USRE41945E1 - Impact sound insulation - Google Patents
Impact sound insulation Download PDFInfo
- Publication number
- USRE41945E1 USRE41945E1 US11/782,999 US78299907A USRE41945E US RE41945 E1 USRE41945 E1 US RE41945E1 US 78299907 A US78299907 A US 78299907A US RE41945 E USRE41945 E US RE41945E
- Authority
- US
- United States
- Prior art keywords
- substrate
- recited
- rubber
- flooring system
- decorative
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Expired - Lifetime
Links
- 238000009413 insulation Methods 0.000 title 1
- 239000000758 substrate Substances 0.000 claims abstract description 183
- 229920001971 elastomer Polymers 0.000 claims abstract description 56
- 239000005060 rubber Substances 0.000 claims abstract description 56
- 238000009408 flooring Methods 0.000 claims abstract description 52
- 239000000463 material Substances 0.000 claims abstract description 33
- 239000002245 particle Substances 0.000 claims abstract description 13
- 238000000034 method Methods 0.000 claims description 30
- 239000000853 adhesive Substances 0.000 claims description 14
- 230000001070 adhesive effect Effects 0.000 claims description 14
- 229920002635 polyurethane Polymers 0.000 claims description 6
- 239000004814 polyurethane Substances 0.000 claims description 6
- 238000009434 installation Methods 0.000 claims description 3
- 239000011230 binding agent Substances 0.000 claims 2
- 238000013016 damping Methods 0.000 claims 1
- 239000004636 vulcanized rubber Substances 0.000 claims 1
- 239000003292 glue Substances 0.000 description 9
- 239000011810 insulating material Substances 0.000 description 9
- 238000010276 construction Methods 0.000 description 4
- 238000004519 manufacturing process Methods 0.000 description 4
- 239000000919 ceramic Substances 0.000 description 3
- -1 masonry Substances 0.000 description 3
- 239000002023 wood Substances 0.000 description 3
- 240000005428 Pistacia lentiscus Species 0.000 description 2
- 230000009286 beneficial effect Effects 0.000 description 2
- 239000004567 concrete Substances 0.000 description 2
- 238000005336 cracking Methods 0.000 description 2
- 239000007788 liquid Substances 0.000 description 2
- 239000011120 plywood Substances 0.000 description 2
- 244000043261 Hevea brasiliensis Species 0.000 description 1
- 230000005540 biological transmission Effects 0.000 description 1
- 239000004566 building material Substances 0.000 description 1
- 230000006835 compression Effects 0.000 description 1
- 238000007906 compression Methods 0.000 description 1
- 239000007799 cork Substances 0.000 description 1
- 239000006260 foam Substances 0.000 description 1
- 239000011440 grout Substances 0.000 description 1
- 239000010440 gypsum Substances 0.000 description 1
- 229910052602 gypsum Inorganic materials 0.000 description 1
- 230000005923 long-lasting effect Effects 0.000 description 1
- 239000004579 marble Substances 0.000 description 1
- 239000013521 mastic Substances 0.000 description 1
- 239000004570 mortar (masonry) Substances 0.000 description 1
- 229920003052 natural elastomer Polymers 0.000 description 1
- 229920001194 natural rubber Polymers 0.000 description 1
- 239000007787 solid Substances 0.000 description 1
- 239000004575 stone Substances 0.000 description 1
- 125000000391 vinyl group Chemical group [H]C([*])=C([H])[H] 0.000 description 1
- 229920002554 vinyl polymer Polymers 0.000 description 1
Images
Classifications
-
- A—HUMAN NECESSITIES
- A63—SPORTS; GAMES; AMUSEMENTS
- A63C—SKATES; SKIS; ROLLER SKATES; DESIGN OR LAYOUT OF COURTS, RINKS OR THE LIKE
- A63C19/00—Design or layout of playing courts, rinks, bowling greens or areas for water-skiing; Covers therefor
- A63C19/04—Mats or carpets for courts
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
- E04F15/00—Flooring
- E04F15/18—Separately-laid insulating layers; Other additional insulating measures; Floating floors
- E04F15/20—Separately-laid insulating layers; Other additional insulating measures; Floating floors for sound insulation
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
- E04F15/00—Flooring
- E04F15/18—Separately-laid insulating layers; Other additional insulating measures; Floating floors
- E04F15/20—Separately-laid insulating layers; Other additional insulating measures; Floating floors for sound insulation
- E04F15/206—Layered panels for sound insulation
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/31504—Composite [nonstructural laminate]
- Y10T428/31826—Of natural rubber
Definitions
- the invention is directed to sound insulating material for use in flooring.
