Patent Application
20160017603
The present invention relates to sub-flooring systems, including underlayment assemblies, and related methods, including heating (and/or cooling) sub-flooring systems and methods applying hydronics and hydronic structures.
An “ondol” is an underfloor heating system used in traditional Korean architecture. The system typically included a cooking fire or stove in a kitchen that was surrounded by one or more rooms of the house built on a raised masonry floor two or three feet higher than the kitchen. Extending through the raised masonry floor were horizontal smoke passages that led to a standing chimney providing a draft through the passages. Heat from the fire or stove would travel through the horizontal smoke passages to heat the rooms of the house. The horizontal smoke passages were usually covered by stone slabs, clay or concrete, which formed the heated floor of the rooms, and a water-impervious layer, such as oiled paper, which formed the finished flooring on the heated floor.
It is appreciated that an efficient ondol system required a delicate balance between two conflicting factors. On the one hand, for fuel to burn well in the fire or stove, the passages should provide good air flow from the fire to the chimney. On the other hand, for effective heating of the rooms, hot air should linger in the passages as long as possible to warm the stone slabs, clay or concrete forming the heated floor. To accomplish this, the passages were lengthened for multiple passes under each room, thus preventing the hot air from exiting through the chimney too quickly. When the correct balance was achieved, a room could be kept warm all night by the stone slabs, clay or concrete heated by a fire that lasted only a couple of hours.
Evolution of Korean architecture led to multi-story housing and improved ondol systems. However, flue gases from burning wood or coal caused many deaths from carbon monoxide poisoning. As a result, flue gas systems have given way to electric heating elements and/or piping circulating heated water (or “hydronics”).
In a “poured floor” or “wet floor” system, electric heating elements or hydronic piping extend through a “light” (more porous) concrete floor that is poured above a concrete slab. The wet floor system has many drawbacks, including the 15-20 day curing period for both layers of concrete, the upper layer of which cannot be poured until the lower layer has completely cured. The curing period can also be extended significantly if the concrete is poured during rainy or winter season. In cold climate, the concrete can even freeze.
After curing, the concrete can absorb water which can significantly increase its weight and evaporate during warmer weather causing the finishing flooring or laminate to buckle and warp. Moreover, in high-rise buildings and multi-story residential buildings, concrete can create poor acoustics as sound and impact waves can travel through concrete between floors and echo throughout the building. In that regard, while impact and/or sound may involve different physical events with different physical effects, impact and/or sound deadening are used interchangeably and collectively herein as “impact and/or sound deadening” or “ISD.”
Laying a sub-floor and piping in a “poured floor” or “wet floor” system is labor and time intensive. Different stages of construction and installation of a poured or wet floor system require time, scheduling and a team of professional workers with an array of different skills and experience. If any part of the sub-floor, piping or heating element in a “poured floor” or “wet floor” system is subsequently damaged, the concrete sub-floor of the entire room or area must be cracked and removed in order to access and replace the damaged piping or heating element. The concrete sub-floor must then be repoured over the replacement piping or heating element.
Accordingly, there is a need for a heating and/or cooling sub-flooring system which advantageously uses hydronics or hydronic principles for thermal conduction while minimizing or avoiding entirely the use of concrete. It is desirable that such sub-flooring system be easy to install, in terms of labor, time and the skills required of workers whether or not they are trained professionals. It is further desirable that such sub-flooring system, including underlayment assembly and/or sub-flooring panels, use environmentally-friendly components and that such sub-flooring system be adapted for use in multi-dwelling highrise buildings and multi-story residential buildings with significantly improved impact and/or sound deadening.
The present invention is directed to an ISD sub-flooring system, including a sub-flooring panel assembly and an underlayment assembly, that is environmentally-friendly and relatively inexpensive to manufacture and install in terms of material and labor. The sub-flooring system also provides significantly improved impact and/or sound deadening properties (collectively referred to herein as ISD properties).
A sub-flooring panel of the present invention is adapted to adjoin with other sub-flooring panels. The panel includes a base body having an upper surface formed with a groove for receiving a temperature control element, e.g., a hydronic heating and/or cooling piping adapted to pass fluid. The groove is lined with one or more thermally-conductive (TC) liners that come into contact with the piping after it is laid in the groove. The TC liners extend over surfaces of the base body for improving thermal transfer between the piping and the base body. A protective cap member covers the groove to protect the piping and provide a flat smooth surface generally continuous with the upper surface of the sub-flooring panel.
Each sub-flooring panel has side surfaces formed with tongue and groove connectors for releasably joining with adjacent sub-flooring panels to span an area. The sub-flooring panels are joined with the piping grooves aligned to form a predetermined groove pattern over the area so that a single continuous elongated piping can be placed in the grooves.
