US20220081915A1

US20220081915A1 - Contiguous sound attenuating panel system

Info

Publication number: US20220081915A1
Application number: US17/020,069
Authority: US
Inventors: John Igo; Nicola Busatta; Tonj Ciotti
Original assignee: Formulated Materials LLC
Current assignee: Formulated Materials LLC
Priority date: 2020-09-14
Filing date: 2020-09-14
Publication date: 2022-03-17

Abstract

The present disclosure describes a contiguous sound attenuating panel system. The sound attenuating panel has a top surface, a bottom surface, a first end, a second end, an adhesive strip on the top surface of the first end, and an engagement flap on the top surface of the second end. The adhesive strip has a first edge and a second edge. The second edge is located further from the first end than the first edge. When installed, the first end of a first sound attenuating panel abuts and is substantially coplanar with the second end of a second sound attenuating panel. The width of the engagement flap of the second sound attenuating panel terminates substantially at the location of the second edge of the adhesive strip of the first sound attenuating panel such that the engagement flap contacts and substantially covers the adhesive strip.

Description

TECHNICAL FIELD

The present disclosure relates generally to above-ground floor systems, and, more specifically, to an above-ground, contiguous sound attenuating panel system that maintains the flexural strength of the flooring system.

BACKGROUND

Builders commonly use sound attenuating material in multi-stored buildings to reduce the transmission of impact sound from one floor to another. This material is commonly referred to as sound mats, which are placed as the first layer of floor systems. Typically, the entire floor system utilizes four layers in the following order: subfloor, sound mat, underlayment, and the final flooring goods (such as vinyl planks, tile, or carpet). In most cases, sound mats come in rolls or panels of rigid or semi-rigid material. During installation, to connect one panel to another, the panels are pressed together and a loose flap extends from one panel over the top of the other panel with an adhesive adherence. Since the flap is pulled over the actual connection area between the two panels, the actual contact between the two panels is a blind act. Unfortunately, current systems cannot ensure a flush fit between adjacent panels due to the practical realities stemming from the installer's inability to confirm constant contact between the panels as the installer adhered the flap. The inevitable seams that are created beneath the flap (i.e. wherever no flush contact between the panel exists) creates a number of quality problems as the rest of the flooring layers are installed. For example, underlayments typically comprise of a wet slurry pumped directly on top of the sound mat and are left to dry. As the underlayment begins to dry, the seams compromise the flexural strength of the underlayment and cracks develop above the seams of the sound mat gaps. Also, the sound attenuating qualities of the sound mat are compromised when the underlayment falls and dries down the seam because of the now-direct contact of the underlayment with the subfloor. This disclosure provides a contiguous sound attenuating panel system that provides quality-assured sound attenuation, while substantially preserving the flexural strength of the flooring system. In particular, the disclosed sound attenuating panel system provides a mechanism which allows the installer to ensure flush contact between adjacent panels during the blind act of adjoining two panels.

