US20060230699A1 - Sound control flooring systems and methods therefor - Google Patents
Sound control flooring systems and methods therefor Download PDFInfo
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- US20060230699A1 US20060230699A1 US11/086,158 US8615805A US2006230699A1 US 20060230699 A1 US20060230699 A1 US 20060230699A1 US 8615805 A US8615805 A US 8615805A US 2006230699 A1 US2006230699 A1 US 2006230699A1
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- 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
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- 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
- E04F15/182—Underlayers coated with adhesive or mortar to receive the flooring
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- 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
- E04F15/203—Separately-laid layers for sound insulation
Definitions
- 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.
- 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.
- 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.
- 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.
- FIG. 1 is a side plan view of an example sound control flooring system, according to the present invention.
- FIG. 2 is a plan view of an alternate example sound control flooring system, according to the present invention.
- FIG. 3 is a perspective view of the sound control flooring system of FIG. 2 .
- 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.
- the sound control flooring system 100 preferably, and by way of example only, includes a subfloor assembly 102 , one or more walls 118 associated with the subfloor assembly 102 , a first layer 110 of sound control material disposed atop the subfloor assembly 102 , a second layer 112 of sound control material disposed atop the first layer 110 , an overlay 114 disposed above the second layer 112 , and a finished flooring 116 disposed above the overlay 114 .
- the subfloor assembly 102 is preferably a conventionally known subfloor assembly installed as a structural framework member upon which components of a floor are installed and potentially forming an upper portion of a ceiling disposed below the subfloor assembly 102 .
- the subfloor assembly 102 may suitably comprise a plurality of load-bearing wood joists 104 running in parallel and spaced apart relationship along a lower portion of a subfloor 106 , which may suitable be provided as a plywood member. It is to be appreciated that the subfloor assembly 102 may suitably be provided as a unitary concrete assembly, or as any other appropriate structural member. Additionally, the subfloor assembly 102 may suitably include a waterproof membrane 108 , preferably a load-bearing waterproof membrane, positioned on an upper surface thereof.
- 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 .
- 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.
- a polyolefin e.g., polyethylene, polypropylene, etc.
- a polyvinyl halide e.g., polyvinyl chloride, polyvinylidene chloride, polyvinyltetra
- 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 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 1 ⁇ 8 inch, 1 ⁇ 4 inch, 1 ⁇ 3 inch, 1 ⁇ 2 inch, 2 ⁇ 3 inch, 3 ⁇ 4 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 .
- the flooring system 100 may suitably include one or more spacers 120 , preferably constructed of, e.g., 1 ⁇ 8 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 .
- 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 .
- the spacers 120 may suitably be disposed atop the first layer 110 and in abutting contact with the walls 118 .
- 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 .
- 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
- 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
- the use of a three dimensional matrix filamentous mat as the first layer 110 suitably provides a plurality of advantages.
- 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.
- 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.
- 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.
- 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 .
- 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.
- 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.
- 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.
- ROOFSHIELD Liner Rolpanit, Inc., Toronto, Canada
- DIFOLEN-S OttoWolff, Chicago, Ill.
- TEN CATE Nicholson, Pendergrass, Ga.
- 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.
- the second layer 112 is preferably provided as a plastic mat having a plurality of conical, dimple-like and/or cuspated projections extending therefrom, such as disclosed in U.S. Pat. No. 5,619,832, the contents of which are hereby incorporated in their entirety.
- the second layer 112 is preferably disposed above the first layer 110 in an overlay manner and may suitably include a fastening member, as described hereinabove, for securely associating the second layer 112 to the first layer 110 .
- the second layer 112 suitably operates in a manner similar to the operation of the first layer 110 by absorbing sound and/or generally reducing the transmission of sound to the subfloor assembly 102 and elsewhere.
- the second layer 112 may suitably be provided as any material exhibiting desired sound control characteristics, suitably as hereinabove described.
- the second layer 112 is preferably coextensively disposed above the first layer 110 . Accordingly, the second layer 112 is preferably provided in a size and configuration so as to overlay substantially all of the first layer 110 , thereby creating a two layer subfloor assembly 102 overlay system that overlies the entire subfloor assembly 102 , which may or may not be coextensive with the spacers 120 .
- the sound control flooring system 100 may suitably include one or more bracing members disposed between the overlay 114 and the subfloor assembly 102 to provide structural reinforcement for the finished flooring 116 .
- the second layer 112 is preferably provided in a reduced size, relative to the size of the first layer 110 , and is preferably positioned atop the first layer 110 in a position adapted to receive maximum exposure to sound.
