AU2017100598A4 - Floor underlay with acoustic properties and use thereof - Google Patents

Abstract

A flooring underlay for use in flooring assemblies wherein the flooring underlay includes a top layer of material, an intermediate layer of material, and a bottom layer of material wherein the intermediate layer of material has a lesser density than the top and bottom layers of material.

Description

H:\mm\In terwoveti\NRPortbl\DCO.MMM4564829_L.d<ic-23/Oi/20.l7 2017100598 23 May 2017 - 1 -

FLOOR UNDERLAY WITH ACOUSTIC PROPERTIES AND USE THEREOF

Technical Field [0001] The present invention relates to a layered floor underlay, and use thereof, and in particular a layered floor underlay including multiple layers with differing densities.

[0002] Due to increases in housing density resulting from increased population combined with urbanisation, there is a desire to use building materials that provide significant sound attenuation to provide a better quality of life for residents.

[0003] The present invention seeks to provide a layered floor underlay, and use thereof that is inexpensive and which includes significant sound attenuation properties when used as part of a flooring assembly.

Summary of the Disclosure [0004] According to a first aspect, embodiments are disclosed of a flooring underlay for use in flooring assemblies wherein the flooring underlay includes a top layer of material, an intermediate layer of material, and a bottom layer of material wherein the intermediate layer of material has a lesser density than the top and bottom layers of material.

[0005] In one form the top layer of material is composed of heat sealed or woven polyester.

[0006] In one form the bottom layer of material is composed of heat sealed or woven polyester.

[0007] In one form the intermediate layer is composed of needle punched or felt polyester. H:\mm\InterwovenSNRPortfal\DCaMMM456482y_l.doc-23/05/2017 2017100598 23 May 2017 -2- [0008] In one form the thickness of the top layer of material is about 0.5 mm to about 5 mm. In another form, the thickness of the top layer of material is about I mm to about 3 mm.

[0009] In one form the thickness of the bottom layer of material is about 0.5 mm to about 5 mm. In another form the thickness of the bottom layer of material is about 1 mm to about 3 mm.

[0010] In one form the thickness of the intermediate layer is about 4 mm to about 12 mm. In another form the thickness of the intermediate layer is about 6 mm to about 10 mm.

[0011] In one form the density of the top layer of material is between about 60 to about 120 kg/m3. In another form the density of the top layer of material is between about 80 to about 100 kg/m3.

[0012] In one form the density of the bottom layer of material is between about 60 to about 120 kg/m3. In another form the density of the bottom layer of material is between about 80 to about 100 kg/m3.

[0013] In one form the density of the intermediate layer of material is between about 30 to about 60 kg/m3. In another form the density of the intermediate layer of material is between about 40 to about 50 kg/m3.

[0014] In one form the top layer of material is thermally bonded to the intermediate layer of material. In another alternative form the top layer of material is bonded to the intermediate layer of material by use of an adhesive.

[0015] In one form the bottom layer of material is thermally bonded to the intermediate layer of material. In another alternative form the bottom layer of material is H;\inm\I]iterwoveti\NRPoi'tbl\DCOMMM4564829_l.d<ic-23/Oi/20I7 2017100598 23 May 2017 -3- bonded to the intermediate layer of material by use of an adhesive. In one form the flooring underlay includes an additional layer composed of a metalised film, or foil that is bonded to an outside surface of either the top layer of material or the bottom layer of material. In one form the additional layer composed of a metalised film is bonded to an outside surface of the top layer of material.

[0016] In one form the thickness of the underlay measured from one outer planar surface to another outer planar surface is about 8 mm to about 16 mm. In another form the thickness of the underlay measured from one outer planar surface to another outer planar surface is about 10 mm to about 14 mm.

[0017] In one form the underlay is located between a substrate surface and a floor covering. In one form the substrate surface is selected from any one or a combination of the following: a concrete slab, a screed, fibre cement sheeting, particle board sheeting, plywood sheeting and/or wooden sheeting.

[0018] In one form the floor covering is selected from any one or a combination of the following: wooden floor boards, engineered composite floor boards, bamboo floor boards, floating floor boards, particle board sheeting, plywood sheeting, fibre cement sheeting, carpet, carpet tiles, ceramic tiles and stone tiles.