- a sound insulating material which exhibits the strength characteristics required to properly support the decorative top layer of the flooring.
- Ceramic, masonry, and wood tiles have been used for many years in the construction industry. These materials are used for many reasons including strength, durability, and appearance. However, despite their numerous desirable qualities, these materials typically exhibit poor acoustic properties. Poor sound or acoustic properties are extremely undesirable in all structure, but in particular in high-rise buildings which are used as office buildings, hotels, apartments, and the like. As the occupants of one floor do not want to be disturbed from the occupants of the floor above, it is typical to add insulating material between the subfloor and the decorative tiles. In fact, standards have been developed and modified to insure that sound is not transmitted. The ASTM Impact Sound related tests are E492-90 and E 989-89. Where noise codes exist, generally IIC50 is specified. These apply to either finished floors of wood, ceramic, tile, stone, marble, vinyl, carpet, laminate, or floating floors of gypsum, lightweight concrete, mortar beds, plywood, and backer board.
- the structural stability of the material is weak. In other words, the material can easily be compressed when a force is applied thereto. Consequently, while the materials described above work well in ceilings and walls, structural support must be added in order for the insulating materials to be used in flooring systems. Without the support, the tiles would crack and deform as pressure is applied. The introduction of the support layer further adds to the height requirements, resulting in greater expense.
- An object of the present invention is to provide an insulating material for use with decorative flooring tile and the like which minimizes the height required. Another object of the invention is to provide an insulating material which has the acoustic properties and the strength characteristics required to be used in a flooring system.
- the flooring system has a subfloor, a decorative top layer, and a substrate provided therebetween.
- the substrate has a top surface and an oppositely facing bottom surface. The bottom surface positioned proximate the subfloor and the top surface is positioned proximate the decorative top layer. Voids are provided in the substrate which extend between the top surface and the bottom surface.
- the substrate is manufactured from rubber in sheets which are cut to the desired configuration. The substrate has the strength characteristics to support the decorative layer and prevent damage thereto and the sound dampening characteristics to provide decibel reduction through the substrate.
- the invention is also directed to a substrate for use in a flooring system which has a subfloor and a decorative upper layer.
- the substrate is made in a sheet which has a bottom surface, a top surface, side surfaces and end surfaces.
- the top surface and the oppositely facing bottom surface are essentially parallel to each other and are spaced apart by the thickness of the substrate.
- Voids are provided in the substrate, the voids are provided between particles of rubber or other similar material.
- FIG. 1 is a perspective view of a substrate according to the present invention.
- FIG. 2 is an enlarged cross sectional view of the substrate of FIG. 1 .
- FIG. 3 is a cross sectional view of a flooring system in which the substrate of FIG. 1 is incorporated.
- the flooring system 2 has a base or subfloor 4 .
- the subfloor 4 is an integral part of the building or structure and can be in the form of a concrete slab, plywood floor, or any other known material commonly used in the building industry.
- a sound absorbing substrate 6 and decorative top layer 7 Positioned above the subfloor is a sound absorbing substrate 6 and decorative top layer 7 .