- most rooms of a dwelling structure contain furniture and other articles arranged therein in a manner that causes substantially all of the foot traffic generated therein to occur along a narrowly defined portion of the room's floor.
- the foot traffic is concentrated along a high traffic region 150 ( FIGS. 2 and 3 ) that is disposed generally centrally over the floor.
- the second layer 112 is preferably disposed atop the first layer 110 in a position generally below the floor high traffic region 150 so as to maximize the amount of sound reduction effected by the flooring system 100 of the present system.
- the alternate example embodiment of the sound control flooring system 100 is preferably installed according to a method that involves identifying a region of the floor to be the high traffic region 150 .
- the high traffic region 150 is identified and/or demarcated by defining an inner perimeter that is inwardly offset relative to the walls 118 by a consistent distance 152 .
- the high traffic region 150 is preferably a quadrilateral-like portion having a first pair of edges that are parallel to each other and a second pair of edges that are also parallel to each other.
- One set of region 150 edges are preferably parallel with a pair of opposed walls 118 of the room and the other set of region 150 edges are preferably parallel with another pair of opposed walls 118 of the room.
- the distance 152 separating the region 150 edges from the walls 118 is preferably a distance continuous along entirety of the interface between the edges and the walls 118 .
- the distance 152 is established as approximately eighteen inches, although any other distance, such as four to sixteen inches and in excess of eighteen inches, may be employed, with regard given to the physical dimensions of the room, the intended application of the room, and the like.
- the second layer 112 is preferably disposed atop the first layer 110 only along the region of the floor corresponding to the high traffic region 150 .
- the second layer 112 is disposed atop the first layer 110 only along a middle portion of the floor corresponding to the high traffic region 150 and extends from a midpoint of the floor to a perimeter thereof that is defined to terminate at a position inwardly offset from the walls 118 by the predetermined distance 152 , preferably eighteen inches.
- the system 100 preferably includes a spacer assembly 122 , preferably constructed of, e.g., 1 ⁇ 8 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.
- 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.
- the flooring system 100 is in a state to receive an overlay that will operate as a situs for installation of finished flooring.
- the second layer 112 preferably receives an overlay 126 thereabove that covers the entirety of the second layer 112 and extends to and abuts the spacer assembly 122 .
- the overlay 126 is preferably any appropriate overlay material as known in the art, such as, for example, gypsum, concrete, mortar, wood, and the like.
- the first layer 110 preferably also receives an overlay 124 thereover that covers the entirety of the first layer 110 and extends in abutting relationship between the spacer assembly 122 and the walls 118 (or, optionally, the spacers 120 ).
- the overlay 124 is also preferably any appropriate overlay material as known in the art, such as, for example, gypsum, concrete, mortar, wood, and the like.
- a reduced amount of overlay 126 material is employed, relative to conventional techniques. Because the first layer 110 includes on at least a portion thereof the second layer 112 , the amount of overlay 126 required to complete the flooring system 100 is reduced, thereby reducing costs associated with installing a flooring system.
- the flooring system 100 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.
- 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.
- the sound control flooring system 100 and its various components 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.
- the flooring system 100 may suitably be modified in any of a plurality of ways for controlling sound and minimizing installation complications.
- a portion of the flooring system 100 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.
- 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.
- 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.
Abstract
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 sound absorbing material disposed atop at least a portion of the subfloor assembly, a second layer of sound absorbing material disposed atop at least a portion of the first layer of material, and a cementitious overlay, adapted to receive finished flooring thereon, disposed atop at least a portion of the second layer of material. In an example embodiment, the second layer of sound absorbing material is disposed atop a portion of the first layer of material that generally corresponds to an area of the flooring system adapted to receive a high volume of foot traffic thereon.
