SELF-ADHESIVE MEMBRANE

Abstract

A decoupling assembly for positioning between an underlying surface and a flooring material, the decoupling assembly including a decoupling membrane having a base panel having opposing upper and lower surfaces and a plurality of projections extending from the lower surface for contacting an underlying surface and supporting the base panel above the underlying surface. Each projection includes a bottom surface. The assembly further includes a plurality of adhesive fasteners, each adhesive fastener having an inner surface fixed to the bottom surface of a respective one of the plurality of projections, and an adhesive outer surface opposite the inner surface. The assembly further includes a plurality of release members, each release member covering the outer surface of one respective adhesive fastener, each release member being removable to expose the outer surface of the respective adhesive fastener for adhering the decoupling membrane to the underlying surface.

Description

FIELD

The present subject matter of the teachings described herein relates generally to membranes for covering an underlying surface, such as a floor, wall and/or other partition, to provide a mounting surface for a covering material.

BACKGROUND

U.S. Pat. No. 8,112,827 (DeGooyer et al.) discloses a shower drain adapter system configured to allow use of a bondable waterproof membrane with a shower pan drain system comprises a drain body and an integrated bonding flange extending upwardly from the drain body. The integrated bonding flange is operable to be sealably attached to a bondable waterproof membrane to provide a substantially waterproof seal between the membrane and the adapter. A lower mating flange is separable from the drain body, the lower mating flange operable to mate with a component of a shower pan drain system installable on a waste pipe. The lower mating flange includes a substantially rigid frame; and a pliable gasket disposed at least partially about the frame, the pliable gasket having an inner diameter sized to correspond to an outer diameter of a portion of the drain body.

U.S. Pat. No. 4,917,933 (Schluter) discloses a plastic sheet which is used as a subcarrier for insulating linings of building surfaces. The sheet is formed by parallel, alternating, dovetail-shaped channels and grooves. A coarse-meshed lattice matting, having filaments, is glued or partially fused to the backside of the plastic sheet and serves to anchor the sheet to the underlying foundation. This lattice matting stretches over the entire backside or inner surface of the sheet. The webs of the plastic sheet are expandable and can compensate for stresses occurring between the underlying foundation and the external facing material such as ceramic tile.

SUMMARY

This summary is intended to introduce the reader to the more detailed description that follows and not to limit or define any claimed or as yet unclaimed invention. One or more inventions may reside in any combination or sub-combination of the elements or process steps disclosed in any part of this document including its claims and figures.

According to one broad aspect of the teachings disclosed herein, a decoupling assembly for positioning between an underlying surface and a flooring material may include a decoupling membrane. The decoupling membrane may have a base panel having opposing upper and lower surfaces and a plurality of projections extending from the lower surface for contacting an underlying surface and supporting the base panel above the underlying surface. Each projection may have a bottom surface. The assembly may also include a plurality of adhesive fasteners. Each adhesive fastener may have an inner surface fixed to the bottom surface of a respective one of the plurality of projections, and an adhesive outer surface opposite the inner surface. A plurality of release members may be provided. Each release member may cover the outer surface of one respective adhesive fastener. Each release member may be removable to expose the outer surface of the respective adhesive fastener for adhering the decoupling membrane to the underlying surface.

The combined area of the outer surfaces of the adhesive fasteners measured in a first plane containing the outer surfaces of the adhesive fasteners may be between about 35% and about 65% of an area of the base panel projected in the first plane.

At least some of the release members may be removable independently from the other release members.

At least some of the release members may be joined together to form a release sheet. The release sheet may be removable in a single piece.

At least one adhesive fastener may be fixed to the bottom surface of each projection.

Adhesive fasteners may be provided on the bottom surfaces of only a portion of the plurality of projections.

Adhesive fasteners may be provided on the bottom surfaces of between about 40% and 95% of the plurality of projections.