- the sound absorbing substrate 6 may be affixed to the subfloor 4 and/or the decorative top layer 7 by means of mastic or glue layers 20 .
- mastics or glues are well known in the industry, a further explanation of the glue will not be provided.
- the decorative top layer may be wood, linoleum, ceramic tile, carpet, or any other known flooring. Individual components of the decorative top layer 7 are positioned in place and secured to each other by frictional engagement, glue, grout, or other conventional means. As decorative flooring is commonly used, a further explanation of the specifics relating to the decorative top layer 7 will not be provided.
- the substrate 6 has a bottom surface 8 , a top surface 10 , side surfaces 12 and end surfaces 14 .
- the top surface 10 and the oppositely facing bottom surface 8 are essentially parallel to each other and are spaced from each other by a distance or thickness t.
- the side surfaces 12 are spaced from each other and are essentially parallel to each other.
- End surfaces 14 are cut to conform to the shape required for the particular application.
- the length of the substrate will be governed by the particular installation. This provides maximum flexibility to the installer of the substrate.
- the use of a continuous sheet of substrate provides advantages which will be more fully described below.
- Voids 16 are provided in the substrate 6 and are randomly positioned in the substrate. The size and configuration of respective voids is also random.
- the substrate 6 is manufactured from recycled rubber. During the manufacturing process SBR and natural rubber are mixed with a polyurethane and cured under moderate temperature to form a large cylindrical member of the rubber. In order to provide a continuous sheet of the substrate 6 , the substrate 6 is cut from a cylindrical member. As the cylindrical member is rotated, blades engage an outside layer of the cylindrical member and cause the outside layer to be cut away from the cylindrical member, thereby forming a continuous sheet of the substrate 6 .
- This process of manufacturing the substrate is significantly different than the vulcanized method generally used to manufacture substrates of this type. Therefore, the substrate of the present invention has greater resiliency, as will be more fully discussed below.
- the substrate 6 can be made of SBR rubber, other rubbers, or any combination thereof.
- At least one continuous sheet of the substrate 6 is brought to the job and cut to the appropriate length.
- the rubber material of the present invention has not been vulcanized, the rubber material has the flexibility required to allow the rubber material to be delivered in rolls of sheets.
- the substrate 6 cut to the proper length the substrate is positioned over and covers the subfloor 4 .
- each sheet of the substrate 6 is generally four feet wide, several sheets of substrate may be required to fully cover the subfloor 4 .
- the use of continuous sheets eliminates many of the seams found in the prior art. Previously, individual pieces of some type of substrate would be positioned on the subfloor. The use of many rectangular pieces requires many seams which are difficult to align precisely, thereby causing gaps to be provided therebetween. The use of the sheets minimizes this problem.
- the substrate 6 may or may not be glued or secured to the subfloor 4 . If glue or adhesive 20 or the like is to be used, the glue is generally applied to the subfloor prior to the substrate being finally positioned thereon. As the substrate 6 is in the form of continuous sheets, the weight of the sheets and their frictional interface with the subfloor is generally sufficient to maintain the substrate in position, thereby eliminating the need for glue 20 or the like.
- the decorative top layer 7 can be installed.
- the material may or may not be glued or secured to the substrate. If glue or adhesive 20 is to be used, the glue is generally applied in small areas and the decorative top layer is installed thereon. This process is repeated until the entire decorative top layer is installed.
- the substrate 6 has a density of below 1000 kilograms per meter cubed and a decibel reduction of approximately 20 dB for a substrate having a thickness of 5 mm and 25 dB for a substrate having a thickness of 10 mm.
- the flooring system must have the structural integrity to prevent cracking or breaking of the decorative upper layer.
- the substrate should be as rigid as possible. In fact in many of the previous flooring systems, extra support members are provided to enhance the rigidity characteristics of the substrate. However, the substrate must also have the ability to dampen the sound and provide the appropriate decibel reduction.