The underlayment assembly of the present invention includes layers of ISD material(s) and support structures, including stabilizing supports and at least one rigid board layer and at least one fiberboard layer. Depending on the layout of the sub-flooring panels, stabilizing supports are positioned at selected locations on a bottom slab structure, with the at least one rigid “balance” board and the at least one fiberboard positioned on the stabilizing supports. These layers may be affixed to each other by ISD adhesive and the like, and they may be affixed to the stabilizing supports by fasteners, such as screws or nails.
The stabilizing supports are advantageously portable, and adjustable in height for supporting the structures above it at any desired horizontal level, for example, to compensate for any tilting or unevenness of the bottom slab structure. Each stabilizing support has a tubular member containing a noncompressible, volume-filling particulate substance, and a piston inserted in the tubular member and resting on the surface of the particulate substance. The stabilizing supports further include ISD cushion pads and/or liners. The stabilizing supports also significantly increase the ISD properties of the underlayment assembly by providing a noncompressible layer of space that can both bear the weight load of the structures above while allowing the layer to be filled with a loose, volume-filling (“LVF”) substance with ISD properties, for example, natural fiber chips.
The present invention also includes methods of installing a sub-flooring system having a sub-flooring panel assembly and an underlayment assembly. The methods include forming a sub-flooring panel assembly by joining a plurality of sub-flooring panels with their piping grooves aligned, providing TC liners in the grooves and elsewhere on the panels, resting a piping on overlying TC liners along perforations positioned above the grooves and pressing on the piping with sufficient force to tear the perforations and drop into the grooves. Before the piping is laid in the grooves, an underlying TC liner may be placed in the groove or be wrapped on the piping so that the underlying TC liner accompanies the piping into the groove. With the piping installed in the grooves having direct and indirect contact with the overlapping TC liners, thermal transfer between the piping and the base body of the panel is increased.
The methods also include installing the underlayment assembly prior to installing the sub-flooring panel assembly. Installing the underlayment assembly includes installing and assembling stabilizing supports at selected locations on a slab structure relative to layouts of the sub-flooring panels, balance boards and/or fiberboards, for example, under their corner areas. Tubular members of the supports are affixed to their respective selected locations on the slab structure. The particulate substance is placed in the tubular members. The pistons are inserted into their respective tubular members and positioned on the particulate substance in the tubular members. The height of each piston is advantageously adjustable by methods including increasing or decreasing the amount of particulate substance contained in its respective tubular member, adding or removing ISD pads, and/or replacing the piston with a taller or shorter piston. The balance boards and/or fiberboards are placed on the stabilizing supports, followed by the assembly of sub-flooring panels.
The present invention further includes alternate embodiments of underlayment assemblies. In some embodiments, an underlayment assembly includes one or more generally rigid stabilizing panels, multiples of each are arranged in a side-by-side configuration to form a layer above a supporting surface, such as a slab. Each stabilizing panels has an upper portion, a lower portion and one or more pistons. The pistons are adapted to be supported in one or more first recesses formed in the upper portion, wherein the height of each piston is adjustable by the arrangement and/or amount of particulate substance contained in each first recess. The lower portion may have one or more second recesses adapted to form one or more insulation air pockets. One or more pistons may have a respective inner cavity, each adapted to form an insulation air pocket.
In more detailed embodiments, the first and second recesses of a respective stabilizing panel are generally in vertical alignment with each other. Moreover, each piston may have an inner cavity generally in vertical alignment with respective first and second recesses.
In more detailed embodiments, each stabilizing panel includes at least one tubular member configured to circumferentially line a respective first recess and to circumferentially contain particulate substance in the respective first recess.
In some embodiments, the underlayment assembly further includes one or more generally rigid sound trapping panels, each having at least one recess adapted to form at least one insulation air pocket. The one or more sound trapping panels may be arranged in a side-by-side configuration to fonts a layer of sound trapping panels, for example, between the layer of stabilizing panels and the sub-flooring panels. Each sound trapping panels is raised and supported by the one or more pistons above the layer of stabilizing panels. The underlayment assembly may include one or more layers of sound trapping panels, wherein the air pockets of the layers of sound trapping panels are vertically offset.
The present invention also includes a method of installing an underlayment assembly, comprising providing a support surface, providing a first amount of particulate substance on the support surface; positioning at least one stabilizing panel on the first amount of particulate substance, the at least one stabilizing panel having an upper portion, a lower portion and at least one piston, the upper portion having at least one first recess; providing a second amount of particulate substance in the at least one first recess; and positioning the at least one piston above the second amount of particulate substance.