The adhesive fastener may be a hot melt adhesive, and/or a pressure sensitive adhesive. In some examples, the adhesive may be a low viscosity hot melt named HL-8128X, made available by H.B. Fuller Company.

The base panel and release members may be rollable while coupled together to configure the decoupling assembly in a rolled configuration that includes radially alternating layers of the base panel, the adhesive fastener and the release member. In the rolled configuration at least one release member may be positioned radially between the outer surface of adhesive fastener on the bottom surface of one projection and at least a portion of the upper surface of the base panel.

Each projection may include a root portion adjacent the lower surface of the base panel, and a tip portion comprising the bottom surface and spaced apart from the lower surface of the base panel. Each projection may generally taper laterally inwardly from the tip portion to the root portion.

Projection may include at least one sidewall extending between the root portion and the tip portion. The at least one sidewall may be inclined at a first angle relative to a vertical plane. The first angle is between about 0 and about 15 degrees.

The at least one sidewall may include a first sidewall and a second sidewall opposite the first sidewall. The first and second sidewalls may be non-parallel and may converge toward the root portion.

Each projection may include a root portion adjacent the lower surface of the base panel, and a tip portion comprising the bottom surface and spaced apart from the lower surface of the base panel. Each projection may generally taper laterally inwardly from the root portion to the tip portion.

Each projection extends between a root portion adjacent the lower surface of the base panel, and a tip portion spaced apart from the root portion and comprising the bottom surface. The bottom surface may be spaced apart from the lower surface by a projection height that is between about 1 mm and about 5 mm.

The decoupling membrane may be formed from a resilient plastic material and may be liquid impermeable.

According to another broad aspect of the teachings described herein, a method of installing a decoupling membrane onto an underlying surface may include the step of providing a decoupling membrane having a base panel having opposing upper and lower surfaces and a plurality of projections extending from the lower surface. Each projection may include a bottom surface. A plurality of adhesive fasteners may be provided. Each adhesive fastener may include an inner surface fixed to the bottom surface of one projection and an adhesive outer surface. A plurality of release members may be provided and each release member may cover one adhesive outer surface. The method may also include the steps of removing the release members to expose the adhesive fasteners; positioning the decoupling membrane over the underlying surface; and bonding the exposed adhesive fasteners directly to the underlying surface to adhere the decoupling membrane to the underlying surface.

The step of bonding the exposed adhesive outer surfaces to the underlying surface may be completed in the absence of an intervening bonding agent.

The release members may be individually removable or may be removed in unison.

According to another broad aspect of the teachings described herein, a method of producing a decoupling assembly for covering an underlying surface may include the steps of:

a) forming a decoupling membrane having base panel having opposing upper and lower surfaces and a plurality of projections extending from the lower surface, each projection comprising a bottom surface;

b) fixing an adhesive fastener to bottom surface of at least some of the projections, each adhesive fastener comprising an inner surface fixed to the bottom surface of the respective projection and an adhesive outer surface; and

c) covering each adhesive outer surface with a removable release member.

The method may also include the step of rolling the base panel and release members together to provide a generally cylindrical rolled member, wherein at least one removable release member is positioned radially intermediate one adhesive fastener and a portion of the upper surface.

DRAWINGS

The drawings included herewith are for illustrating various examples of articles, methods, and apparatuses of the teaching of the present specification and are not intended to limit the scope of what is taught in any way.

In the drawings:

FIG. 1 is a perspective view of a portion of a decoupling membrane;

FIG. 2 is a bottom view of the portion of the decoupling membrane of FIG. 1;

FIG. 3 is an end view of a decoupling membrane;

FIG. 4 is a perspective view of the decoupling membrane of FIG. 3 in a rolled configuration;

FIG. 5 is an enlarged view of a portion of the decoupling membrane of FIG. 4;

FIG. 6 is an enlarged view of a portion of the decoupling membrane of FIG. 3;

FIG. 7 is a side view of a flooring system including a decoupling membrane;

FIG. 8 is a sectional view of a portion of the flooring system of FIG. 7, taken along line 8-8;

FIG. 9 is side view of another example of a decoupling membrane;

FIG. 10 is a bottom view of a portion of the decoupling membrane of FIG. 9;

FIG. 11 is a side view of a portion of another example of a decoupling membrane;

FIG. 12 is a block diagram of a method of installing a decoupling membrane for over an underlying surface; and

FIG. 13 is a block diagram of method of producing a decoupling membrane.