- prior art teaches of sound dampening materials used in the substrate. These materials generally have air voids and the like to dampen the sound, which lessens the rigidity of the substrate. Therefore, prior art substrates are either extremely thick or require the use of a separate support member to provide the strength and/or sound dampening characteristics required.
- the substrate 6 of the present invention is configured to achieve the sound dampening and strength requirements with a relatively thin cross section and without the need for an additional support member.
- the rubber provides the structural integrity required.
- the substrate is flexible, when a force is applied to the top surface 10 of the substrate 6 , the rubber particles 30 will compress only a relatively small amount. Therefore, as the compression of the substrate in the y direction is not great, the movement of the decorative upper layer 7 in the y direction is also not significant. Consequently, the likelihood of damage to the upper layer because of cracking and the like is essentially eliminated.
- the substrate 6 also has the sound dampening characteristics required. As the manufacturing process provides random voids 16 between the particles of rubber, the configuration of the substrate 6 dampens the sound.
- substrate 6 has various advantages over the prior art. Unlike other materials used to dampen sound, the rubber sheets are highly elastic with long lasting flexibility. The material does not wear, harden, or grow bittle over time. Consequently, as the substrate maintains its integrity and characteristics over time, the decorative top layer 7 does not wear as quickly and thereby extends the life of the top layer 7 .
- the rubber substrate 6 is also moisture insensitive compared to other materials such as cork. Therefore, in environments where the floor system is exposed to liquids, the performance of the rubber substrate 6 will be unaffected by the liquid and will not degrade over time.
- the use of sheets provides a solid surface on which the top layer is positioned.
- the substrate would be made from numerous squares (or rectangles) which would be positioned in abutting relationship. If any of the individual pieces were not properly aligned, a gap or space would be provided between the pieces. While the top layer positioned over the spaces, the spaces would not properly support the top layer, creating a weak area in which the top layer could crack over time.
- the use of the rubber substrate 6 also allows radiant heat to be positioned in the floor. As the rubber is stable over a range of temperatures, the present invention can be used with radiant heat systems. Many other sound dampening materials would not be adaptable with radiant heat.
- the use of the substrate minimizes the overall height of the flooring system. This can be an extremely important factor in reducing the cost to construct a building or the like.
- the use of the flooring system described herein can eliminate approximately 13 to 14 millimeters of height.
- the use of the substrate 6 reduces the space required. This reduction of height required for the flooring system is particularly significant in multi-story or high rise buildings. In these buildings, a reduction of a meter or less in height reduces the amount of building material used and is a significant cost savings.
Landscapes
- Engineering & Computer Science (AREA)
- Architecture (AREA)
- Civil Engineering (AREA)
- Structural Engineering (AREA)
- Floor Finish (AREA)
Abstract
Description
Claims (50)
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US11/782,999 USRE41945E1 (en) | 2001-08-16 | 2007-07-25 | Impact sound insulation |
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US09/931,320 US6920723B2 (en) | 2001-08-16 | 2001-08-16 | Impact sound insulation |
US11/782,999 USRE41945E1 (en) | 2001-08-16 | 2007-07-25 | Impact sound insulation |
Related Parent Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US09/931,320 Reissue US6920723B2 (en) | 2001-08-16 | 2001-08-16 | Impact sound insulation |
Publications (1)
Publication Number | Publication Date |
---|---|
