Recycled energy absorbing underlayment and moisture barrier for hard flooring system

Abstract

A flooring underlayment comprising a plurality of recycled fibers formed into a nonwoven fiber batt, and a resin intermixed with the recycled fibers in the nonwoven fiber batt, the resin bonding the recycled fibers together. The invention includes a flooring underlayment comprising a plurality of recycled fibers formed into a nonwoven fiber batt, wherein the nonwoven fiber batt is formed using a method selected from the group comprising resin bonding, thermal bonding, mechanical bonding, and combinations thereof. The invention includes a nonwoven fiber batt comprising a blend of recycled fibers and binder fibers formed into a nonwoven fiber batt, and a resin intermixed with the recycled fibers and the binder fibers in the nonwoven fiber batt, wherein the resin and the binder fibers bond the recycled fibers and the binder fibers in the nonwoven fiber batt together.

1 . A flooring underlayment comprising: 
 a plurality of recycled fibers formed into a nonwoven fiber batt; and    a resin intermixed with the recycled fibers in the nonwoven fiber batt, the resin bonding the recycled fibers together.    
   
   
       2 . The flooring underlayment of  claim 1  wherein the recycled fibers are shoddy fibers.  
   
   
       3 . The flooring underlayment of  claim 1:   wherein the flooring underlayment comprises an upper surface and a lower surface; and    wherein the flooring underlayment further comprises a moisture barrier attached to the upper surface or the lower surface of the nonwoven fiber batt.    
   
   
       4 . The flooring underlayment of  claim 3  wherein the moisture barrier comprises: a flap that extends past the edge of the nonwoven fiber batt.  
   
   
       5 . The flooring underlayment of  claim 3  wherein the moisture barrier is closed cell foam.  
   
   
       6 . The flooring underlayment of  claim 3  wherein the nonwoven fiber batt has a ratio of basis weight to thickness greater than about 2 to 1.  
   
   
       7 . The flooring underlayment of  claim 3  wherein the moisture barrier is attached to the nonwoven fiber batt without an adhesive.  
   
   
       8 . The flooring underlayment of  claim 3  wherein the nonwoven fiber batt has a density at most about 10 pounds per cubic foot.  
   
   
       9 . The flooring underlayment of  claim 3  wherein the flooring underlayment is attached to a flooring layer.  
   
   
       10 . A flooring system comprising: 
 a subfloor;    a flooring layer positioned above the subfloor; and    the flooring underlayment of  claim 1  positioned between the subfloor and the flooring layer.    
   
   
       11 . A flooring underlayment comprising a plurality of recycled fibers formed into a nonwoven fiber batt, wherein the nonwoven fiber batt is formed using a method selected from the group comprising: resin bonding, thermal bonding, mechanical bonding, and combinations thereof.  
   
   
       12 . The flooring underlayment of  claim 11:   wherein the flooring underlayment comprises an upper surface and a lower surface; and    wherein the flooring underlayment further comprises a moisture barrier attached to the upper surface or the lower surface of the nonwoven fiber batt.    
   
   
       13 . The flooring underlayment of  claim 12  wherein the nonwoven fiber batt has a density at most about 10 pounds per cubic foot.  
   
   
       14 . The flooring underlayment of  claim 13  wherein the recycled fibers are shoddy fibers.  
   
   
       15 . A flooring system comprising: 
 a subfloor;    a flooring layer positioned above the subfloor; and    the flooring underlayment of  claim 14  positioned between the subfloor and the flooring layer.    
   
   
       16 . A nonwoven fiber batt comprising: 
 a blend of recycled fibers and binder fibers formed into a nonwoven fiber batt; and    a resin intermixed with the recycled fibers and the binder fibers in the nonwoven fiber batt;    wherein the resin and the binder fibers bond the recycled fibers and the binder fibers in the nonwoven fiber batt together.    
   
   
       17 . The nonwoven fiber batt of  claim 16:   wherein the nonwoven fiber batt comprises an upper surface and a lower surface; and    wherein the nonwoven fiber batt further comprises a moisture barrier attached to the upper surface or the lower surface of the nonwoven fiber batt.    
   
   
       18 . The nonwoven fiber batt of  claim 16  wherein the nonwoven fiber batt has a density at most about 10 pounds per cubic foot.  
   
   
       19 . The nonwoven fiber batt of  claim 16  wherein the binder fibers have a weight per unit length at most about 5 denier.  
   
   
       20 . A flooring system comprising: 
 a subfloor;    a flooring layer positioned above the subfloor; and    the nonwoven fiber batt of  claim 16  positioned between the subfloor and the flooring layer.