DETAILED DESCRIPTION

Various apparatuses or processes will be described below to provide an example of an embodiment of each claimed invention. No embodiment described below limits any claimed invention and any claimed invention may cover processes or apparatuses that differ from those described below. The claimed inventions are not limited to apparatuses or processes having all of the features of any one apparatus or process described below or to features common to multiple or all of the apparatuses described below. It is possible that an apparatus or process described below is not an embodiment of any claimed invention. Any invention disclosed in an apparatus or process described below that is not claimed in this document may be the subject matter of another protective instrument, for example, a continuing patent application, and the applicants, inventors or owners do not intend to abandon, disclaim or dedicate to the public any such invention by its disclosure in this document.

Decoupling membranes may be used when installing covering material, including for example ceramic tiles, stone tiles and other such flooring, over an underlying surface. The underlying surface may be a subfloor, wall, stair case or any other type of partition or surface. The underlying surface may be formed from any suitable material, including, for example wood, concrete, particle board, oriented strand board (OSB) drywall, and sheetrock.

The decoupling membrane can be positioned between the underlying surface and the covering material to help decouple or isolate the covering material from the underlying surface. To provide an assembled covering system, the decoupling membrane is bonded to the underlying surface, and then the floor covering material is bonded to an upper surface of the decoupling membrane. The decoupling membrane may be somewhat flexible and/or resilient to help isolate the covering material from the underlying surface.

For example, the decoupling membrane may help prevent stress transfer from the underlying surface to the covering material. Preventing stress transfer may help prevent covering materials, such as tiles, from cracking, loosening or otherwise being damaged as a result of movement of the underlying surface.

Optionally, the decoupling membrane may be liquid impermeable and/or vapour impermeable. Providing an impermeable membrane may help prevent the transfer of water or moisture between the underlying surface and the floor covering.

Referring to FIG. 1, an example of a decoupling membrane 100 includes a base panel 102 having opposing upper and lower surfaces 104 and 106 and a plurality of projections 108 extending from the lower surface 106 (see also FIG. 3). The projections 108 are for contacting an underlying surface 110 (FIG. 7), such as a subfloor, and supporting the lower surface 106 above the underlying surface 110.

Referring to FIG. 7, when installed as part of a flooring system, the decoupling membrane 100 is positioned between the underlying surface 110 (e.g. a subfloor) and the floor covering material 112 (e.g. tiles). In the illustrated example, the decoupling membrane 100 is adhered to the underlying surface 110 via the adhesive fasteners 114 on the bottoms of the projections 108, and the upper surface 104 (and interiors of the projections 108) is coated with a conventional bonding compound 116, such as thin-set mortar. The floor covering tiles 112 are place on top of the layer of thin-set 116, and joints 118 between the tiles 112 are filled with mortar 120.

Referring to FIG. 3, the base panel 102 and projections 108 may be formed from any suitable material, including for example, polypropylene, plastic and rubber. Optionally the base panel 102 and projections 108 can be formed to be generally vapour and/or liquid impermeable. Alternatively, the base panel 102 and/or the projections 108 may be vapor and/or liquid permeable. In the illustrated example, the base panel 102 and projections 108 are integrally formed together, such that they are of integral, one-piece construction. Alternatively, the projections 108 and base panel 102 may be formed from separate members that are joined or coupled together.

