U.S. patent application number 17/020069 was filed with the patent office on 2022-03-17 for contiguous sound attenuating panel system.
This patent application is currently assigned to Formulated Materials, LLC. The applicant listed for this patent is Formulated Materials LLC. Invention is credited to Nicola Busatta, Tonj Ciotti, John Igo.
Application Number | 20220081915 17/020069 |
Document ID | / |
Family ID | 1000005092780 |
Filed Date | 2022-03-17 |
United States Patent
Application |
20220081915 |
Kind Code |
A1 |
Igo; John ; et al. |
March 17, 2022 |
CONTIGUOUS SOUND ATTENUATING PANEL SYSTEM
Abstract
The present disclosure describes a contiguous sound attenuating
panel system. The sound attenuating panel has a top surface, a
bottom surface, a first end, a second end, an adhesive strip on the
top surface of the first end, and an engagement flap on the top
surface of the second end. The adhesive strip has a first edge and
a second edge. The second edge is located further from the first
end than the first edge. When installed, the first end of a first
sound attenuating panel abuts and is substantially coplanar with
the second end of a second sound attenuating panel. The width of
the engagement flap of the second sound attenuating panel
terminates substantially at the location of the second edge of the
adhesive strip of the first sound attenuating panel such that the
engagement flap contacts and substantially covers the adhesive
strip.
Inventors: |
Igo; John; (Edmond, OK)
; Busatta; Nicola; (Conegliano Veneto, IT) ;
Ciotti; Tonj; (Harpers Ferry, WV) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Formulated Materials LLC |
Oklahoma City |
OK |
US |
|
|
Assignee: |
Formulated Materials, LLC
|
Family ID: |
1000005092780 |
Appl. No.: |
17/020069 |
Filed: |
September 14, 2020 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
E04F 2290/041 20130101;
E04F 15/203 20130101; E04F 15/02155 20130101 |
International
Class: |
E04F 15/20 20060101
E04F015/20; E04F 15/02 20060101 E04F015/02 |
Claims
1. A contiguous sound attenuating panel system comprising: a first
sound attenuating panel and a second sound attenuating panel,
wherein each of the first sound attenuating panel and the second
sound attenuating panel comprise: a top surface and a bottom
surface; a first end and a second end; an adhesive strip on the top
surface of the first end, the adhesive strip having a first edge
and a second edge, wherein the second edge is located further from
the first end than the first edge; and an engagement flap on the
top surface of the second end, the engagement flap extending a
width beyond the second end; and the first end of the first sound
attenuating panel abuts the second end of the second sound
attenuating panel such that the top surface of the first sound
attenuating panel and the top surface of the second sound
attenuating panel are substantially coplanar, and wherein the width
of the engagement flap of the second sound attenuating panel
terminates substantially at the location of the second edge of the
adhesive strip of the first sound attenuating panel such that the
engagement flap of the second sound attenuating panel contacts and
substantially covers the adhesive strip of the first sound
attenuating panel.
2. The contiguous sound attenuating panel system of claim 1,
wherein the width of the engagement flap of the second sound
attenuating panel terminates at the location of the second edge of
the adhesive strip of the first sound attenuating panel.
3. The contiguous sound attenuating panel system of claim 1,
wherein the width of the engagement flap of the second sound
attenuating panel extends no more than 0.5 inches past the location
of the second edge of the adhesive strip of the first sound
attenuating panel.
4. The contiguous sound attenuating panel system of claim 3,
wherein the width of the engagement flap of the second sound
attenuating panel extends no more than 0.125 inches past the
location of the second edge of the adhesive strip of the first
sound attenuating panel.
5. The contiguous sound attenuating panel system of claim 1,
wherein each of the first sound attenuating panel and the second
sound attenuating panel further comprise a first side and a second
side, and wherein the adhesive strip and the engagement flap extend
from the first side to the second side.
