Floor Underlayment

Abstract

A method of installing a laminate wood floor over a subflooring is provided. The method includes a layered composition including a foam sheet and a melted portion, the melted portion being a surface polymer layer that provides a smooth surface. The foam sheet being a polymer that provides cushioning, the foam sheet and the melted portion being formed of the same material. The method includes placing the layered melted portion-foam composition over the subflooring. The method further includes laying the laminate wood floor over the layered melted portion-foam composition.

What is claimed is: 
     
         1 . A method of forming a floor underlayment for placement between a laminate wood floor and a subflooring, the method comprising:
 forming a foam sheet from a polymer; and   heating at least one surface of the foam sheet to form a melted portion that is integrally formed with the foam sheet.   
     
     
         2 . The method of  claim 1  further comprising forming the foam sheet by extruding the foam sheet. 
     
     
         3 . The method of  claim 2  further comprising heating the at least one surface of the foam sheet to form the melted portion after extruding the foam sheet. 
     
     
         4 . The method of  claim 3  further comprising heating the at least one surface of the foam sheet until the melted portion of the foam sheet reaches a molten or semi-molten state. 
     
     
         5 . The method of  claim 3  further comprising heating the at least one surface of the foam sheet using at least one heated roller. 
     
     
         6 . The method of  claim 3  further comprising heating the at least one surface of the foam sheet using at least one laser diode. 
     
     
         7 . The method of  claim 1  wherein the at least one surface of the foam sheet includes a bottom surface of the foam sheet. 
     
     
         8 . The method of  claim 1  wherein the at least one surface of the foam sheet includes top and bottom surfaces of the foam sheet. 
     
     
         9 . The method of  claim 1  further comprising coupling a polymer film to the melted portion so that the polymer film extends beyond one side of the foam sheet. 
     
     
         10 . A method of forming a floor underlayment for placement between a laminate wood floor and a subflooring, the method comprising:
 forming a foam sheet from a polymer; and   cooling at least one surface of the foam sheet to form a vapor barrier portion that is integrally formed with the foam sheet.   
     
     
         11 . The method of  claim 10  further comprising forming the foam sheet by extruding the foam sheet. 
     
     
         12 . The method of  claim 11  further comprising cooling the at least one surface of the foam sheet to form the vapor barrier portion after extruding the foam sheet. 
     
     
         13 . The method of  claim 12  further comprising cooling the at least one surface of the foam sheet to form the vapor barrier portion while the foam sheet is in a molten state as a result of extruding the foam sheet. 
     
     
         14 . The method of  claim 12  further comprising cooling the at least one surface of the foam sheet using at least one chill roll. 
     
     
         15 . A floor underlayment for placement between a laminate wood floor and a subflooring, the floor underlayment comprising:
 a foam sheet made from a polymer and configured to provide cushioning; and   a melted portion integrally formed with the foam sheet and configured to act as a vapor barrier.   
     
     
         16 . The floor underlayment of  claim 15  further comprising a polymer film coupled to the melted portion and extending beyond one side of the foam sheet. 
     
     
         17 . The floor underlayment of  claim 15 , wherein the foam sheet is made from a low-density polyethylene. 
     
     
         18 . The floor underlayment of  claim 15 , wherein the foam sheet has a thickness between about 0.03 inches and about 0.1 inches. 
     
     
         19 . The floor underlayment of  claim 15 , wherein the melted portion has a thickness between about 1 millimeters and about 10 millimeters. 
     
     
         20 . The floor underlayment of  claim 15 , wherein the foam sheet has a density between about 1 pounds per cubic foot and about 6 pounds per cubic foot.