Description
- 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:
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FIG. 1 is a side plan view of an example sound control flooring system, according to the present invention; -
FIG. 2 is a plan view of an alternate example sound control flooring system, according to the present invention; and -
FIG. 3 is a perspective view of the sound control flooring system ofFIG. 2 . - 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
FIG. 1 is an example embodiment of a sound control flooring system 100. The sound control flooring system 100 preferably, and by way of example only, includes asubfloor assembly 102, one ormore walls 118 associated with thesubfloor assembly 102, afirst layer 110 of sound control material disposed atop thesubfloor assembly 102, asecond layer 112 of sound control material disposed atop thefirst layer 110, anoverlay 114 disposed above thesecond layer 112, and a finishedflooring 116 disposed above theoverlay 114. Thesubfloor assembly 102 is preferably a conventionally known subfloor assembly installed as a structural framework member upon which components of a floor are installed and potentially forming an upper portion of a ceiling disposed below thesubfloor assembly 102. Thesubfloor assembly 102 may suitably comprise a plurality of load-bearingwood joists 104 running in parallel and spaced apart relationship along a lower portion of asubfloor 106, which may suitable be provided as a plywood member. It is to be appreciated that thesubfloor assembly 102 may suitably be provided as a unitary concrete assembly, or as any other appropriate structural member. Additionally, thesubfloor assembly 102 may suitably include awaterproof membrane 108, preferably a load-bearing waterproof membrane, positioned on an upper surface thereof. - 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. Thewall 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 thesubfloor assembly 106. In connection with a preferred example embodiment, thefirst 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 thesubfloor assembly 102. Additionally, thefirst 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. Thefirst layer 110 is also preferably disposed with its longitudinal axis in parallel relationship to the longitudinal axis of thesubfloor assembly 102, thereby maximizing the extent of contact between thefirst layer 110 and thesubfloor assembly 102. Accordingly, thefirst layer 110 is preferably disposed as asubfloor assembly 102 overlay that operates to receive and/or filter sound and/or vibration emanating from a region above thefirst layer 110 and reduce the transmission of the same to thesubfloor assembly 102. - The
first layer 110 may suitably be disposed on thesubfloor assembly 106 in a manner that provides continuous contact with edges of thefirst layer 110 and thewalls 118. Alternatively, the flooring system 100 may suitably include one ormore spacers 120, preferably constructed of, e.g., ⅛ inch packaging foam, disposed along the inner perimeter of thewalls 118 at or near the junction of thewalls 118 and thesubfloor assembly 106. Accordingly, thefirst layer 110 may suitably be provided in a size and configuration that extends along the entirety of thesubfloor assembly 106 and extends to and generally remains in abutting contact with thespacers 120. Alternatively, thespacers 120 may suitably be disposed atop thefirst layer 110 and in abutting contact with thewalls 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 thesubfloor assembly 102 to increase the association between thefirst layer 110 and thesubfloor 102. Such association may be especially advantageous in connection with a conventional configuration of thefirst 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 thesubfloor 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 installedfirst 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 thefirst 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, thefirst 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, thefirst 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 thefirst layer 110 for augmenting the sound control flooring system's 100 sound reduction capacity. With reference to a preferred embodiment and as illustrated inFIG. 1 , thesecond layer 112 is preferably provided as a plastic mat having a plurality of conical, dimple-like and/or cuspated projections extending therefrom, such as disclosed in U.S. Pat. No. 5,619,832, the contents of which are hereby incorporated in their entirety. In a preferred embodiment, thesecond layer 112 is preferably disposed above thefirst layer 110 in an overlay manner and may suitably include a fastening member, as described hereinabove, for securely associating thesecond layer 112 to thefirst layer 110. Thesecond layer 112 suitably operates in a manner similar to the operation of thefirst layer 110 by absorbing sound and/or generally reducing the transmission of sound to thesubfloor assembly 102 and elsewhere. However, it is to be appreciated that thesecond layer 112 may suitably be provided as any material exhibiting desired sound control characteristics, suitably as hereinabove described. - With reference to a preferred embodiment and
FIG. 1 , thesecond layer 112 is preferably coextensively disposed above thefirst layer 110. Accordingly, thesecond layer 112 is preferably provided in a size and configuration so as to overlay substantially all of thefirst layer 110, thereby creating a twolayer subfloor assembly 102 overlay system that overlies theentire subfloor assembly 102, which may or may not be coextensive with thespacers 120. With continued reference to this example embodiment, the sound control flooring system 100 may suitably include one or more bracing members disposed between theoverlay 114 and thesubfloor assembly 102 to provide structural reinforcement for thefinished flooring 116. - With reference to an alternate preferred embodiment and
FIGS. 2 and 3 , thesecond layer 112 is preferably provided in a reduced size, relative to the size of thefirst layer 110, and is preferably positioned atop thefirst layer 110 in a position adapted to receive maximum exposure to sound. For example, most rooms of a dwelling structure contain furniture and other articles arranged therein in a manner that causes substantially all of the foot traffic generated therein to occur along a narrowly defined portion of the room's floor. Most frequently, the foot traffic is concentrated along a high traffic region 150 (FIGS. 2 and 3 ) that is disposed generally centrally over the floor. Accordingly, and as will be more fully described hereinafter, thesecond layer 112 is preferably disposed atop thefirst layer 110 in a position generally below the floorhigh traffic region 150 so as to maximize the amount of sound reduction effected by the flooring system 100 of the present system. - With continued reference to