SUMMARY

The present invention provides a contiguous sound attenuating panel system which overcomes the deficiencies described above, and has other advantages.
In one embodiment, a contiguous sound attenuating panel system is provided. The system comprises a first sound attenuating panel and a second sound attenuating panel. Each of the first sound attenuating panel and the second sound attenuating panel comprise a top surface, a bottom surface, a first end, a second end, an adhesive strip on the top surface of the first end, and an engagement flap on the top surface of the second end. The adhesive strip has a first edge and a second edge. The second edge is located further from the first end than the first edge. The engagement flap extends a width beyond the second end. When installed, the first end of the first sound attenuating panel abuts the second end of the second sound attenuating panel such that the top surface of the first sound attenuating panel and the top surface of the second sound attenuating panel are substantially coplanar. The width of the engagement flap of the second sound attenuating panel terminates substantially at the location of the second edge of the adhesive strip of the first sound attenuating panel such that the engagement flap of the second sound attenuating panel contacts and substantially covers the adhesive strip of the first sound attenuating panel.
In some embodiments, the width of the engagement flap of the second sound attenuating panel terminates at the location of the second edge of the adhesive strip of the first sound attenuating panel. In other embodiments, the width of the engagement flap of the second sound attenuating panel extends no more than 0.5 inches past the location of the second edge of the adhesive strip of the first sound attenuating panel. In another embodiment, each of the first sound attenuating panel and the second sound attenuating panel has a first side and a second side. The adhesive strip and the engagement flap extend from the first side to the second side.
In an additional embodiment, a contiguous sound attenuating panel system is provided. The system has a first sound attenuating panel and a second sound attenuating panel. Each of the first sound attenuating panel and the second sound attenuating panel have a top surface, a bottom surface, a first end, a second end, an engagement channel on the top surface of the first end, an adhesive strip on the top surface of the first end, and an engagement flap on the top surface of the second end. The engagement channel has a first width. The adhesive strip has a first edge and a second edge. The second edge is located further from the first end than the first edge. The adhesive strip is spaced away from the first end a distance at least equal to the first width. The engagement flap extends a second width beyond the second end. When installed, the engagement channel of the first sound attenuating panel receives a portion of the second end of the second sound attenuating panel such that the top surface of the first sound attenuating panel and the top surface of the second sound attenuating panel are substantially coplanar. The second width of the engagement flap of the second sound attenuating panel terminates substantially at the location of the second edge of the adhesive strip of the first sound attenuating panel such that the engagement flap of the second sound attenuating panel contacts and substantially covers the adhesive strip of the first sound attenuating panel.
In another embodiment, a sound attenuating panel is provided. The sound attenuating panel has a top surface, a bottom surface, a first end, a second end, an engagement channel on the top surface of the first end, an adhesive strip on the top surface of the first end, and an engagement flap on the top surface of the second end. The engagement channel has a first width. The adhesive strip has a first edge and a second edge. The second edge is located further from the first end than the first edge. The adhesive strip is spaced away from the first end a distance at least equal to the first width. The engagement flap extends a second width beyond the second end.

BRIEF DESCRIPTION OF THE DRAWINGS

The drawings included with this application illustrate certain aspects of the embodiments described herein. However, the drawings should not be viewed as exclusive embodiments.

FIG. 1 is a perspective view of a sound attenuating panel having an engagement channel with the engagement flap folded back and the adhesive strip covered by a removable strip in accordance with one embodiment of the present disclosure.

FIG. 2 is a perspective view of a sound attenuating panel having an engagement channel with the engagement flap raised and the removable strip partially removed from the adhesive strip in accordance with one embodiment of the present disclosure.

FIG. 3 is a side view of a sound attenuating panel having an engagement channel with the engagement flap folded back and the adhesive strip covered by a removable strip in accordance with one embodiment of the present disclosure.

FIG. 4 is a side view of a sound attenuating panel having an engagement channel with the engagement flap raised and the removable strip partially removed from the adhesive strip in accordance with one embodiment of the present disclosure.

FIG. 5 is a side view showing two sound attenuating panels, each having an engagement channel, prior to engagement in accordance with one embodiment of the present disclosure.

FIG. 6 is a side view showing two sound attenuating panels, each having an engagement channel, installed together in accordance with one embodiment of the present disclosure.

FIG. 7 is a perspective view of a sound attenuating panel without an engagement channel with the engagement flap folded back and the adhesive strip covered by a removable strip in accordance with one embodiment of the present disclosure.

FIG. 8 is a side view showing two sound attenuating panels, each without an engagement channel, installed together in accordance with one embodiment of the present disclosure.