6. A contiguous sound attenuating panel system comprising: a first
sound attenuating panel and a second sound attenuating panel,
wherein each of the first sound attenuating panel and the second
sound attenuating panel comprise: a top surface and a bottom
surface; a first end and a second end; an engagement channel on the
top surface of the first end, the engagement channel having a first
width; an adhesive strip on the top surface of the first end, the
adhesive strip having a first edge and a second edge, wherein the
second edge is located further from the first end than the first
edge, and wherein the adhesive strip is spaced away from the first
end a distance at least equal to the first width; and an engagement
flap on the top surface of the second end, the engagement flap
extending a second width beyond the second end; and the engagement
channel of the first sound attenuating panel receives a portion of
the second end of the second sound attenuating panel such that the
top surface of the first sound attenuating panel and the top
surface of the second sound attenuating panel are substantially
coplanar, and wherein the second width of the engagement flap of
the second sound attenuating panel terminates substantially at the
location of the second edge of the adhesive strip of the first
sound attenuating panel such that the engagement flap of the second
sound attenuating panel contacts and substantially covers the
adhesive strip of the first sound attenuating panel.
7. The contiguous sound attenuating panel system of claim 6,
wherein the second width of the engagement flap of the second sound
attenuating panel terminates at the location of the second edge of
the adhesive strip of the first sound attenuating panel.
8. The contiguous sound attenuating panel system of claim 5,
wherein the second width of the engagement flap of the second sound
attenuating panel extends no more than 0.5 inches past the location
of the second edge of the adhesive strip of the first sound
attenuating panel.
9. The contiguous sound attenuating panel system of claim 8,
wherein the second width of the engagement flap of the second sound
attenuating panel extends no more than 0.125 inches past the
location of the second edge of the adhesive strip of the first
sound attenuating panel.
10. The contiguous sound attenuating panel system of claim 6,
wherein the first width of the engagement channel is from about 0.1
inch to about 1 inch.
11. The contiguous sound attenuating panel system of claim 10,
wherein the first width of the engagement channel is about 0.25
inch.
12. The contiguous sound attenuating panel system of claim 6,
wherein each of the first sound attenuating panel and the second
sound attenuating panel further comprise a first side and a second
side, and wherein the engagement channel, the adhesive strip, and
the engagement flap extend from the first side to the second
side.
13. The contiguous sound attenuating panel system of claim 6,
wherein each of the first sound attenuating panel and the second
sound attenuating panel have a first thickness and the engagement
channel has a second thickness, and wherein the second thickness is
about 90% to about 99% less than the first thickness.
14. A sound attenuating panel comprising: a top surface and a
bottom surface; a first end and a second end; an engagement channel
on the top surface of the first end, the engagement channel having
a first width; an adhesive strip on the top surface of the first
end, the adhesive strip having a first edge and a second edge,
wherein the second edge is located further from the first end than
the first edge, and wherein the adhesive strip is spaced away from
the first end a distance at least equal to the first width; and an
engagement flap on the top surface of the second end, the
engagement flap extending a second width beyond the second end.
15. The sound attenuating panel of claim 14, wherein the first
width of the engagement channel is from about 0.1 inch to about 1
inch.
16. The sound attenuating panel of claim 15, wherein the first
width of the engagement channel is about 0.25 inch.
17. The sound attenuating panel of claim 14, further comprising a
first side and a second side, wherein the engagement channel, the
adhesive strip, and the engagement flap extend from the first side
to the second side.
18. The sound attenuating panel of claim 14, having a first
thickness and the engagement channel having a second thickness,
wherein the second thickness is about 90% to about 99% less than
the first thickness.
Description
TECHNICAL FIELD
[0001] The present disclosure relates generally to above-ground
floor systems, and, more specifically, to an above-ground,
contiguous sound attenuating panel system that maintains the
flexural strength of the flooring system.
BACKGROUND
[0002] Builders commonly use sound attenuating material in
multi-stored buildings to reduce the transmission of impact sound
from one floor to another. This material is commonly referred to as
sound mats, which are placed as the first layer of floor systems.
Typically, the entire floor system utilizes four layers in the
following order: subfloor, sound mat, underlayment, and the final
flooring goods (such as vinyl planks, tile, or carpet). In most
cases, sound mats come in rolls or panels of rigid or semi-rigid
material. During installation, to connect one panel to another, the
panels are pressed together and a loose flap extends from one panel
over the top of the other panel with an adhesive adherence. Since
the flap is pulled over the actual connection area between the two
panels, the actual contact between the two panels is a blind act.