The method may further include placing a tubular member in the at least one first recess before providing a second amount of particulate substance in the at least one first recess, and also providing at least one sound trapping panel on the at least one stabilizing panel.
These and other features and advantages of the present invention will be better understood by reference to the following detailed description when considered in conjunction with the accompanying drawings wherein:
ISD Sub-Flooring Panel
On the upper surface 12 of the body 11, an elongated recessed formation or piping groove 24 is provided. In the illustrated embodiment of
With reference to
As shown in
As also shown in
As illustrated in
To fill in the top cross-sectional portion 24R of the groove 24 and protect the piping 26, the protective filler or cap member 36 with a generally conforming configuration to the top groove portion 24R is placed in the groove 24 with its side portions 46 resting on the rises 42 on each side of the groove 24. In the illustrated embodiment, the top groove portion 24R has a generally rectangular cross sectional configuration, so the cap member 36 also has a generally rectangular cross-sectional configuration. Moreover, the thickness of the cap member 36 is no greater and generally equal to the depth D2 so that a top surface 48 of the cap member is generally even and co-planar with the top surface 12 of the body 11. As shown in
The piping 26 may be constructed of any suitable material, for example, cross-linked polyethylene (PEX or PEX-AL-PEX), that is fluid-tight and can tolerate exposure to high or low temperatures of fluid passing therethrough and be thermally conductive. The TC sheet liners 30 and 32 may be constructed of any suitable material, for example, aluminum, copper, or any combinations thereof. It is understood that a single TC sheet liner may be used in place of the TC liners 30 and 32; however, installation of the single TC sheet liner into the groove 24 may require additional care and labor compared to installation of the TC sheet liners 30 and 32.
The cap member 36 may be constructed of any suitable material, for example, oriented strand board (OSB) medium-density fiberboard (MDF), particle board, plywood, pre-fabricated agricultural residues, plastics, wood, aluminum, or any combinations thereof. MDF is an engineered wood product formed by breaking down hardwood or softwood fibers into fiberboards, often in a defibrator, combining it with wax and a resin binder, and forming panels by applying high temperature and pressure. MDF is generally denser than plywood. It is made up of separated fibers, but can be used as a building material similar in application to plywood. It is typically stronger and much denser than particle board.
It is noted that the sub-flooring panel of
As understood by one of ordinary skill in the art, the sub-flooring panel 10 may assume in a variety of shapes and sizes. The illustrated embodiment is of a panel 10 with a rectangular shape with a length L, a width W and a thickness T. In one embodiment, the length L may range between about 600 mm and 1,200 mm. The width W may range between about 300 mm and 600 mm. The thickness T may range between about 20 mm and 30 mm. In a more detailed embodiment, the panel 10 has a length L of about 1,200 mm, a width W of about 600 mm, and a thickness T ranging between about 20 mm and 30 mm. The measurements, especially, the width W, should be made with care, or the grooves 24 of adjoining sub-flooring panels will not be aligned. As such, the width W is preferably measured from one outer edge of the upper surface 12 to the opposing outer edge.
As for the piping groove 24, the depth D1 is about 20.0 mm, the depth D2 is about 4.0 mm, the width W1 is about 16.5 mm, and the width W2 is about 24.5 mm. The run 41 has a width of about 4.0 mm and the rise 42 has a width of about 4.0 mm. The piping 26 may have an outer diameter ranging between about 14.0 mm and 20.0 mm, and preferably about 16.0 mm. Each of the thermally-conductive sheet liner 30 and 32 has a thickness ranging between about 0.1 mm and 0.3 mm, and preferably a thickness of about 0.2 mm. The cap member 36 has a width less than the width W2, for example, of about 22.5 mm, so as to allow for expansion and shrinkage of materials due to temperature and humidity.
For any embodiments of the present invention, the sub-flooring panel 10 may further include a layer or coating of waterproofing or water-resistant sealant that is applied to the groove 24, including the trough 25, the rises 41 and the runs 42. The sealant may be also be applied to any other surfaces of the panel, including the upper, front, back and side surfaces 12, 14, 16, 18, 20 and 22, as needed or desired.
ISD Sub-Flooring Panel Assembly
In accordance with a feature of the present invention, a plurality of sub-flooring panels 10 may be joined along the front, back and side surfaces 12, 14, 16 and 18 to form an assembly 100 of sub-flooring panels, as shown in
As shown in
For the sub-flooring panel assembly, the present invention includes sub-flooring panels of different configurations, each with two or more piping grooves 24 tracing predetermined patterns, for receiving different segment portions of an elongated, flexible piping 26. As shown in
Each of the foregoing sub-flooring panels has at least one piping groove 24 that can be covered by a respective protective cap member 36 (or portion thereof). The cap member 36 therefore has generally the same predetermined pattern (e.g., linear, curve, U-shape, etc.) as its piping groove 24.