DETAILED DESCRIPTION

The present disclosure describes a sound attenuating panel system for use in the construction of flooring. The disclosure may be understood more readily by reference to these detailed descriptions. For simplicity and clarity of illustration, where appropriate, reference numerals may be repeated among the different figures to indicate corresponding or analogous elements. In addition, numerous specific details are set forth in order to provide a thorough understanding of the various embodiments described herein. The description is not to be considered as limiting the scope of the embodiments described herein. The drawings are not necessarily to scale and the proportions of certain parts may have been exaggerated to better illustrate details and features of the present disclosure.
As shown by FIGS. 5-8, a contiguous sound attenuating panel system for use in the construction of flooring is illustrated and generally designated by the numeral 10. When system 10 is placed over the primary floor structure, system 10 attenuates sound transmission through the floor. System 10 includes at least two sound attenuating panels 20 a and 20 b. Sound attenuating panels 20 a and 20 b may be any length/width depending upon the system used to manufacture sound attenuating panels 20 a and 20 b and the size of the floor to be covered.
With reference to FIGS. 1-4, a sound attenuating panel is illustrated and generally designated by the numeral 20. In some embodiments, sound attenuating panel 20 is comprised of a plastic or rubber membrane. However, one skilled in the art understands that sound attenuating panel 20 may be manufactured from a number of different types of durable, and pliable, plastic, rubber, or other polymer material having sound attenuating properties.
Sound attenuating panel 20 generally includes a top surface 22, a bottom surface 24, a first end 30, a second end 40, an adhesive strip 36, and an engagement flap 42. Top surface 22 is relatively flat. Bottom surface 24 may take the form of a plurality of outwardly projecting protrusions, air gaps, or any one of the forms known in the art to attenuate sound.
With reference to FIGS. 1-6, in some embodiments, first end 30 includes an engagement channel 34 on top surface 22 and abutting first edge 32. Engagement channel 34 will typically have a first width 35 of about 0.1 inch to about 1 inch. More preferably, engagement channel 34 has a first width 35 of 0.25 inch.
In other embodiments, as shown in FIGS. 7-8, first end 30 does not include an engagement channel 34. In such embodiments, as shown in FIG. 8, when installed, first end 30 of sound attenuating panel 20 a abuts second end 40 of sound attenuating panel 20 b, i.e. panel 20 a directly contacts panel 20 b at ends 30, 40.
With reference to FIGS. 3-4, sound attenuating panel 20 may have a first thickness 50 and engagement channel 34 may have a second thickness 52. In some embodiments, second thickness 52 is about 90% to about 99% less than first thickness 50. The difference between first thickness 50 and second thickness 52 allows top surface 22 of one sound attenuating panel 20 to be substantially coplanar to top surface 22 of a second sound attenuating panel 20 when two sound attenuating panels 20 are installed for use in contiguous sound attenuating panel system 10.
Adhesive strip 36 is on top surface 22 spaced from first edge 32 of first end 30 a distance at least equal to first width 35. Adhesive strip 36 has a first edge 37 a and a second edge 37 b. Second edge 37 b is located further from first edge 32 of first end 30 than first edge 37 a. In some embodiments, adhesive strip 36 includes a removable strip 38 such that removal of the strip exposes an adhesive material 39.
With reference to FIGS. 5-6 and 7-8, engagement flap 42 provides for engagement of one sound attenuating panel 20 a to another sound attenuating panel 20 b by contacting engagement flap 42 of sound attenuating panel 20 b to adhesive strip 36 of adjacent sound attenuating panel 20 a. Engagement flap 42 is on top surface 22 of second end 40 and extends a second width 43. As shown in FIGS. 1, 3, 5, and 7, when sound attenuating panels 20 are not installed, engagement flap 42 may be folded back over top surface 22 of sound attenuating panel 20 towards first end 30.
