Patent Application
20060230699
The present invention is directed to sound control flooring systems and methods therefor. More particularly, the present invention is directed to sound control flooring systems generally including at least two layers of sound control material disposed between a subfloor and finished flooring assembly, and to methods for installing sound control flooring systems.
Sound and the transmission thereof in buildings, particularly between floors in multistory dwellings and commercial buildings, can be a serious problem. Transmitted sound is typically caused by impact generated by forceful meeting of an object with a floor or airborne sound. The transmission of sound between floors may disturb or be an annoyance to individuals present in the area below or adjacent to the room in which the sound is generated.
In general, impact sound is generated due to pedestrian footfall on the floor, movement of heavy objects over the floor, and any other contact made with the floor. Airborne sound is usually due to speech or music. The transmission of sound between floors is particularly a problem where the upper finished flooring is made of concrete, ceramic tiles, or hardwood. Installation of thick carpeting may be required to prevent the transmission of sound. However, in multi-family, stacked construction, hard surfaces are desirable, yet noisy for surrounding neighbors. Additionally, carpet is not an aesthetically desirable component. An alternative to the use of carpeting to prevent sound transmission has been the use of a sound rated floor system, such as one disclosed in U.S. Pat. No. 4,685,259, or a floating floor, such as one disclosed in U.S. Pat. No. 4,879,856. The use of sound rated floor system or a floating floor substantially reduces the transmission of sound between floors by isolating the flooring from the floor substructure. Products that create a floating floor have resilience, create an air space and the thicker the better. Accordingly, what is needed is a sound control flooring system that is inexpensive, simple and quick to install, is resilient, allows for a thin concrete topping while creating maximum airspace and change composition.
In accordance with one example aspect, the present invention is directed to a sound control flooring system adapted to reduce the transmission of airborne sound in a building structure. The system generally includes a subfloor assembly; a first layer of material disposed atop at least a portion of the subfloor assembly, wherein the first layer of material is constructed of a sound absorbing material; a second layer of material disposed atop at least a portion of the first layer of material, wherein the second layer of material is constructed of a sound absorbing material; and a cementitious overlay disposed atop at least a portion of the second layer of material, wherein the overlay is adapted to receive finished flooring thereon.
In accordance with another example aspect, the present invention is directed to a sound control flooring system adapted to reduce the transmission of airborne sound in a building structure. The system generally includes a subfloor assembly; and a first layer of material disposed atop substantially all of the subfloor assembly, wherein the first layer of material is constructed of a sound absorbing material. The system generally also includes a second layer of material disposed atop a portion of the first layer of material, wherein the second layer of material is constructed of a sound absorbing material; and wherein the portion of the first layer of material corresponds to an area of the flooring system adapted to receive a high volume of foot traffic thereon; and a cementitious overlay disposed atop at least a portion of the second layer of material and the first layer of material, and wherein the overlay is adapted to receive finished flooring thereon.
In accordance with yet another aspect, the present invention is directed to a method for installing a sound control flooring system adapted to reduce the transmission of airborne sound in a building structure. The method generally includes the steps of disposing a first layer of material atop at least a portion of a subfloor assembly, wherein the first layer of material is constructed of a sound absorbing material; disposing a second layer of material atop at least a portion of the first layer of material, wherein the second layer of material is constructed of a sound absorbing material; and disposing a cementitious overlay atop at least a portion of the second layer of material, and wherein the overlay is adapted to receive finished flooring thereon.
These and other features and a more thorough understanding of the present invention may be achieved by referring to the following description and claims, taken in conjunction with the accompanying drawings, wherein:
Disclosed according to the present invention are sound control flooring systems and methods for installing sound control systems. The systems and methods of the present invention are suitably useful for controlling sound and/or noise in commercial and residential multi-story building structures, such as, for example, condominiums, apartments, office buildings, hotels, schools, athletic floors, and the like. The systems and methods preferably control sound by including at least two layers of sound control material disposed between a subfloor assembly and a finished floor assembly. The layers of sound control material preferably lower both structural and airborne sound transmission by absorbing vibrational energy and otherwise generally reducing the continued transmission thereof. Accordingly, the presence of the sound control layers in a flooring assembly suitably reduces the noise profile of a building structure, especially noise generated by foot traffic of individuals and other noise generated by impact with a floor.
Illustrated with reference to
The sound control flooring system 100 is preferably a component integral with a building, and, accordingly, is associated with one or more walls 118 in generally perpendicular relationship. The wall 118 may suitably be a drywall member fastened to a wall support member (not shown), or be provided according to any of a plurality of known configurations.