In the embodiment of
By combining selected sub-flooring panels 10A-10E and any other sub-flooring panels, a variety of sub-flooring panel assemblies can be formed, each with a continuous groove G adapted to receive an elongated, flexible piping 26. It is understood that inlet/outlet sub-flooring panel 10I/O for the ingress/egress of a piping into a room or area can be “customized” by using a selected portion of any of the foregoing sub-floor panels 10A, 10B, 10C, 10D or 10E. Moreover, “customizing” a sub-flooring panel with additional inlet/outlet grooves may be performed by workers as needed or desired during installation. Thus, for a room or area of any size or shape, the temperature thereof can be affected or controlled by a sub-flooring panel system 100 of the present invention adapted to receive one or more piping(s) 26 that are laid in the grooves 24 of the sub-flooring panels 10. In both
Manufacture of ISD Sub-Flooring Panel
With reference to
ISD Underlayment Assemblies
As shown in
In accordance with another embodiment of a sub-flooring system 300, the underlayment assembly 200 has a plurality of base stabilizing supports 210 and one or more underlayment layers. As shown in
The supports 210 are conveniently portable, repositionable and advantageously adjustable in height to serve multiple purposes and functions, including (1) leveling and stabilizing the sub-flooring panel assembly 100, especially where the slab 63 is not horizontally level, and (2) height-setting of the sub-flooring panel 100 (and hence of the finishing flooring or laminate 90). The supports also significantly increase the ISD properties of the underlayment assembly 200 by providing a stable and noncompressible layer that can both bear the weight load of the structures above while allowing the layer to be filled with a loose, volume-filling (“LVF”) substance 228 with ISD properties, for example, natural fiber chips, such as wood chips and/or annually renewal fiber chips such as kenaf chips, cotton, peanut shells, rice husks, coconut husks and the like, and synthetic fibers such as fiberglass and the like, or any combinations of any or all of the foregoing. By allowing the LVF substance 228 to stay loose and fluffy, their ISD properties are maximized.
As shown in the embodiment of
An ISD inner liner 221 is provided with a surrounding side portion 221S and a base portion 221B, where the side portion 221S lines an inner side surface 222 of the tubular member 212 and the base portion 221B seals the lower opening 217 of the tubular member 212. The ISD liner 221 is affixed to the inner side surface 222 of the tubular member 212 and an upper surface of the ISD pad 219 by ISD adhesive 242 or the like. The upper opening 215 allows communication between outside the tubular member 212 and the interior volume V, which is partially filled or occupied by a noncompressible, volume-filling particulate (“VFP”) substance 218. As shown in
As their names suggest, the ISD pad 219 and ISD liner 221 are made of any suitable material with ISD properties, for example, rubber and/or expanded polypropylene (EPP) which is an exceptionally eco-friendly, flexible and versatile plastic foam designed for lightweight, energy management and cushioning applications. The tubular member 212 is made of any suitable material that is rigid and lightweight but can bear weight and compression loads, for example, PVC, other plastics, metal, concrete, or any combinations thereof. It is understood that the cross sectional pattern X of the tubular member is not limited to a circle, but may in fact be a variety of shapes, for example, the circular and polygonal shapes shown in
The volume-filling particulate (“VFP”) substance 218 is pourable, spreadable and noncompressible. For example, the VFP substance 218 may be sand with sand particles having a diameter ranging from about 0.0625 mm (or 1/16 mm) to 2 mm. For example, the VFP substance may be silt with silt particles having a diameter ranging from about 0.0625 mm down to 0.004 mm. It is understood that the VFP substance may include sand, silt, or any combinations thereof. It is also understood that sand, silt, or any combinations thereof, may be combined with finer gravel particles having a diameter of about 6.3 mm or less to form other suitable VFP substances.
In the illustrated embodiment of
In the illustrated embodiment, the piston 214 includes a generally solid body 214B and it may include an upper ISD piston pad 230 and/or a lower ISD piston pad 232. The piston body 214B is constructed of any suitable material that is generally noncompressible with ISD properties and can bear significant weight and pressure loads, for example, oriented strand board (OSB), medium density fiberboard (MDF), particle board (PB), wood, plastic, concrete, or any combinations thereof. The upper and lower ISD pads 230 and 232 are affixed to upper and lower surfaces of the piston body 214B by ISD adhesive 242 or the like. As their names suggest, the upper and lower ISD pads 230 and 232 are also constructed of a material with ISD properties. The upper and lower pads have a girth/width slightly greater than that of the piston body so that a peripheral lip 234 is formed around the piston body 214B which prevents direct lateral contact between the piston body and the tubular member 212, as the present invention recognizes that direct contact between “nonISD” components may undesirably amplify impact and/or sound waves.