As shown in FIGS. 6 and 8, when two sound attenuating panels 20 a, 20 b are installed, engagement flap 42 of sound attenuating panel 20 b has a second width 43 that terminates substantially at the location of second edge 37 b of adhesive strip 36 of sound attenuating panel 20 a such that engagement flap 42 of sound attenuating panel 20 b contacts and substantially covers adhesive strip 36 of sound attenuating panel 20 a. In some embodiments, second width 43 of engagement flap 42 of sound attenuating panel 20 b terminates at the location of second edge 37 b of adhesive strip 36 of sound attenuating panel 20 a. In other embodiments, second width 43 of engagement flap 42 of sound attenuating panel 20 b extends no more than 0.5 inches past the location of second edge 37 b of adhesive strip 36 of sound attenuating panel 20 a. In additional embodiments, second width 43 of engagement flap 42 of sound attenuating panel 20 b extends no more than 0.125 inches past the location of second edge 37 b of adhesive strip 36 of sound attenuating panel 20 a.
Contiguous sound attenuating panel system 10 ensures a substantially perfect abutting seam between sound attenuating panels 20. Second width 43 of engagement flap 42 of sound attenuating panel 20 b terminating at, or substantially at, the location of second edge 37 b of adhesive strip 36 of sound attenuating panel 20 a ensures direct contact between sound attenuating panel 20 a and sound attenuating panel 20 b. Adhesive strip 36 of sound attenuating panel 20 a is set at the exact distance that second width 43 of engagement flap 42 of sound attenuating panel 20 b must stretch to create a substantially perfect abutting seam between sound attenuating panel 20 a and sound attenuating panel 20 b. While an installer may be blind to the seam due to engagement flap 42, there is effectively a 0% chance that sound attenuating panel 20 a and sound attenuating panel 20 b have shifted away from one another to create a valley/gap because, if sound attenuating panels 20 a and 20 b had shifted apart, engagement flap 42 of sound attenuating panel 20 b would not contact and substantially cover adhesive strip 36 of sound attenuating panel 20 a. Thus, second width 43 provides guidance to an installer to ensure no valley (gap).
In some embodiments, sound attenuating panel 20 includes a first side 26 and a second side 28. In such embodiments, engagement channel 34, if sound attenuating panels 20 include engagement channel 34, adhesive strip 36, and engagement flap 42 may each extend from first side 26 to second side 28.
With reference to FIGS. 5-6, installation of contiguous sound attenuating panel system 10 includes the steps of: placing a first sound attenuating panel 20 a on a subfloor (not shown) such that bottom surface 24 contacts the subfloor; placing second end 40 of a second sound attenuating panel 20 b in close proximity to first end 30 of first sound attenuating panel 20 a; receiving a portion of second end 40 of second sound attenuating panel 20 b in engagement channel 34 of first sound attenuating panel 20 a such that top surface 22 of first sound attenuating panel 20 a and top surface 22 of second sound attenuating panel 20 b are substantially coplanar; and, folding over engagement flap 42 of second sound attenuating panel 20 b to contact and substantially cover adhesive strip 36 of first sound attenuating panel 20 a. Engagement flap 42 extends and terminates substantially at the location of second edge 37 b of first sound attenuating panel 20 a. In other embodiments, installation of sound attenuating panel system 10 includes the steps of: removing a removable strip 38 from adhesive strip 36 of first sound attenuating panel 20 a to expose adhesive material 39; and folding over engagement flap 42 of second sound attenuating panel 20 b to contact and substantially cover adhesive material 39.