FIG. 3 , the alternate example embodiment of the sound control flooring system 100 is preferably installed according to a method that involves identifying a region of the floor to be thehigh traffic region 150. In a preferred embodiment, thehigh traffic region 150 is identified and/or demarcated by defining an inner perimeter that is inwardly offset relative to thewalls 118 by aconsistent distance 152. In other words, thehigh traffic region 150 is preferably a quadrilateral-like portion having a first pair of edges that are parallel to each other and a second pair of edges that are also parallel to each other. One set ofregion 150 edges are preferably parallel with a pair of opposedwalls 118 of the room and the other set ofregion 150 edges are preferably parallel with another pair of opposedwalls 118 of the room. Accordingly, thedistance 152 separating theregion 150 edges from thewalls 118 is preferably a distance continuous along entirety of the interface between the edges and thewalls 118. In a preferred embodiment, thedistance 152 is established as approximately eighteen inches, although any other distance, such as four to sixteen inches and in excess of eighteen inches, may be employed, with regard given to the physical dimensions of the room, the intended application of the room, and the like. - Returning to
FIG. 2 and with continued reference to the alternate sound control flooring system 100, thesecond layer 112 is preferably disposed atop thefirst layer 110 only along the region of the floor corresponding to thehigh traffic region 150. Thus, as illustrated, thesecond layer 112 is disposed atop thefirst layer 110 only along a middle portion of the floor corresponding to thehigh traffic region 150 and extends from a midpoint of the floor to a perimeter thereof that is defined to terminate at a position inwardly offset from thewalls 118 by thepredetermined distance 152, preferably eighteen inches. - 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 thefirst layer 110 and in a position so as to perimetrically abut and generally frame thesecond layer 112. Thespacer assembly 122 is preferably provided as a generally rectangular member hollow along substantially all of its inner portion, in which inner portion thesecond layer 112 is position. Accordingly, thespacer 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 thespacer 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 thespacer 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 thesubfloor assembly 106 and thesecond layer 112 has been positioned atop thefirst layer 110, preferably only along a region corresponding to thehigh traffic region 150, and, optionally, thespacers 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 toFIG. 2 , thesecond layer 112 preferably receives anoverlay 126 thereabove that covers the entirety of thesecond layer 112 and extends to and abuts thespacer assembly 122. Theoverlay 126 is preferably any appropriate overlay material as known in the art, such as, for example, gypsum, concrete, mortar, wood, and the like. Thefirst layer 110 preferably also receives anoverlay 124 thereover that covers the entirety of thefirst layer 110 and extends in abutting relationship between thespacer assembly 122 and the walls 118 (or, optionally, the spacers 120). Theoverlay 124 is also preferably any appropriate overlay material as known in the art, such as, for example, gypsum, concrete, mortar, wood, and the like. Thus, it is to be appreciated that in one advantage of the present invention, a reduced amount ofoverlay 126 material is employed, relative to conventional techniques. Because thefirst layer 110 includes on at least a portion thereof thesecond layer 112, the amount ofoverlay 126 required to complete the flooring system 100 is reduced, thereby reducing costs associated with installing a flooring system. - With the
overlays finished flooring 116 thereon. However, if thespacers overlays finished flooring 116 thereon. Depending on the particular configuration and arrangement of thespacers overlays overlay 124/126 and thespacer 120/122 so as to provide a flush and continuous surface. - The
finished flooring 116 is then installed atop theoverlays spacers finished flooring 116 is any conventional and desired flooring, such as, for example, hardwood, natural stone, ceramic tile, vinyl, and the like. Additionally, thefinished flooring 116 is fixedly associated with theoverlays - 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 thesecond 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 thehigh traffic region 150, may suitably include thefirst layer 110 and thesecond layer 112 being provided as a generally unitary construction, with the remainder of thefirst 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, thehigh traffic region 150 receives a component, which is preferably provided as a two layer assembly, more preferably thefirst layer 110 having thesecond 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.
Claims (29)
1. A sound control flooring system adapted to reduce the transmission of airborne sound in a building structure, wherein the system comprises:
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.
2. The sound control flooring system of claim 1 , wherein the first layer of material is a three dimensional matrix filamentous mat manufactured from a thermoplastic material.
3. The sound control flooring system of claim 2 , wherein the second layer of material is thermoplastic mat having a plurality of projections extending from a surface thereof.
4. The sound control flooring system of claim 3 , wherein the projections are at least one of a conical projection, a pyramidal projection, a frustro-conical projection, and a cuspated projection.
5. The sound control flooring system of 3, wherein the first layer of material is disposed atop substantially all of the subfloor assembly.
6. The sound control flooring system of claim 5 , wherein the second layer of material is disposed atop a portion of the first layer of material.