The material used to form the base panel and/or projections may be resilient, elastic and be selected to have the desired mechanical properties (strength, etc.) to withstand the expected loading to which the decoupling membrane may be subjected.

Referring to FIG. 6, each projection 108 includes a bottom surface 122 for engaging the underlying surface 110. Referring also to FIG. 3, adhesive fasteners 114 are fixed to the bottom surfaces 122 of the projections 108. Each adhesive fastener includes an inner surface 115 that is bonded to the bottom surface 122 of a respective projection 108, and an opposed outer surface 117.

The adhesive fasteners 114 may be any suitable type of fastening member that is operable to bond the bottom surfaces of the projections to the underlying surface, including, for example, a layer or bead of chemical adhesive or glue. Examples of suitable adhesives include glues, contact cement, double-sided tape, or other adhesives. In the example illustrated, the adhesive fastener is a hot melt pressure sensitive adhesive made available by H.B. Fuller Company.

Optionally, the adhesive may be applied directly to the bottom surfaces 122 in any suitable manner (rolling, spraying, coating, etc.) so that when the adhesive dries an inner surface of the layer of adhesive is bonded to the bottom surface 122 and an opposing outer surface of the adhesive layer is exposed for bonding to the underlying surface. In this configuration the inner and outer surfaces of the layer of adhesive can provide the inner and outer surfaces 115 and 117, respectively. Alternatively, the adhesive fasteners may include a layer of adhesive that is carried on a suitable substrate. For example, the adhesive fastener 114 may include a substrate having a first surface coupled to the bottom surface 122 of a projection 108, and an opposed second surface that is coated with adhesive. The first surface can be coupled to the bottom surface 122 of the projections using any suitable mechanism, including an adhesive and a mechanical fastener. In this configuration, the inner surface of the adhesive layer would be bonded to the second surface of the substrate, and the outer surface of the adhesive layer would be exposed for bonding to the underlying surface. Accordingly, the outer surface 117 can be provided by the outer surface of the adhesive layer and the inner surface 115 can be provided by the substrate or fastening mechanism used to secured the substrate to the projection 108.

Optionally, each adhesive fastener 114 may cover only a portion of the bottom surface 122 of its corresponding projection 108, as shown for example in FIG. 2. Alternatively, substantially the entire bottom surfaces 122 of the projections 108 may be coated with a suitable adhesive, as shown in FIGS. 3 and 6.

Referring to FIG. 2, in the illustrated example, adhesive fasteners 114 are provided on all of the bottom surfaces 122, such that each projection 108 are individually adhered to the underlying surface 110. Alternatively, adhesive fasteners 114 may only be provided on some of the bottom surfaces 122, such that only some of the projections 108 are bonded to the underlying surface 110. For example, adhesive fasteners may be provided on the bottom surfaces of only a portion of the projections 108, and optionally may be provided on the bottom surfaces of between about 40% and about 95% of the projections 108 or may be provided on the bottom surfaces of between about 70% to about 90% of the projections.

In the illustrated example, the adhesive fasteners 114 on the bottoms 122 of the projections 108 are sticky at the time of manufacture, and remain sticky until bonded to the underlying surface 110. The adhesive fasteners do not need to be activated or otherwise treated to become sticky. Having a plurality of projections 108 provided with exposed, sticky adhesive fasteners may make it difficult to handle or transport the membrane.

Referring to FIG. 3, in the illustrated example, at least one release member 124 is provided to cover the adhesive outer surface 117 of each adhesive fastener 114, to prevent the adhesive outer surface 117 from being exposed during transport of the membrane 100. Each release member 124 includes an inner surface 126, facing the lower surface 106 and bonded to the adhesive fasteners 114, and an outer surface 128 opposite the inner surface 126.

When the decoupling membrane 100 is at its desired destination, for example at the location where it is intended to be installed, the release member 124 is removed to expose the adhesive fasteners 114. The exposed adhesive fasteners 114 can then be pressed against the underlying surface 110 to adhere the decoupling membrane 100 to the underlying surface 110.