USRE41945E1 true USRE41945E1 (en) | 2010-11-23 |
Family
ID=25460593
Family Applications (2)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US09/931,320 Ceased US6920723B2 (en) | 2001-08-16 | 2001-08-16 | Impact sound insulation |
US11/782,999 Expired - Lifetime USRE41945E1 (en) | 2001-08-16 | 2007-07-25 | Impact sound insulation |
Family Applications Before (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US09/931,320 Ceased US6920723B2 (en) | 2001-08-16 | 2001-08-16 | Impact sound insulation |
Country Status (2)
Country | Link |
---|---|
US (2) | US6920723B2 (en) |
CA (1) | CA2398262C (en) |
Cited By (10)
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US8113495B2 (en) | 2005-05-02 | 2012-02-14 | Downey Paul C | Vibration damper |
US8240430B2 (en) | 2002-10-01 | 2012-08-14 | Downey Paul C | Noise and vibration mitigating mat |
US20130025965A1 (en) * | 2010-03-08 | 2013-01-31 | Kuraray Co., Ltd. | Sound insulation floor structure and sound insulation floor component as well as method for reducing floor impact sound |
US8640824B2 (en) * | 2012-05-10 | 2014-02-04 | Michael Freedman & Associates, Inc. | Acoustical vinyl flooring and methods of manufacture |
EP2777928A1 (en) | 2013-03-15 | 2014-09-17 | International Inc. Ecore | Recycled rubber backed cushioned vinyl |
US9174565B2 (en) | 2013-06-21 | 2015-11-03 | Ecore International Inc. | Recyclable rubber securement mat with self-provided incline stop |
US9289169B2 (en) | 2007-05-18 | 2016-03-22 | Optiscan Biomedical Corp. | Analyte monitoring systems and methods |
US9914011B2 (en) | 2015-06-25 | 2018-03-13 | Pliteq Inc. | Impact damping mat, equipment accessory and flooring system |
US10604946B2 (en) | 2012-05-10 | 2020-03-31 | Michael Freedman & Associates, Inc. | Method of manufacturing an acoustical flooring tile |
US10676920B2 (en) | 2015-06-25 | 2020-06-09 | Pliteq Inc | Impact damping mat, equipment accessory and flooring system |
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CA2454972C (en) * | 2003-01-09 | 2007-05-22 | Mel Gallant | Sound suppressing flooring and method of manufacturing same |
US7181891B2 (en) * | 2003-09-08 | 2007-02-27 | Quiet Solution, Inc. | Acoustical sound proofing material and methods for manufacturing same |
EP1678251B1 (en) * | 2003-09-23 | 2009-05-06 | Haydale Limited | Rubber compositions, methods of making rubber compositions, rubber and rubber-containing articles |
US20050069694A1 (en) * | 2003-09-26 | 2005-03-31 | Gilder Stephen D. | Anti-microbial carpet underlay and method of making |
PT103108A (en) | 2004-04-16 | 2004-12-31 | Amorim Revestimentos S A | Flooring for building, includes intermediate plate made from wood fibers agglomerate and set on balance sheet over backing cork plate made from cork agglomerate |
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US7921965B1 (en) | 2004-10-27 | 2011-04-12 | Serious Materials, Inc. | Soundproof assembly and methods for manufacturing same |
US20070039268A1 (en) * | 2004-12-01 | 2007-02-22 | L&P Property Management Company | Energy Absorptive/Moisture Resistive Underlayment Formed using Recycled Materials and a Hard Flooring System Incorporating the Same |
US7798287B1 (en) | 2005-01-20 | 2010-09-21 | Serious Materials, Inc. | Acoustical ceiling panels |
US20060230699A1 (en) * | 2005-03-22 | 2006-10-19 | Keene James R | Sound control flooring systems and methods therefor |
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US8113495B2 (en) | 2005-05-02 | 2012-02-14 | Downey Paul C | Vibration damper |
US9289169B2 (en) | 2007-05-18 | 2016-03-22 | Optiscan Biomedical Corp. | Analyte monitoring systems and methods |
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US9174565B2 (en) | 2013-06-21 | 2015-11-03 | Ecore International Inc. | Recyclable rubber securement mat with self-provided incline stop |
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Also Published As
Publication number | Publication date |
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CA2398262C (en) | 2010-09-28 |
CA2398262A1 (en) | 2003-02-16 |
US6920723B2 (en) | 2005-07-26 |
US20030033779A1 (en) | 2003-02-20 |
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