Unfortunately, current systems cannot ensure a flush fit between
adjacent panels due to the practical realities stemming from the
installer's inability to confirm constant contact between the
panels as the installer adhered the flap. The inevitable seams that
are created beneath the flap (i.e. wherever no flush contact
between the panel exists) creates a number of quality problems as
the rest of the flooring layers are installed. For example,
underlayments typically comprise of a wet slurry pumped directly on
top of the sound mat and are left to dry. As the underlayment
begins to dry, the seams compromise the flexural strength of the
underlayment and cracks develop above the seams of the sound mat
gaps. Also, the sound attenuating qualities of the sound mat are
compromised when the underlayment falls and dries down the seam
because of the now-direct contact of the underlayment with the
subfloor. This disclosure provides a contiguous sound attenuating
panel system that provides quality-assured sound attenuation, while
substantially preserving the flexural strength of the flooring
system. In particular, the disclosed sound attenuating panel system
provides a mechanism which allows the installer to ensure flush
contact between adjacent panels during the blind act of adjoining
two panels.
SUMMARY
[0003] The present invention provides a contiguous sound
attenuating panel system which overcomes the deficiencies described
above, and has other advantages.
[0004] In one embodiment, a contiguous sound attenuating panel
system is provided. The system comprises a first sound attenuating
panel and a second sound attenuating panel. Each of the first sound
attenuating panel and the second sound attenuating panel comprise a
top surface, a bottom surface, a first end, a second end, an
adhesive strip on the top surface of the first end, and an
engagement flap on the top surface of the second end. The adhesive
strip has a first edge and a second edge. The second edge is
located further from the first end than the first edge. The
engagement flap extends a width beyond the second end. When
installed, the first end of the first sound attenuating panel abuts
the second end of the second sound attenuating panel such that the
top surface of the first sound attenuating panel and the top
surface of the second sound attenuating panel are substantially
coplanar. The width of the engagement flap of the second sound
attenuating panel terminates substantially at the location of the
second edge of the adhesive strip of the first sound attenuating
panel such that the engagement flap of the second sound attenuating
panel contacts and substantially covers the adhesive strip of the
first sound attenuating panel.
[0005] In some embodiments, the width of the engagement flap of the
second sound attenuating panel terminates at the location of the
second edge of the adhesive strip of the first sound attenuating
panel. In other embodiments, the width of the engagement flap of
the second sound attenuating panel extends no more than 0.5 inches
past the location of the second edge of the adhesive strip of the
first sound attenuating panel. In another embodiment, each of the
first sound attenuating panel and the second sound attenuating
panel has a first side and a second side. The adhesive strip and
the engagement flap extend from the first side to the second
side.
[0006] In an additional embodiment, a contiguous sound attenuating
panel system is provided. The system has a first sound attenuating
panel and a second sound attenuating panel. Each of the first sound
attenuating panel and the second sound attenuating panel have a top
surface, a bottom surface, a first end, a second end, an engagement
channel on the top surface of the first end, an adhesive strip on
the top surface of the first end, and an engagement flap on the top
surface of the second end. The engagement channel has a first
width. The adhesive strip has a first edge and a second edge. The
second edge is located further from the first end than the first
edge. The adhesive strip is spaced away from the first end a
distance at least equal to the first width. The engagement flap
extends a second width beyond the second end. When installed, the
engagement channel of the first sound attenuating panel receives a
portion of the second end of the second sound attenuating panel
such that the top surface of the first sound attenuating panel and
the top surface of the second sound attenuating panel are
substantially coplanar. The second width of the engagement flap of
the second sound attenuating panel terminates substantially at the
location of the second edge of the adhesive strip of the first
sound attenuating panel such that the engagement flap of the second
sound attenuating panel contacts and substantially covers the
adhesive strip of the first sound attenuating panel.
[0007] In another embodiment, a sound attenuating panel is
provided. The sound attenuating panel has a top surface, a bottom
surface, a first end, a second end, an engagement channel on the
top surface of the first end, an adhesive strip on the top surface
of the first end, and an engagement flap on the top surface of the
second end. The engagement channel has a first width. The adhesive
strip has a first edge and a second edge. The second edge is
located further from the first end than the first edge. The
adhesive strip is spaced away from the first end a distance at
least equal to the first width. The engagement flap extends a
second width beyond the second end.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] The drawings included with this application illustrate
certain aspects of the embodiments described herein. However, the
drawings should not be viewed as exclusive embodiments.