With reference to FIGS. 7-8, another embodiment of contiguous sound attenuating panel system 10 includes sound attenuating panels 20 that lack engagement channel 34. In such embodiments, sound attenuating panel 20 includes a top surface 22, a bottom surface 24, a first end 30, a second end 40, an adhesive strip 36 on top surface 22 of first end 30, and an engagement flap 42 on top surface 22 of second end 40. Adhesive strip 36 has a first edge 37 a and a second edge 37 b. Second edge 37 b is located further from first end 30 than first edge 37 a. Engagement flap 42 extends a second width 43 beyond second end 40. When installed, first end 30 of first sound attenuating panel 20 a abuts second end 40 of second sound attenuating panel 20 b such that top surface 22 of first sound attenuating panel 20 a and top surface 22 of second sound attenuating panel 20 b are substantially coplanar. Second width 43 of engagement flap 42 of second sound attenuating panel 20 b terminates substantially at the location of second edge 37 b of adhesive strip 36 of first sound attenuating panel 20 a such that engagement flap 42 of second sound attenuating panel 20 b contacts and substantially covers adhesive strip 36 of first sound attenuating panel 20 a.
In some embodiments, second width 43 of engagement flap 42 of second sound attenuating panel 20 b terminates at the location of second edge 37 b of adhesive strip 36 of first sound attenuating panel 20 a. In other embodiments, second width 43 of engagement flap 42 of second sound attenuating panel 20 b extends no more than 0.5 inches past the location of second edge 37 b of adhesive strip 36 of first sound attenuating panel 20 a. In other embodiments, second width 43 of engagement flap 42 of second sound attenuating panel 20 b extends no more than 0.125 inches past the location of second edge 37 b of adhesive strip 36 of first sound attenuating panel 20 a. In another embodiment, each of first sound attenuating panel 20 a and second sound attenuating panel 20 b have a first side 26 and a second side 28. Adhesive strip 36 and engagement flap 42 from first side 26 to second side 28.
Contiguous sound attenuating panel system 10 derives the unexpected result of two sound attenuating panels 20 a, 20 b being substantially coplanar and in direct contact when installed. Second width 43 of engagement flap 42 of second sound attenuating panel 20 b terminating at, or substantially at, the location of second edge 37 b of adhesive strip 36 of first sound attenuating panel 20 a ensures direct contact between first sound attenuating panel 20 a and second sound attenuating panel 20 b. Adhesive strip 36 is set at the exact distance that second width 43 of engagement flap 42 must stretch to create a substantially perfect abutting seam between first sound attenuating panel 20 a and second sound attenuating panel 20 b. If first sound attenuating panel 20 a and second sound attenuating panel 20 b have shifted away from one another to create a valley/gap, engagement flap 42 of second sound attenuating panel 20 b would not contact and substantially cover adhesive strip 36 of first sound attenuating panel 20 a. By substantially or completely covering adhesive strip 36, an installer can ensure no valley (gap) is created between sound attenuating panels 20 thereby providing a consistent surface to support the poured underlayment. Thus, the resulting flooring system will have improved flexural strength.
Although the disclosed invention has been shown and described in detail with respect to a preferred embodiment, it will be understood by those skilled in the art that various changes in the form and detailed area may be made without departing from the spirit and scope of this invention as claimed. Thus, the present invention is well adapted to carry out the object and advantages mentioned as well as those which are inherent therein. While numerous changes may be made by those skilled in the art, such changes are encompassed within the spirit of this invention as defined by the appended claims.