Optionally, each release member 124 may be an individual or discrete member. In this configuration, the release members 124 may be independently removable. This may allow a user to expose some of the adhesive outer surfaces 117, while leaving others covered. This may facilitate a staged uncovering of the adhesive fasteners as the decoupling membrane is rolled out or installed. Alternatively, each release member 124 may be a portion of a larger release sheet, or other suitable member. In this configuration, the release members 124 are joined together and can be removed together. Optionally, the release sheet can be removable in a single piece, including all of the release members 124. Alternatively, portions or groups of the release members 124 may be joined together to form two or more release sheets. Each release sheet may be removable independently of the other release sheets, but may include multiple release members 124 which would be removed in unison.

The release members 124 may be formed from any suitable material that can be releasably bonded to the adhesive fasteners 114. Preferably, the release members 124 are formed from a material, or otherwise coated or treated, such that the bond strength between the adhesive fasteners 114 and the bottom surfaces 122 of the projections 108 is greater than the bond strength between the adhesive fasteners 114 and the release members 124. If the release members 124 are joined together to form one or more release sheets, the entire sheet may be formed from the release sheet material or coated/treated, or only portions of the sheet that form the release members 124 may be treated.

To install a conventional decoupling membrane, an underlying surface is first covered with an adhesive compound (e.g. thin set) and the membrane is then pressed onto the thin set. A second layer of adhesive compound is applied to the upper surface of the membrane to secure the covering material to the membrane. Providing a self-adhesive decoupling membrane 100, having one or more adhesive fasteners 114 positioned on the bottom surfaces 122 of the projections 108, may eliminate the need to use a separate bonding agent, such as thin-set mortars, chemical adhesives or other adhesive mortars, to fasten the decoupling membrane to the underlying surface. In the illustrated example, the adhesive fasteners 114 can be directly bonded to the underlying surface 110 (FIG. 7), without the need for a separate layer of adhesive compound between the membrane 100 and the underlying surface 110. This may help simplify the installation process. Conventional adhesive compounds can then be applied to the upper surface 104 of the decoupling membrane 100 to secure the floor covering material, for example tiles 112, to the membrane 100.

Using a conventional membrane, substantially all of the underlying surface is coated with thin-set prior to positioning the membrane. As the membrane includes a plurality of projections spacing its lower surface from the underlying surface, typically only the projections actually contact the thin-set and there is no direct contact between the thin-set and the lower surface of the membrane. In conventional membrane installations, the thin-set located between the projections may not actually bond to anything, and may be wasted. That is, the area covered by the thin-set is greater than the total area of the bottoms of the projections. In contrast, providing adhesive fasteners on the bottoms of the projections may allow the total area covered by adhesive to generally match the total area of the bottoms of the projections (which may be between about 35% and about 65% of the projected area of the base panel), which may eliminate the need to spread unused adhesive compound located between the projections and help reduce the total amount of adhesive material used to secure the decoupling membrane in place. Reducing the amount of adhesive used may help reduce the cost of installing the decoupling membrane.

Referring to FIG. 6, each projection may extend between a root portion 130, adjacent the lower surface 106 of the base panel 102, and a tip portion 132, comprising the bottom surface 122. The distance 134 between the bottom surface and the lower surface defines a projection height. The projection height 134 may be between about 1 mm and about 5 mm, and may be about 3 mm.

Each projection 108 may include one or more sidewalls 136 extending between the bottom surface 122 and the lower surface 106. Optionally, at least some of the projections 108 can generally taper from the tip portion 132 to the root portion 130. In this configuration the root width 138 is less than the tip width 140. In the illustrated example, the tip width 140 may be between about 2 mm and about 30 mm or greater than 30 mm, and the root width 138 may be between about 2 mm and about 30 mm or greater than 30 mm.