[0009] FIG. 1 is a perspective view of a sound attenuating panel
having an engagement channel with the engagement flap folded back
and the adhesive strip covered by a removable strip in accordance
with one embodiment of the present disclosure.
[0010] FIG. 2 is a perspective view of a sound attenuating panel
having an engagement channel with the engagement flap raised and
the removable strip partially removed from the adhesive strip in
accordance with one embodiment of the present disclosure.
[0011] FIG. 3 is a side view of a sound attenuating panel having an
engagement channel with the engagement flap folded back and the
adhesive strip covered by a removable strip in accordance with one
embodiment of the present disclosure.
[0012] FIG. 4 is a side view of a sound attenuating panel having an
engagement channel with the engagement flap raised and the
removable strip partially removed from the adhesive strip in
accordance with one embodiment of the present disclosure.
[0013] FIG. 5 is a side view showing two sound attenuating panels,
each having an engagement channel, prior to engagement in
accordance with one embodiment of the present disclosure.
[0014] FIG. 6 is a side view showing two sound attenuating panels,
each having an engagement channel, installed together in accordance
with one embodiment of the present disclosure.
[0015] FIG. 7 is a perspective view of a sound attenuating panel
without an engagement channel with the engagement flap folded back
and the adhesive strip covered by a removable strip in accordance
with one embodiment of the present disclosure.
[0016] FIG. 8 is a side view showing two sound attenuating panels,
each without an engagement channel, installed together in
accordance with one embodiment of the present disclosure.
DETAILED DESCRIPTION
[0017] The present disclosure describes a sound attenuating panel
system for use in the construction of flooring. The disclosure may
be understood more readily by reference to these detailed
descriptions. For simplicity and clarity of illustration, where
appropriate, reference numerals may be repeated among the different
figures to indicate corresponding or analogous elements. In
addition, numerous specific details are set forth in order to
provide a thorough understanding of the various embodiments
described herein. The description is not to be considered as
limiting the scope of the embodiments described herein. The
drawings are not necessarily to scale and the proportions of
certain parts may have been exaggerated to better illustrate
details and features of the present disclosure.
[0018] As shown by FIGS. 5-8, a contiguous sound attenuating panel
system for use in the construction of flooring is illustrated and
generally designated by the numeral 10. When system 10 is placed
over the primary floor structure, system 10 attenuates sound
transmission through the floor. System 10 includes at least two
sound attenuating panels 20a and 20b. Sound attenuating panels 20a
and 20b may be any length/width depending upon the system used to
manufacture sound attenuating panels 20a and 20b and the size of
the floor to be covered.
[0019] With reference to FIGS. 1-4, a sound attenuating panel is
illustrated and generally designated by the numeral 20. In some
embodiments, sound attenuating panel 20 is comprised of a plastic
or rubber membrane. However, one skilled in the art understands
that sound attenuating panel 20 may be manufactured from a number
of different types of durable, and pliable, plastic, rubber, or
other polymer material having sound attenuating properties.
[0020] Sound attenuating panel 20 generally includes a top surface
22, a bottom surface 24, a first end 30, a second end 40, an
adhesive strip 36, and an engagement flap 42. Top surface 22 is
relatively flat. Bottom surface 24 may take the form of a plurality
of outwardly projecting protrusions, air gaps, or any one of the
forms known in the art to attenuate sound.
[0021] With reference to FIGS. 1-6, in some embodiments, first end
30 includes an engagement channel 34 on top surface 22 and abutting
first edge 32. Engagement channel 34 will typically have a first
width 35 of about 0.1 inch to about 1 inch. More preferably,
engagement channel 34 has a first width 35 of 0.25 inch.
[0022] In other embodiments, as shown in FIGS. 7-8, first end 30
does not include an engagement channel 34. In such embodiments, as
shown in FIG. 8, when installed, first end 30 of sound attenuating
panel 20a abuts second end 40 of sound attenuating panel 20b, i.e.
panel 20a directly contacts panel 20b at ends 30, 40.