Claims

What is claimed is:

1. A contiguous sound attenuating panel system comprising:

a first sound attenuating panel and a second sound attenuating panel, wherein each of the first sound attenuating panel and the second sound attenuating panel comprise:

a top surface and a bottom surface;

a first end and a second end;

an adhesive strip on the top surface of the first end, the adhesive strip having a first edge and a second edge, wherein the second edge is located further from the first end than the first edge; and

an engagement flap on the top surface of the second end, the engagement flap extending a width beyond the second end; and

the first end of the first sound attenuating panel abuts the second end of the second sound attenuating panel such that the top surface of the first sound attenuating panel and the top surface of the second sound attenuating panel are substantially coplanar, and wherein the width of the engagement flap of the second sound attenuating panel terminates substantially at the location of the second edge of the adhesive strip of the first sound attenuating panel such that the engagement flap of the second sound attenuating panel contacts and substantially covers the adhesive strip of the first sound attenuating panel.

2. The contiguous sound attenuating panel system of claim 1, wherein the width of the engagement flap of the second sound attenuating panel terminates at the location of the second edge of the adhesive strip of the first sound attenuating panel.

3. The contiguous sound attenuating panel system of claim 1, wherein the width of the engagement flap of the second sound attenuating panel extends no more than 0.5 inches past the location of the second edge of the adhesive strip of the first sound attenuating panel.

4. The contiguous sound attenuating panel system of claim 3, wherein the width of the engagement flap of the second sound attenuating panel extends no more than 0.125 inches past the location of the second edge of the adhesive strip of the first sound attenuating panel.

5. The contiguous sound attenuating panel system of claim 1, wherein each of the first sound attenuating panel and the second sound attenuating panel further comprise a first side and a second side, and wherein the adhesive strip and the engagement flap extend from the first side to the second side.

6. A contiguous sound attenuating panel system comprising:

a top surface and a bottom surface;

a first end and a second end;

an engagement channel on the top surface of the first end, the engagement channel having a first width;

an adhesive strip on the top surface of the first end, the adhesive strip having a first edge and a second edge, wherein the second edge is located further from the first end than the first edge, and wherein the adhesive strip is spaced away from the first end a distance at least equal to the first width; and

an engagement flap on the top surface of the second end, the engagement flap extending a second width beyond the second end; and

the engagement channel of the first sound attenuating panel receives a portion of the second end of the second sound attenuating panel such that the top surface of the first sound attenuating panel and the top surface of the second sound attenuating panel are substantially coplanar, and wherein the second width of the engagement flap of the second sound attenuating panel terminates substantially at the location of the second edge of the adhesive strip of the first sound attenuating panel such that the engagement flap of the second sound attenuating panel contacts and substantially covers the adhesive strip of the first sound attenuating panel.

7. The contiguous sound attenuating panel system of claim 6, wherein the second width of the engagement flap of the second sound attenuating panel terminates at the location of the second edge of the adhesive strip of the first sound attenuating panel.

8. The contiguous sound attenuating panel system of claim 5, wherein the second width of the engagement flap of the second sound attenuating panel extends no more than 0.5 inches past the location of the second edge of the adhesive strip of the first sound attenuating panel.

9. The contiguous sound attenuating panel system of claim 8, wherein the second width of the engagement flap of the second sound attenuating panel extends no more than 0.125 inches past the location of the second edge of the adhesive strip of the first sound attenuating panel.

10. The contiguous sound attenuating panel system of claim 6, wherein the first width of the engagement channel is from about 0.1 inch to about 1 inch.

11. The contiguous sound attenuating panel system of claim 10, wherein the first width of the engagement channel is about 0.25 inch.

12. The contiguous sound attenuating panel system of claim 6, wherein each of the first sound attenuating panel and the second sound attenuating panel further comprise a first side and a second side, and wherein the engagement channel, the adhesive strip, and the engagement flap extend from the first side to the second side.

13. The contiguous sound attenuating panel system of claim 6, wherein each of the first sound attenuating panel and the second sound attenuating panel have a first thickness and the engagement channel has a second thickness, and wherein the second thickness is about 90% to about 99% less than the first thickness.

14. A sound attenuating panel comprising:

a top surface and a bottom surface;

a first end and a second end;

an engagement flap on the top surface of the second end, the engagement flap extending a second width beyond the second end.

15. The sound attenuating panel of claim 14, wherein the first width of the engagement channel is from about 0.1 inch to about 1 inch.

16. The sound attenuating panel of claim 15, wherein the first width of the engagement channel is about 0.25 inch.

17. The sound attenuating panel of claim 14, further comprising a first side and a second side, wherein the engagement channel, the adhesive strip, and the engagement flap extend from the first side to the second side.

18. The sound attenuating panel of claim 14, having a first thickness and the engagement channel having a second thickness, wherein the second thickness is about 90% to about 99% less than the first thickness.