The sound control flooring system 100 also includes the first layer 110 of sound control material disposed atop at least a portion of the subfloor assembly 106. In connection with a preferred example embodiment, the first layer 110 is provided as a highly porous three dimensional matrix filamentous mat manufactured from a thermoplastic material, such as a polyolefin (e.g., polyethylene, polypropylene, etc.), a polyvinyl halide (e.g., polyvinyl chloride, polyvinylidene chloride, polyvinyltetrafluoride, polyvinyl chlorotrifluoride), polystyrene, polyamide, a polyvinylester (e.g., polyvinyl acetate, etc.), and mixtures, copolymers and modifications thereof. The preferred mat includes a plurality of filaments that are heat fused to one another at randomly spaced points to form a three-dimensional, convoluted and mutually interconnected filamentatious body and is preferably constructed in accordance with techniques well known to one of ordinary skill in the art, such as disclosed by, for example, U.S. Pat. Nos. 3,687,759; 3,691,004; 4,212,692, etc., the contents of all of which are hereby incorporated by reference in their entireties.
The first layer 110, preferably provided as the three dimensional matrix filamentous mat, is preferably disposed in the sound control flooring system 100 in a manner by which it overlies a portion of, more preferably substantially all, of the subfloor assembly 102. Additionally, the first layer 110 may be provided in any appropriate thickness, such as approximately ⅛ inch, ¼ inch, ⅓ inch, ½ inch, ⅔ inch, ¾ inch, 1 inch, or any other appropriate size, Metric or English, given the particular configuration and requirements of a building assembly. The first layer 110 is also preferably disposed with its longitudinal axis in parallel relationship to the longitudinal axis of the subfloor assembly 102, thereby maximizing the extent of contact between the first layer 110 and the subfloor assembly 102. Accordingly, the first layer 110 is preferably disposed as a subfloor assembly 102 overlay that operates to receive and/or filter sound and/or vibration emanating from a region above the first layer 110 and reduce the transmission of the same to the subfloor assembly 102.
The first layer 110 may suitably be disposed on the subfloor assembly 106 in a manner that provides continuous contact with edges of the first layer 110 and the walls 118. Alternatively, the flooring system 100 may suitably include one or more spacers 120, preferably constructed of, e.g., ⅛ inch packaging foam, disposed along the inner perimeter of the walls 118 at or near the junction of the walls 118 and the subfloor assembly 106. Accordingly, the first layer 110 may suitably be provided in a size and configuration that extends along the entirety of the subfloor assembly 106 and extends to and generally remains in abutting contact with the spacers 120. Alternatively, the spacers 120 may suitably be disposed atop the first layer 110 and in abutting contact with the walls 118.
With reference to an example embodiment, a fastening means, such as a glue-like adhesive, a mechanical fastener (e.g., screw, staple, rivet, mortar, and the like), pressure sensitive tape, and the like, may suitably and optionally be provided between the first layer 110 and the subfloor assembly 102 to increase the association between the first layer 110 and the subfloor 102. Such association may be especially advantageous in connection with a conventional configuration of the first layer 110 filamentous mat in which the mat is commercially provided in rolled form. Accordingly, the fasteners may suitably overcome the curling tendencies of the mat as the mat is being positioned atop the subfloor assembly 102.
The use of a three dimensional matrix filamentous mat as the first layer 110 suitably provides a plurality of advantages. With reference to a first example advantage, the mat, suitably an account of the chemical composition of its structure, its three dimensional arrangement, etc., operates as a sound control mat. Accordingly, the presence of the mat in proximity to the sonic projections of sound suitably causes a reduction in the deleterious effects of the sound. With reference to another example advantage, the mat also exhibits a crush resistance property that allows it to withstand a level of compressive load without crushing away the peak and valley configurations thereof. The ability of the mat to withstand a given compressive load properly varies with certain factors, such as the filament diameter, the material used for construction of the mat, the size of the mat, etc., as known to one of ordinary skill in the art. However, the crush resistance property of the mat suitably ensures that the disposition of the mat as a load bearing surface positioned beneath additional overlays and finished flooring will not impair its sound absorbing capacity. With reference to another example advantage, the mat is preferably constructed from materials that are resistant to water, mold and other environmental factors, and/or be treated with anti-microbial agents, thereby reducing and/or otherwise eliminating the need for providing repair access to the installed first layer 110.