[0023] With reference to FIGS. 3-4, sound attenuating panel 20 may
have a first thickness 50 and engagement channel 34 may have a
second thickness 52. In some embodiments, second thickness 52 is
about 90% to about 99% less than first thickness 50. The difference
between first thickness 50 and second thickness 52 allows top
surface 22 of one sound attenuating panel 20 to be substantially
coplanar to top surface 22 of a second sound attenuating panel 20
when two sound attenuating panels 20 are installed for use in
contiguous sound attenuating panel system 10.
[0024] Adhesive strip 36 is on top surface 22 spaced from first
edge 32 of first end 30 a distance at least equal to first width
35. Adhesive strip 36 has a first edge 37a and a second edge 37b.
Second edge 37b is located further from first edge 32 of first end
30 than first edge 37a. In some embodiments, adhesive strip 36
includes a removable strip 38 such that removal of the strip
exposes an adhesive material 39.
[0025] With reference to FIGS. 5-6 and 7-8, engagement flap 42
provides for engagement of one sound attenuating panel 20a to
another sound attenuating panel 20b by contacting engagement flap
42 of sound attenuating panel 20b to adhesive strip 36 of adjacent
sound attenuating panel 20a. Engagement flap 42 is on top surface
22 of second end 40 and extends a second width 43. As shown in
FIGS. 1, 3, 5, and 7, when sound attenuating panels 20 are not
installed, engagement flap 42 may be folded back over top surface
22 of sound attenuating panel 20 towards first end 30.
[0026] As shown in FIGS. 6 and 8, when two sound attenuating panels
20a, 20b are installed, engagement flap 42 of sound attenuating
panel 20b has a second width 43 that terminates substantially at
the location of second edge 37b of adhesive strip 36 of sound
attenuating panel 20a such that engagement flap 42 of sound
attenuating panel 20b contacts and substantially covers adhesive
strip 36 of sound attenuating panel 20a. In some embodiments,
second width 43 of engagement flap 42 of sound attenuating panel
20b terminates at the location of second edge 37b of adhesive strip
36 of sound attenuating panel 20a. In other embodiments, second
width 43 of engagement flap 42 of sound attenuating panel 20b
extends no more than 0.5 inches past the location of second edge
37b of adhesive strip 36 of sound attenuating panel 20a. In
additional embodiments, second width 43 of engagement flap 42 of
sound attenuating panel 20b extends no more than 0.125 inches past
the location of second edge 37b of adhesive strip 36 of sound
attenuating panel 20a.
[0027] Contiguous sound attenuating panel system 10 ensures a
substantially perfect abutting seam between sound attenuating
panels 20. Second width 43 of engagement flap 42 of sound
attenuating panel 20b terminating at, or substantially at, the
location of second edge 37b of adhesive strip 36 of sound
attenuating panel 20a ensures direct contact between sound
attenuating panel 20a and sound attenuating panel 20b. Adhesive
strip 36 of sound attenuating panel 20a is set at the exact
distance that second width 43 of engagement flap 42 of sound
attenuating panel 20b must stretch to create a substantially
perfect abutting seam between sound attenuating panel 20a and sound
attenuating panel 20b. While an installer may be blind to the seam
due to engagement flap 42, there is effectively a 0% chance that
sound attenuating panel 20a and sound attenuating panel 20b have
shifted away from one another to create a valley/gap because, if
sound attenuating panels 20a and 20b had shifted apart, engagement
flap 42 of sound attenuating panel 20b would not contact and
substantially cover adhesive strip 36 of sound attenuating panel
20a. Thus, second width 43 provides guidance to an installer to
ensure no valley (gap).
[0028] In some embodiments, sound attenuating panel 20 includes a
first side 26 and a second side 28. In such embodiments, engagement
channel 34, if sound attenuating panels 20 include engagement
channel 34, adhesive strip 36, and engagement flap 42 may each
extend from first side 26 to second side 28.
