Patent Application
20220081915
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.
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.
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.
The drawings included with this application illustrate certain aspects of the embodiments described herein. However, the drawings should not be viewed as exclusive embodiments.
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
With reference to
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
In other embodiments, as shown in
With reference to
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 37a and a second edge 37b. Second edge 37b is located further from first edge 32 of first end 30 than first edge 37a. 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
As shown in
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 20b terminating at, or substantially at, the location of second edge 37b of adhesive strip 36 of sound attenuating panel 20a ensures direct contact between sound attenuating panel 20a and sound attenuating panel 20b. Adhesive strip 36 of sound attenuating panel 20a is set at the exact distance that second width 43 of engagement flap 42 of sound attenuating panel 20b must stretch to create a substantially perfect abutting seam between sound attenuating panel 20a and sound attenuating panel 20b. While an installer may be blind to the seam due to engagement flap 42, there is effectively a 0% chance that sound attenuating panel 20a and sound attenuating panel 20b have shifted away from one another to create a valley/gap because, if sound attenuating panels 20a and 20b had shifted apart, engagement flap 42 of sound attenuating panel 20b would not contact and substantially cover adhesive strip 36 of sound attenuating panel 20a. 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
With reference to
In some embodiments, second width 43 of engagement flap 42 of second sound attenuating panel 20b terminates at the location of second edge 37b of adhesive strip 36 of first sound attenuating panel 20a. In other embodiments, second width 43 of engagement flap 42 of second sound attenuating panel 20b extends no more than 0.5 inches past the location of second edge 37b of adhesive strip 36 of first sound attenuating panel 20a. In other embodiments, second width 43 of engagement flap 42 of second sound attenuating panel 20b extends no more than 0.125 inches past the location of second edge 37b of adhesive strip 36 of first sound attenuating panel 20a. In another embodiment, each of first sound attenuating panel 20a and second sound attenuating panel 20b 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 20a, 20b being substantially coplanar and in direct contact when installed. Second width 43 of engagement flap 42 of second sound attenuating panel 20b terminating at, or substantially at, the location of second edge 37b of adhesive strip 36 of first sound attenuating panel 20a ensures direct contact between first sound attenuating panel 20a and second sound attenuating panel 20b. 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 20a and second sound attenuating panel 20b. If first sound attenuating panel 20a and second sound attenuating panel 20b have shifted away from one another to create a valley/gap, engagement flap 42 of second sound attenuating panel 20b would not contact and substantially cover adhesive strip 36 of first sound attenuating panel 20a. 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.