In the illustrated example, the sidewalls 136 of the projections 108 are inclined at an angle 142 relative to the vertical direction. The angle 142 may be between 0 and about 15 degrees, and may be between 0 and about 5 degrees. In this configuration, the interior of each projection defines overhang regions 144, illustrated as the shaded area in FIG. 8. Providing such overhang regions 144 may help retain the adhesive compound 116 applied to the top 102 of the decoupling membrane 100 within the interior 146 of the projection 108. This may help secure the adhesive compound 116, and covering material 112 mounted thereto, to the decoupling membrane 100.

Alternatively, instead of tapering from tip to root (i.e. narrowing from a greater width at the tip to a narrower width of the root), each projection may be of a different, suitable shape and may, for example, have vertical sidewalls (i.e. no taper where the tip width 140 equals the root width 138) or may generally taper from the root portion to the tip portion (i.e. the root width 138 is less than the tip width 140). While illustrated as generally square or rectangular in cross-sectional shape, each projection may define a generally circular cross-sectional shape (i.e. may be cylindrical or frusto-conical) or any other suitable shape. Optionally, the projections need not be of the same cross-sectional shape, and a single base panel may include projections having two or more different cross-sectional shapes.

The strength of the connection between decoupling membrane 100 and the underlying surface 110 may be based on the strength of the adhesive fasteners 114 and the surface area of the bottom surfaces 122 of the projections 108, or a combination thereof. Optionally, the projections 108 can be sized such that the combined area of the bottom surfaces 122 measured in a first plane 150 (FIG. 3) containing the bottom surfaces 122 may be between about 35% and about 65% of an area of the base panel 102 projected in the first plane 150.

Optionally, the decoupling membrane 100 may be rolled up. This may make it easier to store and/or transport the decoupling membrane 100. Referring to FIG. 4, in the illustrated example the base panel 102 and release members 124 may be rolled while coupled together to provide a generally cylindrical rolled member 152. In this rolled configuration, the rolled decoupling membrane 100 includes radially alternating layers of the base panel 102, the adhesive fastener 114 and the release member 124.

To help prevent the decoupling membrane from sticking to itself when rolled, the release members 124 covering the adhesive fasteners 114 are positioned radially between the adhesive fasteners 114 and an overlying portion of the base panel 102 (for example the upper surface 104) that is opposing, and optionally pressed against, the adhesive fastener 114 in the rolled configuration. Referring to FIG. 5, in the illustrated example a release member 124 is positioned radially between each adhesive fastener 114 and a portion of the upper surface 104 of the base panel 102.

Optionally, the release members 124 used to cover the adhesive fasteners may comprise a plurality of separate release members, or at least some of the release members may be joined together to form one or more release sheets. Referring to FIG. 3, in the illustrated example all of the release members 124 are joined together to form one continuous release sheet. Providing a continuous release sheet may make it easier to apply the release members over the adhesive fasteners 114, and may allow all of the release members 124 to be removed together. In this configuration the release sheet may be removable as a single piece.

Referring to FIG. 9, another example of a self-adhesive decoupling membrane 200 includes a base panel having a plurality of projections. The decoupling membrane 200 is generally analogous to the decoupling membrane 100, and like features are represented using like reference characters indexed by 100.

In this example, adhesive fasteners 214 are only provided on the bottom surfaces 222 of some of the projections 208. Each adhesive fastener 214 is covered by a separate release member 224, which are not connected to form a single release sheet.

Referring to FIG. 10, another example of a self-adhesive decoupling membrane 300 includes a base panel 302 having a plurality of projections 308. The decoupling membrane 300 is generally analogous to the decoupling membrane 100, and like features are represented using like reference characters indexed by 200.

In this example, adhesive fasteners 314 are only provided on every other projection 108 in each row and column of projections. While only some of the projections 208 are provided with adhesive fasteners 214, the release members 224 covering each adhesive fastener 214 are connected to form a single release sheet, the perimeter of which is shown using dashed lines for clarity.