In the illustrated embodiment, the effective height h of the piston 214 (the piston body 214B with or without the upper and/or lower ISD pads 230 and 232) is also lesser than the height H of the tubular member 212, although it is understood that the height h need not be so lesser, provided the combined height of the piston body h and the height (or depth) h′ of the VFP substance 218 is sufficient so that the upper surface of the piston body 214U supported on the VFP substance 218 is higher than the upper rim 212U of the tubular member 212 (see
It is understood that one or more of the foregoing ISD pads and/or ISD liner may not be used, or that additional ISD pads or ISD liners may be used, as needed or appropriate, depending on a number of factors, including the structure of the slab 63, and the quantity and nature of underlayment layers, and/or the finishing floor 90.
Where the interior volume of the tubular member 212 (with or without the inner liner 221) is V, the portion occupied by the VFP substance 218 ranges between about 20% to 80% of V, preferably between about 30% to 70%, and more preferably about 50%. In addition to, or in lieu of the foregoing volume ratios, where the height of the tubular member 212 is H, the height h of the piston 214 ranges between about 50% to 100% of H, preferably between about 60%-80% of H, and more preferably about 75% of H. These ratios ensure that the piston 214 remains in the tubular member 212 and can properly support the structures above the supports 210. It is understood that these ratios can vary depending on the how horizontally level the slab 63 is. For example, where the slab 63 (whose left portion is shown in
The piston 214 is configured with at least one longitudinal channel 236 extending through at least the upper ISD pad 230 and the piston body 214B. In the illustrated embodiment, the channel 236 extends also through the lower ISD pad 232. The channel serves multiple purposes and function, including use as a handhold which facilitates the insertion, placement and removal of the piston 214 from the tubular member 212. The channel 236 also advantageously allows impact and sound waves from the sub-flooring panel 10 and the finished flooring 90 above to pass through the piston 214 and be trapped and absorbed by the VFP substance 218. To that end, the piston 214 may have more than one longitudinal channel 236.
A plurality of the supports 10 are placed on the slab in selected positions relative to the sub-flooring panel assembly above it, as illustrated in
In the illustrated embodiment of
In another embodiment as illustrated in
Installation and Assembly
For a room or an area to be covered by the sub-flooring panel assembly, a slab 63 is provided, on which one or more layers of ISD underlayment are installed. In the embodiments of
Each panel 10 may already have an overlying TC liner 32 (with perforations 61) affixed or laminated to the upper surface 12 (see
Elongated linear and curved strips of cap members 36 are then placed so that each groove 24 along the entirety of the pattern G, whether or not a segment of the piping 26 is in the groove, is covered and the piping below protected, taking care to avoid tearing or otherwise damaging the TC liners. Finishing flooring or laminates 90 are then installed above the sub-flooring panel assembly 100.
In another embodiment where supports 210 are used, the supports 210 are placed in selected locations on the slab 63. A “map,” for example, the top plan views of
To assemble and install a support 210, adhesive 242 is applied to the upper surface 63P of the slab at the selected location. Where the ISD base pad 219 is used, it is placed on the adhesive and affixed to the selected location. Adhesive 242 is applied to the upper surface of the ISD base pad 219 and the tubular member 212 is affixed thereto. Where the ISD liners 221B and 221S are used, adhesive 242 is applied to the inner surface 222 of the tubular member 212. The liners 221B and 221S are placed inside the tubular member 212 to line the interior volume V. It is understood that the liners 221B and 221S can be affixed to the tubular member 212 prior to installation.
The piston 214 may be assembled prior to insertion into the tubular member 214. The upper and lower pads 230 and 232 are affixed to the piston body 214B by adhesive 242. The pads are arranged relative to the piston body 214B in a manner whereby the channel 236 is aligned and the lips are provided in the periphery of the upper and lower pads 230 and 232.