[0019] According to a second aspect there is provided the use of a flooring underlay according to any one of the preceding claims as an intermediary layer in a layered flooring assembly [0020] Other aspects, features, and advantages will become apparent from the following detailed description when taken in conjunction with the accompanying drawings, which are a part of this disclosure and which illustrate, by way of example, principles of inventions disclosed.

Detailed Description H:\mmM]iterw»veti\NRI:'ortfal\DCOMMM456482y_l.d<x;-23/05/20.!7 2017100598 23 May 2017 -4- [0021] In the foregoing description of preferred embodiments, specific terminology has been resorted to for the sake of clarity. However, the invention is not intended to be limited to the specific terms so selected, and it is to be understood that each specific term includes all technical equivalents which operate in a similar manner to accomplish a similar technical purpose. Terms such as "front" and "rear", "inner" and "outer", "top" "bottom", "above", "below”, "upper" and "lower" and the like are used as words of convenience to provide reference points and are not to be construed as limiting terms.

[0022] The reference in this specification to any prior publication (or information derived from it), or to any matter which is known, is not, and should not be taken as, an acknowledgement or admission or any form of suggestion that prior publication (or information derived from it) or known matter forms part of the common general knowledge in the field of endeavour to which this specification relates.

[0023] In this specification, the word “comprising” is to be understood in its “open” sense, that is, in the sense of “including”, and thus not limited to its “closed” sense, that is the sense of “consisting only of’. A corresponding meaning is to be attributed to the corresponding words “comprise”, “comprised” and “comprises” where they appear.

[0024] In addition, the foregoing describes only some embodiments of the invention(s), and alterations, modifications, additions and/or changes can be made thereto without departing from the scope and spirit of the disclosed embodiments, the embodiments being illustrative and not restrictive.

[0025] It was surprisingly found that a flooring underlay that included a top layer of material, a bottom layer of material and an intermediate layer of material, wherein the intermediate layer of material was of a lesser density than the top and bottom layers, had significantly increased sound absorption properties when located between a substrate surface and a floor covering. In particular, it was found the sound attenuation provided by the flooring underlay as here described was equivalent to the sound attenuation found in H:\mm\htter\w ven\NRPortbl\DCC\MM\l4564829_Ldnc-23/Cl.V20.l7 2017100598 23 May 2017 -5- acoustic reduction materials which are significantly larger in thickness.

[0026] In addition, it was also found that a layered flooring assembly including the flooring underlay as herein described included increased water repellence properties; increased thermal insulation, increased impact absorption and also provided a vapour barrier to a layered flooring assembly when used as part of the layered flooring assembly.

[0027] In certain embodiments, the top and bottom layers of material may be composed of polyester fibres such as needle punched or woven polyester. The thickness of the polyester fibres may range in thickness from between 0.5 mm up to about 5 mm and preferably about 1 mm to about 4 mm.

[0028] The density of the polyester fibre layer suitable for the first layer of material is desired to be in the range of about 60 kg/m3 to about 120kg/m3. It is preferred that the •2 density of the polyester fibre layer is in the range of about 90 kg/m .

[0029] In certain embodiments, the intermediate layer of material may be composed of needle punched or felt polyester. The thickness of the needle punched or felt polyester of the intermediate layer may be in the range of about 4 mm to about 12 mm and preferably about 6 mm to about 10 mm.

[0030] The density of the needle punched or felt polyester that makes up the intermediate layer may be from about 30 kg/m3 to about 50kg/m3. It is preferred that the density of the polyester fibre layer is in the range of about 45 kg/m3.

[0031] Providing the top and/or bottom layers of material to be composed of polyester fibres provides the flooring underlay with several advantageous properties including airborne sound absorption, water repellence, thermal insulation as well as providing that loads are distributed evenly across the surface of the flooring underlay avoiding so called “pin” loading. In addition, providing the top and bottom layer of material is composed of the heat sealed or woven polyester fibres gives the flooring H:\nim\I]iterwoveii\NRl,ortbl\DCC\MMM4564829_l.d<ic-23/05/2017 2017100598 23 May 2017 -6- underlay the “stiffness” and dimensional stability required to support many types of floor coverings and particularly those that are rigid and prone to cracking such as ceramic, porcelain or stone tiles, [0032] In certain embodiments, the flooring underlay includes a further layer composed of a metalised polymer film that may be bonded to either the outside surface of the top layer of material or the outside surface of the bottom layer of material, or both. A metalised polymer film (or metallised films) are polymer films coated with a thin layer of metal, usually aluminium. They offer the glossy metallic appearance of an aluminium foil at a reduced weight.