Despite the foregoing discussion of the first layer 110 provided as a three dimensional matrix filamentous mat, it is to be appreciated that the first layer 110 may suitably be provided as any material exhibiting sound control and/or dampening characteristics, given the aims of the present invention. For example, the first layer 110 may suitably be provided as elastic foam, such as described in U.S. Pat. No. 4,681,786, the contents of which are hereby incorporated in their entirety, a honeycomb-like structure of cardboard, such as described in U.S. Pat. No. 4,685,259, the contents of which are hereby incorporated in their entirety, fiber glass, kraft paper, mineral wools, a plastic mat having projections (e.g., pyramidal, conical, conico-frustral, and the like) emanating therefrom, as variously described in U.S. Pat. Nos. 3,729,364, 5,619,832, 5,489,462, and 5,383,314 the contents of all which are hereby incorporated in their entirety, and the like. Additionally, the first layer 110 may suitably also include a layer of a non-woven material associated with a surface thereof, such as one sold under the trademarks ROOFSHIELD (Liner Rolpanit, Inc., Toronto, Canada), DIFOLEN-S (OttoWolff, Chicago, Ill.), TEN CATE (Nicholson, Pendergrass, Ga.), and the like.
The sound control flooring system 100 suitably also includes a second layer 112 of sound control material disposed above the first layer 110 for augmenting the sound control flooring system's 100 sound reduction capacity. With reference to a preferred embodiment and as illustrated in
With reference to a preferred embodiment and
With reference to an alternate preferred embodiment and
With continued reference to
Returning to
Continuing with a more thorough discussion of the constitution of the alternate example embodiment of the sound control flooring system 100, the system 100 preferably includes a spacer assembly 122, preferably constructed of, e.g., ⅛ inch thick packaging foam, disposed atop the first layer 110 and in a position so as to perimetrically abut and generally frame the second layer 112. The spacer assembly 122 is preferably provided as a generally rectangular member hollow along substantially all of its inner portion, in which inner portion the second layer 112 is position. Accordingly, the spacer assembly 122 may suitably be provided as four elongate, generally rectangular members, each disposed relative to each other so as to collectively define a frame-like member. However, it is to be appreciated that the spacer assembly 122 may suitably be provided as a unitary frame-like assembly, or in any other suitable form. It is also to be appreciated that the spacer assembly 122 is an optional component of the flooring system 100 and need not be included.
Once the first layer 110 has been position atop the subfloor assembly 106 and the second layer 112 has been positioned atop the first layer 110, preferably only along a region corresponding to the high traffic region 150, and, optionally, the spacers 122 have been installed, the flooring system 100 is in a state to receive an overlay that will operate as a situs for installation of finished flooring. With continued reference to
With the overlays 124, 126 installed, the flooring system 100 is generally in a state ready to receive finished flooring 116 thereon. However, if the spacers 120, 122 are present, they suitably are cut and/or leveled so that upper portions thereof are coplanar with the overlays 124, 126 to thereby ensure a fully leveled and even surface for the receipt of the finished flooring 116 thereon. Depending on the particular configuration and arrangement of the spacers 120, 122 relative to the overlays 124, 126, and especially if gaps exist therebetween, a non-woven fabric or similar member may suitably be fastened (with, e.g., mortar) atop the overlay 124/126 and the spacer 120/122 so as to provide a flush and continuous surface.
The finished flooring 116 is then installed atop the overlays 124, 126 and, if optionally present, the spacers 120, 122. The finished flooring 116 is any conventional and desired flooring, such as, for example, hardwood, natural stone, ceramic tile, vinyl, and the like. Additionally, the finished flooring 116 is fixedly associated with the overlays 124, 126 through any appropriate fasteners, as conventionally known in the art.
It is to be appreciated that the foregoing discussion of the sound control flooring system 100 and its various components, particularly the first layer 110 and the second layer 112, is by way of example only and that a plurality of alternate configurations thereof are contemplated, each of which generally incorporates an aim of the present invention to provide a sound control flooring system that includes a plurality of different compositions of material within the floor and maximize sound control properties. With reference to an additional example embodiment, particularly the high traffic-focused embodiment, the flooring system 100 may suitably be modified in any of a plurality of ways for controlling sound and minimizing installation complications. Accordingly, a portion of the flooring system 100, preferably a portion corresponding to the high traffic region 150, may suitably include the first layer 110 and the second layer 112 being provided as a generally unitary construction, with the remainder of the first layer 110 to be disposed within the remainder of the flooring system 100 to be added as a separate component. In other words, as the flooring system 100 is installed, the high traffic region 150 receives a component, which is preferably provided as a two layer assembly, more preferably the first layer 110 having the second layer 112 associated thereon and/or therewith. Once the component (i.e., the two layer assembly) is installed, the remainder of the flooring system 100 (i.e., that portion of the flooring system 100 that does not include a layer of sound control material associated therewith) receives one or more layers of sound control material thereon.
Although the invention has been described with regard to certain preferred example embodiments, it is to be understood that the present disclosure has been made by way of example only, and that improvements, changes and modifications in the details of construction and the combination and arrangement of parts may be resorted to without departing from the spirit and scope of the invention. Such improvements, changes and modifications within the skill of the art are intended to be covered by the scope of the appended claims.