Referring to FIG. 11, another example of a self-adhesive decoupling membrane 400 includes a base panel 402 having a plurality of projections 408. The decoupling membrane 400 is generally analogous to the decoupling membrane 100, and like features are represented using like reference characters indexed by 300.

In this example, the projections 408 extending from the lower surface 406 of the base panel 402 are configured such that they taper from root 430 to tip 432, and that the root width 438 is greater than the tip width 440.

Referring to FIG. 12 a method 1200 of installing a decoupling membrane for over an underlying surface may include, at step 1202 providing a self-adhesive decoupling membrane having a base panel having opposing upper and lower surfaces and a plurality of projections extending from the lower surface for contacting the underlying surface and supporting the lower surface above the underlying surface. Each projection may include a bottom surface for engaging the underlying surface. An adhesive fastener may be fixed to at least some of the bottom surfaces, and a release member may cover each adhesive fastener

At step 1204, the method may include removing the release members to expose the adhesive fasteners and, at step 1206 positioning the decoupling membrane over the underlying surface. Step 1208 includes bonding the exposed adhesive fasteners directly to the underlying surface to adhere the decoupling membrane to the underlying surface. Optionally, step 1208 may include bonding the adhesive fasteners directly to the underlying surface and can be completed in the absence of an intervening layer of bonding agent or compound.

Referring to FIG. 13, a method 1300 of producing a self-adhesive decoupling membrane for covering an underlying surface may include, at step 1302, forming a base panel having opposing upper and lower surfaces and a plurality of projections extending from the lower surface for contacting an underlying surface and supporting the lower surface above the underlying surface. Each projection may have a bottom surface. At step 1304, an adhesive fastener is fixed to at least some of the bottom surfaces. This step may include spraying, spreading or otherwise coating the bottom surfaces with a chemical adhesive, and/or may include placing one or more discrete chemical fasteners (e.g. double side tape, etc.) on each bottom surface.

At step 1306, each adhesive fastener is covered with a removable release member.

Optionally, the method may also include the step 1308 of rolling the base panel and release members together to provide a generally cylindrical rolled member, in which at least one removable release member is positioned radially intermediate one adhesive fastener and a portion of the upper surface.

Optionally, any of the features of any of these examples may be used alone or in combination or sub-combination with each other. What has been described above has been intended to be illustrative of the invention and non-limiting and it will be understood by persons skilled in the art that other variants and modifications may be made without departing from the scope of the invention as defined in the claims appended hereto.

Claims

1. A decoupling assembly for positioning between an underlying surface and a flooring material, the decoupling assembly comprising: a) a decoupling membrane comprising a base panel having opposing upper and lower surfaces and a plurality of projections extending from the lower surface for contacting an underlying surface and supporting the base panel above the underlying surface, each projection comprising a bottom surface;b) a plurality of adhesive fasteners, each adhesive fastener comprising an inner surface fixed to the bottom surface of a respective one of the plurality of projections, and an adhesive outer surface opposite the inner surface; andc) a plurality of release members, each release member covering the outer surface of one respective adhesive fastener, each release member being removable to expose the outer surface of the respective adhesive fastener for adhering the decoupling membrane to the underlying surface.

2. The decoupling assembly of claim 1, wherein the combined area of the outer surfaces of the adhesive fasteners measured in a first plane containing the outer surfaces of the adhesive fasteners is between about 35% and about 65% of an area of the base panel projected in the first plane.

3. The decoupling assembly of claim 1, wherein at least some of the release members are removable independently from others of the release members.

4. The decoupling assembly of claim 1, wherein at least some of the release members are joined together to form a release sheet, the release sheet being removable in a single piece.

5. The decoupling assembly of claim 1, wherein at least one adhesive fastener is fixed to the bottom surface of each projection.