During or after placement of all the tubular members 212 on the slab 63, the VFP substance 218 is poured or otherwise placed each tubular member 212 (the VFP substance 218 should be of a depth to at least cover any vane formations or grid formation 220). The piston 214 in each tubular member 212 is positioned to rest on the VFP substance 218. A measurement or assessment is made as to the effective height of the upper surface of each piston 214 (with or without upper ISD pad 230). Adjustments are made as needed so that each piston 214 is at a desired height, for example, where the upper surface of all pistons are above the upper rims of their respective tubular member and the upper surfaces of all pistons are at the identical altitude relative to ground (or the identical height from ground). Height adjustments may be made by, for example, by changing (increasing or decreasing) the amount of VFP substance 218 in the tubular member 212, removing or adding ISD pads, and/or replacing with a taller or shorter piston 214. After the desired height(s) are obtained, the spaces around and between the supports 210 are filled with LVF substance 228.
For another underlayment layer, a plurality of balance boards 238 are laid on the supports 210. Where balance boards 238 and fiberboards 240H are about the same sizes and shapes as the sub-flooring panels 10 for forming the sub-flooring panel assembly 100, the balance boards 238 and/or the fiberboards 240H may be installed in the same layout pattern as the sub-flooring panels. As shown in
After each of the balance boards 238 is laid on the supports 210, each is fastened to the supports 210 below it, for example, by fasteners, such as screws, nails or the like, driven through the balance boards and into at least the upper ISD pad 230, the piston body 214B and perhaps into the LVF particulate substance 218. The fiberboards 240 may also be fastened to the supports 210 in the same manner, either separately or simultaneously with the balance boards 238. As shown in
Above the underlayment assembly 200, the sub-flooring panels 10 may be arranged, joined, and laid in any manner depending on a number factors, including the shape and size of the room or area to receive the sub-flooring system 300, and the layout pattern(s) of the fiberboards and the balance boards below it. For example, sub-flooring panels 10D and 10E are arranged and joined along two opposing peripheral edges of the room and area and sub-flooring panels 10A, 10B and/or 10C are arranged and joined for the interior of the room or area. The grooves 24 of adjacent sub-flooring panels are align and connected to form a continuous groove having a pattern G with a generally serpentine portion GS, a linear traversing portion GL, an inlet 24I and an outlet 24O, as shown in
The piping 26 may be laid in the manner as described above. The strips of cap members 36 may be placed in the grooves 24 in the manner described above. Likewise, the finishing flooring or laminate 90 may be installed on the sub-flooring panel assembly. Finishing flooring or laminate may include, for example, laminated engineered wood flooring, hardwood flooring, tile or linoleum flooring.
As mentioned above, the cap members are preferably installed in each groove whether or not it contains the piping or any other elements. The protective cap member protect the piping and provides a smooth and even surface ready for installation of finishing flooring above the sub-flooring panel assembly.
Alternate Underlayment Assemblies
In other embodiments of the present invention, an underlayment assembly 400 includes one or more generally rigid stabilizing panels 402, multiples of which as needed are positioned in a side-by-side configuration, generally in contact and abutting with adjacent panels 402, to form a layer of stabilizing panels between the slab 63 and sub-flooring panels 10. As shown in
With reference to
As better shown in
On each upper ISD pad 416 and supported by the respective particulate substance 414 contained in the respective recess 408 is a respective piston 406. The piston 406 is shaped and sized to fit within the tubular member 410. The piston 406 has a generally solid body surrounding an inner cavity or channel 420 that is generally sealed at its lower end by the upper ISD pad 416 and at its upper end by a third ISD pad 422 that is positioned on the piston 406. The cavity 420 is therefore isolated within the piston 406 and provides an air pocket so as to provide sound, impact and/or thermal insulative properties in the piston 406. A coating or layer of ISD adhesive 424 may be applied to upper and lower surfaces of the piston 406 to affix the ISD pads 422 and 416 thereto.
In some embodiments, the stabilizing panel 402 includes a second or lower portion or layer 430 which is fastened or otherwise attached to the main portion 404, for example, by nails or screws 428 that extend through both portions. The lower portion 430 may be shaped and sized to match and correspond with the main portion 404 in the length and width dimensions, except the lower portion 430 may have a lesser thickness. The lower portion 430 also has a common plurality of recesses 432 which extend the entire thickness of the lower portion 430 to form through-holes 432, with each lower recess 432 being below or generally vertically aligned with the upper recesses 408 of the main portion 404, although the lower recesses 432 have a smaller cross-section than the cross-section of the upper recesses 408. The lower recess 432 forms an inner cavity that is sealed at its upper end by the ISD pad 412 and at its lower end by an ISD sheet 434 that extends between the slab and the lower layer and may be generally coextensive with the lower portion 430. The lower recess 432 therefore provides an air pocket providing sound, impact and/or thermal insulative properties to the lower portion 430 and hence the panel 402. The ISD sheet 434 may be affixed to the slab and/or the lower layer by a layer of ISD adhesive 436.