7. The sound control flooring system of claim 6 , 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.
8. The sound control flooring system of claim 6 , wherein the portion is defined by a first edge, a second edge spaced apart and parallel to the first edge, a third edge perpendicular to the first and second edges, and a fourth edge spaced apart and parallel to the third edge, and wherein the second layer of material is disposed between the first, second, third and fourth edges.
9. The sound control flooring system of claim 8 , wherein the first edge is disposed parallel to a first wall of a building structure and is separated therefrom by a first distance, wherein the second edge is disposed parallel to a second wall of the building structure and is separated therefrom by a second distance, wherein the third edge is disposed parallel to a third wall of the building structure and is separated therefrom by a third distance, and wherein the fourth edge is disposed parallel to a fourth wall of the building structure and is separated therefrom by a fourth distance.
10. The sound control flooring system of claim 9 , wherein the first distance, the second distance, the third distance, and the fourth distance are a substantially identical distance.
11. The sound control flooring system of claim 9 , wherein the first distance, the second distance, the third distance, and the fourth distance are each a distance of eighteen inches.
12. The sound control flooring system of claim 10 , wherein the cementitious overlay is disposed atop at least a portion of the first layer of material.
13. A sound control flooring system adapted to reduce the transmission of airborne sound in a building structure, wherein the system comprises:
a subfloor assembly;
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;
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.
14. The sound control flooring system of claim 13 , wherein the first layer of material is a three dimensional matrix filamentous mat manufactured from a thermoplastic material.
15. The sound control flooring system of claim 14 , wherein the second layer of material is thermoplastic mat having a plurality of projections extending from a surface thereof, and wherein the projections are at least one of a conical projection, a pyramidal projection, a frustro-conical projection, and a cuspated projection.
16. The sound control flooring system of claim 15 , wherein the portion of the first layer of material is defined by a first edge, a second edge spaced apart and parallel to the first edge, a third edge perpendicular to the first and second edges, and a fourth edge spaced apart and parallel to the third edge, and wherein the second layer of material is disposed between the first, second, third and fourth edges.
17. The sound control flooring system of claim 16 , wherein the first edge is disposed parallel to a first wall of a building structure and is separated therefrom by a first distance, wherein the second edge is disposed parallel to a second wall of the building structure and is separated therefrom by a second distance, wherein the third edge is disposed parallel to a third wall of the building structure and is separated therefrom by a third distance, and wherein the fourth edge is disposed parallel to a fourth wall of the building structure and is separated therefrom by a fourth distance, and wherein the first distance, the second distance, the third distance, and the fourth distance are a substantially identical distance.
18. The sound control flooring system of claim 17 , wherein the first distance, the second distance, the third distance, and the fourth distance are each a distance of eighteen inches.
19. A method for installing a sound control flooring system adapted to reduce the transmission of airborne sound in a building structure, wherein the method comprises 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.
20. The method of claim 19 , wherein the first layer of material is a three dimensional matrix filamentous mat manufactured from a thermoplastic material.
21. The method of claim 20 , wherein the second layer of material is thermoplastic mat having a plurality of projections extending from a surface thereof.
22. The method of claim 21 , wherein the projections are at least one of a conical projection, a pyramidal projection, a frustro-conical projection, and a cuspated projection.
23. The method of 3 further comprising the step of disposing the first layer of material atop substantially all of the subfloor assembly.
24. The method of claim 23 , wherein the second layer of material is disposed atop a portion of the first layer of material corresponding to an area of the flooring system adapted to receive a high volume of foot traffic thereon.
25. The method of claim 24 , wherein the portion is defined by a first edge, a second edge spaced apart and parallel to the first edge, a third edge perpendicular to the first and second edges, and a fourth edge spaced apart and parallel to the third edge, and wherein the second layer of material is disposed between the first, second, third and fourth edges.
26. The method of claim 25 , wherein the first edge is disposed parallel to a first wall of a building structure and is separated therefrom by a first distance, wherein the second edge is disposed parallel to a second wall of the building structure and is separated therefrom by a second distance, wherein the third edge is disposed parallel to a third wall of the building structure and is separated therefrom by a third distance, and wherein the fourth edge is disposed parallel to a fourth wall of the building structure and is separated therefrom by a fourth distance.
27. The method of claim 26 , wherein the first distance, the second distance, the third distance, and the fourth distance are a substantially identical distance.
28. The method of claim 27 , wherein the first distance, the second distance, the third distance, and the fourth distance are each a distance of eighteen inches.
29. The method of claim 27 further comprising the step of disposing the cementitious overlay atop at least a portion of the first layer of material.
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