6. The decoupling assembly of claim 1, wherein adhesive fasteners are fixed on the bottom surfaces of only a portion of the plurality of projections.

7. The decoupling assembly of claim 6, wherein adhesive fasteners are fixed on the bottom surfaces of between about 40% and 95% of the plurality of projections.

8. The decoupling assembly of claim 1, wherein the adhesive fastener comprises a hot melt pressure sensitive adhesive.

9. The decoupling assembly of claim 1, wherein the base panel and release members are rollable while coupled together to configure the decoupling assembly in a rolled configuration that includes radially alternating layers of the base panel, the adhesive fastener and the release member.

10. The decoupling assembly of claim 9, wherein in the rolled configuration at least one release member is positioned radially between the outer surface of adhesive fastener on the bottom surface of one projection and at least a portion of the upper surface of the base panel.

11. The decoupling assembly of claim 1, wherein each projection comprises a root portion adjacent the lower surface of the base panel, and a tip portion comprising the bottom surface and spaced apart from the lower surface of the base panel, and wherein each projection generally tapers laterally inwardly from the tip portion to the root portion.

12. The decoupling assembly of claim 11, wherein each projection includes at least one sidewall extending between the root portion and the tip portion, and wherein the at least one sidewall is inclined at a first angle relative to a vertical plane.

13. The decoupling assembly of claim 12, wherein the at least one sidewall comprises a first sidewall and a second sidewall opposite the first sidewall, and wherein the first and second sidewalls are non-parallel and converge toward the root portion.

14. The decoupling assembly of claim 12, wherein the first angle is between about 0 and about 15 degrees.

15. The decoupling assembly of claim 1, wherein each projection comprises a root portion adjacent the lower surface of the base panel, and a tip portion comprising the bottom surface and spaced apart from the lower surface of the base panel, and wherein each projection generally tapers laterally inwardly from the root portion to the tip portion.

16. The decoupling assembly of claim 1, wherein each projection extends between a root portion adjacent the lower surface of the base panel, and a tip portion spaced apart from the root portion and comprising the bottom surface, and wherein the bottom surface is spaced apart from the lower surface by a projection height that is between about 1 mm and about 5 mm.

17. The decoupling assembly of claim 1, wherein the decoupling membrane is formed from a resilient plastic material.

18. The decoupling assembly of claim 1, wherein the decoupling membrane is liquid impermeable.

19. A method of installing a decoupling membrane onto an underlying surface, the method comprising the steps of: a) providing a decoupling membrane having a base panel having opposing upper and lower surfaces and a plurality of projections extending from the lower surface, each projection comprising a bottom surface, a plurality of adhesive fasteners, each adhesive fastener comprising an inner surface fixed to the bottom surface of one projection and an adhesive outer surface, and a plurality of release members, each release member covering one adhesive outer surface;b) removing the release members to expose the adhesive outer surfaces;c) positioning the decoupling membrane over the underlying surface; andd) bonding the exposed adhesive outer surfaces directly to the underlying surface to adhere the decoupling membrane to the underlying surface.

20. The method of claim 19, wherein step d) is completed in the absence of an intervening bonding agent.

21. The method of claim 19, wherein the release members are individually removable.

22. The method of claim 19, wherein step b) includes removing all of the release members in unison.

23. A method of producing a decoupling assembly for covering an underlying surface, the method comprising the steps of: a) forming a decoupling membrane having base panel having opposing upper and lower surfaces and a plurality of projections extending from the lower surface, each projection comprising a bottom surface;b) fixing an adhesive fastener to bottom surface of at least some of the projections, each adhesive fastener comprising an inner surface fixed to the bottom surface of the respective projection and an adhesive outer surface; andc) covering each adhesive outer surface with a removable release member.

24. The method of claim 23, further comprising the step of rolling the base panel and release members together to provide a generally cylindrical rolled member, wherein at least one removable release member is positioned radially intermediate one adhesive fastener and a portion of the upper surface.