The stabilizing panel 402 and the piston 406 provide numerous advantages including many of those provided by the aforementioned stabilizing support 210 and piston 214, as described hereinabove. Moreover, suitable dimensions and configurations described hereinabove with regards to elements of the stabilizing support 210, including the tubular member 212, and the piston 214, are generally applicable to the stabilizing panel 402, tubular member 426, and the piston 406. It is understood that the volume or layer of particulate substance 414 within the recess 408 is of a quantity that allows a lower portion of the piston 406 to sit below an upper edge 426 of the tubular member 410 so that the tubular member 410 can contain the piston 406 and prevent the piston from sliding or otherwise moving outside of the tubular member 410. In turn, the tubular member 410 is contained and prevented from shifting by the recess 408 in the stabilizing panel 402. The body of the stabilizing panel thus supports the tubular member 410 which contains the particulate substance 414 which supports the pistons 406 which supports at least the sub-flooring panels 10 and any other components resting on the pistons 406. Without the body of the stabilizing panel, the tubular member 410 may break or crack under the weight or load imparted to the particulate substance 414 from above, causing the particulate substance 414 to leak. Such leakage can otherwise destabilize the piston 406 and thus the underlayment assembly, possibly leading to collapse of the underlayment assembly and the sub-flooring panels 10. Moreover, in the event of ground movement, such as an earthquake, the body of the stabilizing panel 402 can minimize lateral movement or shifting of the particular substance 414 and tubular members 426, and thus the pistons 406, particularly where the one or more stabilizing panels span the entirety of the room, abutting against the vertical wall isolator pads 510 and/or walls 64 of the room, as shown in
In some embodiments, the stabilizing panel 402 is about 300 mm to 600 mm×about 300 mm to 600 mm, and preferably about 600 mm×600 mm, the upper portion 404 has at thickness of about 19 mm, the lower portion 430 has a thickness of about 6.35 mm, the upper recess 408 has a circular cross-section, with a diameter of about 245 cm, and the lower recess 432 has a circular cross-section, with a diameter of about 110 cm. Furthermore, the piston 406 has an outer diameter of about 230 cm, an inner diameter of about 110 cm, and a height of about 19 cm. The tubular member 426 has an outer diameter generally equal to or no greater than 245 cm, an inner diameter of about 240 cm, a height of about 25 cm.
As shown in
In the illustrated embodiment, each panel 450 has a plurality of larger through-holes 452 and a plurality of smaller through-holes 458, with four larger through-holes 452 arranged in quadrants around one smaller through-holes 458. In the illustrated embodiment, the larger and small through-holes have a circular cross-section. The larger through-holes 452 have a diameter of about 110 cm, and the smaller through-holes 458 have a diameter of about 60 cm.
The main portion 404, the piston 406 and/or the lower portion 430 of the stabilizing panels 402, and/or the sound trapping panels 450 may be constructed of any suitable material that is generally noncompressible with ISD properties and can bear significant weight and pressure loads, for example, oriented strand board (OSB), medium density fiberboard (MDF), particle board (PB), wood, plastic, concrete, or any combinations thereof. It is understood that the main portion 404 and the lower portion 430 of the stabilizing panel 402 may have a single body construction provided the larger recess 408 and the smaller recess 432 may be formed. Outer or exposed surfaces of the main portion 404, the piston 406, the lower portion 430 and the panels 450 may be coated with a water-proofing sealant, as needed or appropriate.
It is understood that the plurality of recesses in the stabilizing panel 402 and the sound trapping panels 450 may vary depending on a number of factors, including size of these panels.
In the illustrated embodiment, one or more sound trapping panels 450 are situated above the layer of stabilizing panels 402, as supported by at least one piston 406 at generally a common height so that multiple trapping panels form a layer of sound trapping panels. It is understood that the amount of particulate substance 414 in each recess 408 on which a respective piston 406 is supported may be adjusted and/or the particulate substance may be arranged as needed or appropriate to support the sound trapping panels in a desirable manner. Being supported on the pistons 406, the sound trapping panels 450 are separated from and raised above the upper surface of the stabilizing panels 402 to provide additional air gaps 515 within the underlayment assembly in further increasing its sound, impact and/or thermal insulative properties.
The underlayment assembly 400 may be arranged in any suitable configuration between the slab 63 and the sub-flooring panels 10. In some embodiments, the configuration includes general vertical alignment of the smaller through-holes 458, the piston 406 and the through-holes 432, as shown in
In some embodiments, an underlayment assembly may include a second layer of sound trapping panels 500 between the first layer of sound trapping panels 450 and the sub-flooring panels 10. As shown in
It is understood that the ISD pads and sheets and the ISD adhesive may be provided and applied where appropriate or needed. Moreover, it is understood that any air pocket or air gap in the underlayment assembly may be left void or be partially or completely filled with particulate substance and/or loose volume filler substance.