[0033] The flooring underlay as herein described is typically designed to be placed on to a substrate surface which may form part of an existing building structure and which may be a new base for a floor assembly in a building. The substrate surface may be composed of any typical composition which can be used as a solid foundation for a flooring assembly and may be composed of concrete such as a concrete slab or screed, fibre cement sheeting, or other hard setting composition. Alternatively, the substrate surface may be composed of wood, or the like, and be in the form of for example, wooden floor boards, engineered composite floor boards, bamboo floor boards, particle board sheeting or plywood sheeting.

[0034] According to certain embodiments, the flooring underlay as herein described may be part of a layered flooring assembly including a floor covering as an upper layer with the composite underlay acting as an intermediary layer positioned on top of a substrate surface and located between the floor covering and the substrate surface.

[0035] The floor covering may be composed of any type of surface that is used as a flooring surface and can include for example one of, or a combination of: wooden floor boards, engineered composite floor boards, bamboo floor boards, floating floor boards, particle board sheeting, plywood sheeting, fibre cement sheeting, carpet, carpet tiles, ceramic tiles and/or stone tiles. 2017100598 23 May 2017

Hi'nimXliitci'VkO ven\NRPortbl\DCC\MM\14564S29_l.doc-23/05/2017 -7- [0036] When selecting a floor covering that is composed of a rigid material it is also optional to include a further layer in the floor assembly that may be located above the flooring underlay as herein described to provide a rigid surface layer for locating the floor covering. The rigid surface layer may be selected from and suitable rigid layer used in construction such as for example, fibre cement sheeting, or a light weight concrete screed with metal reinforcement.

[0037] In certain embodiments the total thickness of the floor underlay as herein described is from about 10mm to about 16 mm in thickness and preferably about 12 mm in thickness. The sound attenuation properties of the floor underlay as herein described were surprisingly found to be equivalent (6 star rating) of sound attenuation flooring assemblies that have a much higher height such as for example the Acousta “Batten” System: Acoustic treatment hight: 69mm and the Regupol: 3 x layers 17mm “dimpled” material -51mm.

[0038] Furthermore, invention(s) have been described in connection with what are presently considered to be the most practical and preferred embodiments, it is to be understood that the invention is not to be limited to the disclosed embodiments, but on the contrary, is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the invention(s). Also, the various embodiments described above may be implemented in conjunction with other embodiments, e.g., aspects of one embodiment may be combined with aspects of another embodiment to realize yet other embodiments. Further, each independent feature or component of any given assembly may constitute an additional embodiment.

Claims (5)

1. The claims defining the invention are as follows:

   1. A flooring underlay for use in flooring assemblies wherein the flooring underlay includes a top layer of material, an intermediate layer of material, and a bottom layer of material wherein the intermediate layer of material has a lesser density than the top and bottom layers of material.
2. 2. A flooring underlay according to claim 1 wherein the top layer and bottom later of material is composed of heat sealed or woven polyester and the intermediate layer is composed of needle punched or felt polyester.
3. 3. A flooring underlay according to any one of the preceding claims wherein the thickness of the top layer of material is about 0.5 mm to about 5 mm and/or the thickness of the bottom layer of material is about 0.5 mm to about 5 mm and/or the thickness of the intermediate layer is about 4 mm to about 12 mm and/or the density of the top layer of material is between about 60 to about 120 kg/nr and/or the density of the bottom layer of material is between about 80 to about 100 kg/m3 and/or the density of the intermediate layer of material is between about 30 to about 60 kg/m3.
4. 4. A flooring underlay according to any one of the preceding claims wherein the top layer of material is thermally bonded to the intermediate layer of material and/or the bottom layer of material is thermally bonded to the intermediate layer of material and/or the thickness of the underlay measured from one outer planar surface to another outer planar surface is about 10 mm to about 14 mm.
5. 5. Use of a flooring underlay according to any one of the preceding claims as an intermediary layer in a layered flooring assembly.