) was more limited. In particular, when a pressure P of 1.90MPa was applied, U(1) and U(2) were compressed to approximately 0.7mm and approximately 0.2mm, respectively.

[0122] The disclosure has been described primarily as described above, with reference to a small number of embodiments. However, other embodiments not described above are similarly conceivable within the scope of the disclosure, as will be readily apparent to those skilled in the art. For example, in any embodiment of this specification, the underlayment element may optionally further comprise a thin foil or film, for example, PE, or be metallized and attached to the substrate matrix by lamination or other means. Such foil or film, for example, with a thickness of 0.01 to 0.05 mm or 0.20 mm, can additionally provide a water vapor barrier and / or gas barrier to the underlayment element. It should be emphasized that when T0 is 0.4 to 3.0 mm, for example 1.0 to 2.5 mm, embodiments in which the limiting member 3 in Figures 1a to 1g, 2a to 2f, 3a to 3d, 4a to 4g and 5a to 5e includes a cork component of 0.25 to 3.0 mm in size, for example 0.25 to 0.40 mm, or consists entirely of such cork component, are included in the disclosure. Embodiments in which the first material is not foamed are also included in this disclosure.

[0123] Embodiment Further aspects of the disclosure are provided below. Embodiments, examples, etc. of these embodiments are largely similar to the embodiments, examples, etc. described above and are therefore referenced in the detailed description above.

[0124] Item 1 An underlay element (1) configured to be placed between a flooring board (10) and a subfloor (12), The aforementioned underlay element comprises a base material matrix (2) and a plurality of limiting members (3) in which at least a portion is embedded in the base material matrix. The substrate matrix (2) has a first material, The first material is compressible and preferably foamed, The limiting member (3) has a second material, The size of each of the limiting members in at least one direction is greater than 0.25 mm, An underlay element in which compression is restricted by the limiting member (3) in at least a part of the underlay element (1), such as the entire underlay element. Item 2 An underlay element as described in item 1, wherein the compressibility when a pressure (P) of 1.90 MPa is applied is 0.60 mm or less, preferably 0.30 mm or less. Item 3 The underlay element according to item 1 or 2, wherein the thickness (T0) of the underlay element is 0.4 to 3.0 mm. Item 4 An underlay element according to any of the above items, wherein the size of the limiting member in at least one direction is greater than 1.00 mm. Item 5 An underlay element according to any of the above items, wherein the size of the limiting member in two or three orthogonal directions is greater than 0.25 mm, for example, greater than 1.00 mm. Item 6 The underlay element described in any of the above items, wherein the restricting member (3) has substantially the same size and / or shape. Item 7 The underlay element according to any of the above items, wherein the limiting member (3) has various sizes and / or shapes. Item 8 The underlay element according to any of the above items, wherein the limiting member (3) has particles (3a) and / or elongated pieces (3b). Item 9 An underlay element according to any of the above items, wherein the density of the second material is greater than the density of the first material. Item 10 The density of the first material is 700 kg / m³ 3 Less than 500 kg / m³ 3 An underlay element described in any of the above items that is less than or equal to. Item 11 An underlay element as described in any of the above items, wherein the elastic modulus of the second material is greater than that of the first material. Item 12 The underlay element according to any of the above items, wherein the first material includes a polymer material such as a thermoplastic material or a crosslinked thermoplastic material. Item 13 An underlay element according to any of the above items, wherein the second material is compressible. Item 14 An underlay element according to any of the above items, wherein the compressive strength of the second material is greater than the compressive strength of the first material. Item 15 The underlay element described in any of the above items, wherein the second material includes a polymer material such as a thermoplastic material or a crosslinked thermoplastic material and / or a mineral-based material. Item 16 An underlay element according to any of the above items, wherein the entire limiting member (3) is embedded in the base material matrix (2). Item 17 An underlay element according to any of the above items, wherein the base material matrix (2) has a cavity (5) and the limiting member (3) is provided inside the cavity. Item 18 The substrate matrix (2) comprises a plurality of substrates (2'), The plurality of limiting members (3) are formed separately, The underlay element according to any of the above items, wherein the underlay element (1) further comprises a first sheet (6a) and a second sheet (6b) that surround at least a portion of the base material and the limiting member. Item 19 An underlay element according to any of the above items, wherein the first material comprises at least one filler, preferably an organic filler and / or an inorganic filler. Item 20 It is configured to be installed on the base floor (12), A laminated flooring material (20) comprising a flooring board (10), preferably at least one floor panel (11), and an underlayment element (1) as described in any of items 1 to 18 above. Item 21 The flooring board (10) comprises a first floor panel (11) and a second floor panel (11'), The laminated flooring material according to item 20, wherein the underlayment element (1) is provided along at least the edges (11a; 11a') of the joints of the first floor panel and the second floor panel. Item 22 The laminated flooring material according to item 20 or 21, wherein the underlayment element (1) is attached to the flooring board (20) with adhesive or the like.

Claims

1. An underlay element (1) configured to be provided between a flooring plank (10) and a subfloor (12), comprising: The underlay element comprises a substrate matrix (2) and a plurality of restricting members (3) at least partially embedded in the substrate matrix; The substrate matrix (2) has a first material comprising a polymeric material; the first material is foamed; the first material is compressible; The density of the first material is 700 kg / m ３ is less than The restricting member (3) has a second material, The size of each of the restricting members in two or three orthogonal directions is greater than 0.25 mm; one of said directions is parallel to the thickness direction (TD) of said underlay element (1); An underlay element, configured such that compression is limited by the limiting member (3) in at least a portion of the underlay element (1), such as the entire underlay element.

2. 2. An underlay element according to claim 1, which has a compression degree of less than or equal to 0.60 mm, preferably less than or equal to 0.30 mm, when subjected to a pressure (P) of 1.90 MPa.

3. 3. An underlay element according to claim 1 or 2, wherein the thickness (T0) of the underlay element is between 0.4 and 3.0 mm.

4. An underlay element according to any one of claims 1 to 3, wherein the limiting member has a size in at least one direction greater than 1.00 mm.

5. An underlay element according to any one of the preceding claims, wherein said limiting members (3) have approximately the same size and / or shape.

6. An underlay element according to any one of the preceding claims, wherein the limiting members (3) have different sizes and / or shapes.

7. The underlay element of any one of claims 1 to 6, wherein the first material comprises a thermoplastic material or a crosslinked thermoplastic material.

8. An underlay element according to any one of the preceding claims, wherein the second material comprises a polymeric material, such as a thermoplastic or crosslinked thermoplastic material, and / or a mineral-based material.

9. An underlay element according to any one of the preceding claims, wherein the limiting member (3) is entirely embedded in the substrate matrix (2).

10. An underlay element according to any one of the preceding claims, wherein the substrate matrix (2) has a cavity (5) and the limiting member (3) is arranged in the cavity.

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