Some embodiments of a method of installing the underlayment assembly 400 include placing the particulate substance 418 on the slab 63 and spreading it over the slab in a manner that can even out or otherwise compensate for any unevenness or unlevelness of the slab. One or more ISD sheets 434 are then placed above the particulate substance 418, followed by installation of one or more stabilizing panels 402. Where the stabilizing panels 502 have separate upper and lower portions 404 and 430, each is assembled prior to installation by affixing the upper and lower portions 404 and 430 together, for example, by nails 428. A coating of ISD adhesive 436 is applied to an upper surface of the ISD sheets 434 and the stabilizing panels 502 are placed on thereon.
A tubular member 410 is placed in a respective recess 408. An ISD pad 412 is placed in a respective recess 408, circumscribed by the respective tubular member 410, of one or more stabilizing panels 502, which creates an air pocket in the recess 432 that is sealed between the ISD pad 412 and the ISD sheet 434. Particulate substance 414 is placed in the recesses 408 (at least partially filling the recess 408), within the tubular member 410 and above the ISD pad 412. The particulate substance 414 is arranged to provide an even and level surface on which an ISD pad 416 is placed.
For a respective recess 408, a piston 406 is placed on the ISD pad 416 within the upper edge 426 of the tubular member 410 lining the recess 408. Care may be taken to arrange the height of the particulate substance 414 in adjacent recesses 408 so that the pistons 406 are supported in a desirable or appropriate manner, including at a desirable or appropriate height so that the pistons in turn can suitably support the components above. An ISD pad 422 is placed on an upper surface of the piston 406 which forms an air pocket in the inner channel 420 of the piston between the ISD pads 422 and 416. A coating of ISD adhesive 424 is applied to the upper and lower surfaces of the piston 406 to affix together the piston 406 and the ISD pads 422 and 416.
ISD sheets 454 and 456 may be affixed to upper and lower surfaces of one or more sound trapping panels 450 before the panels 450 are positioned above the pistons 406. The ISD sheets 454 and 456 seal the recesses 452 and 458 forming air pockets in the panels 450. Additional sound trapping panels 450 may be stacked on top of each other to form one or more layers of sound trapping panels as desired or appropriate above the pistons 406. The different layers may be staggered so the recesses 452 and 458 are staggered. Above the one or more layers of sound trapping panels 450 sub-flooring panels 10 may be installed, as described hereinabove.
One or more additional vertical pads 510, constructed of, for example, Low Density Fiberboard (LDF) pads, or felt pads, or any other ISD pads, may be situated vertically against vertical slab 64, as shown in
In the illustrated embodiment, each stabilizing panel 402 has four pistons 406, and each sound trapping panel 450 is supported by eight pistons. The stabilizing panels 402 and the sound trapping panels 450 are sized and configured such that a sound trapping panel 450 is coextensive with two side-by-side stabilizing panels 402, with four pistons occupying a respective quadrant of the stabilizing panel 402 and supporting one half of the sound trapping panel 450, and a smaller recess 458 of the sound trapping panel 450 in vertical alignment with the piston 406 and the lower recess 432 of the stabilizing panel 402.
The preceding description has been presented with reference to presently preferred embodiments of the invention. Workers skilled in the art and technology to which this invention pertains will appreciate that alterations and changes in the described structure may be practiced without meaningfully departing from the principal, spirit and scope of this invention. In that regard, the drawings are not necessarily to scale. Any feature of any embodiment may be used in combination with any feature of any other embodiment, as needed or desired. It is understood that an electronic heating and/or cooling element may be used in lieu of or in addition to the piping. For example, an electronic heating wire or cord may be placed in the groove of the sub-flooring panel in lieu or in addition to the piping. Accordingly, the foregoing description should not be read as pertaining only to the precise structures described and illustrated in the accompanying drawings, but rather should be read consistent with and as support to the following claims which are to have their fullest and fair scope.
This application is a continuation in part of U.S. patent application Ser. No. 14/300,183, filed Jun. 9, 2014, which claims the benefit of U.S. Provisional Patent Application No. 61/834,384 filed Jun. 12, 2013, the entire contents of both applications are incorporated herein by reference.
| Number | Date | Country | |
|---|---|---|---|
| 61834384 | Jun 2013 | US |
| Number | Date | Country | |
|---|---|---|---|
| Parent | 14300183 | Jun 2014 | US |
| Child | 14869757 | US |