[0029] With reference to FIGS. 5-6, installation of contiguous
sound attenuating panel system 10 includes the steps of: placing a
first sound attenuating panel 20a on a subfloor (not shown) such
that bottom surface 24 contacts the subfloor; placing second end 40
of a second sound attenuating panel 20b in close proximity to first
end 30 of first sound attenuating panel 20a; receiving a portion of
second end 40 of second sound attenuating panel 20b in engagement
channel 34 of first sound attenuating panel 20a such that top
surface 22 of first sound attenuating panel 20a and top surface 22
of second sound attenuating panel 20b are substantially coplanar;
and, folding over engagement flap 42 of second sound attenuating
panel 20b to contact and substantially cover adhesive strip 36 of
first sound attenuating panel 20a. Engagement flap 42 extends and
terminates substantially at the location of second edge 37b of
first sound attenuating panel 20a. In other embodiments,
installation of sound attenuating panel system 10 includes the
steps of: removing a removable strip 38 from adhesive strip 36 of
first sound attenuating panel 20a to expose adhesive material 39;
and folding over engagement flap 42 of second sound attenuating
panel 20b to contact and substantially cover adhesive material
39.
[0030] With reference to FIGS. 7-8, another embodiment of
contiguous sound attenuating panel system 10 includes sound
attenuating panels 20 that lack engagement channel 34. In such
embodiments, sound attenuating panel 20 includes a top surface 22,
a bottom surface 24, a first end 30, a second end 40, an adhesive
strip 36 on top surface 22 of first end 30, and an engagement flap
42 on top surface 22 of second end 40. Adhesive strip 36 has a
first edge 37a and a second edge 37b. Second edge 37b is located
further from first end 30 than first edge 37a. Engagement flap 42
extends a second width 43 beyond second end 40. When installed,
first end 30 of first sound attenuating panel 20a abuts second end
40 of second sound attenuating panel 20b such that top surface 22
of first sound attenuating panel 20a and top surface 22 of second
sound attenuating panel 20b are substantially coplanar. Second
width 43 of engagement flap 42 of second sound attenuating panel
20b terminates substantially at the location of second edge 37b of
adhesive strip 36 of first sound attenuating panel 20a such that
engagement flap 42 of second sound attenuating panel 20b contacts
and substantially covers adhesive strip 36 of first sound
attenuating panel 20a.
[0031] In some embodiments, second width 43 of engagement flap 42
of second sound attenuating panel 20b terminates at the location of
second edge 37b of adhesive strip 36 of first sound attenuating
panel 20a. In other embodiments, second width 43 of engagement flap
42 of second sound attenuating panel 20b extends no more than 0.5
inches past the location of second edge 37b of adhesive strip 36 of
first sound attenuating panel 20a. In other embodiments, second
width 43 of engagement flap 42 of second sound attenuating panel
20b extends no more than 0.125 inches past the location of second
edge 37b of adhesive strip 36 of first sound attenuating panel 20a.
In another embodiment, each of first sound attenuating panel 20a
and second sound attenuating panel 20b have a first side 26 and a
second side 28. Adhesive strip 36 and engagement flap 42 from first
side 26 to second side 28.
[0032] Contiguous sound attenuating panel system 10 derives the
unexpected result of two sound attenuating panels 20a, 20b being
substantially coplanar and in direct contact when installed. Second
width 43 of engagement flap 42 of second sound attenuating panel
20b terminating at, or substantially at, the location of second
edge 37b of adhesive strip 36 of first sound attenuating panel 20a
ensures direct contact between first sound attenuating panel 20a
and second sound attenuating panel 20b. Adhesive strip 36 is set at
the exact distance that second width 43 of engagement flap 42 must
stretch to create a substantially perfect abutting seam between
first sound attenuating panel 20a and second sound attenuating
panel 20b. If first sound attenuating panel 20a and second sound
attenuating panel 20b have shifted away from one another to create
a valley/gap, engagement flap 42 of second sound attenuating panel
20b would not contact and substantially cover adhesive strip 36 of
first sound attenuating panel 20a. By substantially or completely
covering adhesive strip 36, an installer can ensure no valley (gap)
is created between sound attenuating panels 20 thereby providing a
consistent surface to support the poured underlayment. Thus, the
resulting flooring system will have improved flexural strength.
[0033] Although the disclosed invention has been shown and
described in detail with respect to a preferred embodiment, it will
be understood by those skilled in the art that various changes in
the form and detailed area may be made without departing from the
spirit and scope of this invention as claimed. Thus, the present
invention is well adapted to carry out the object and advantages
mentioned as well as those which are inherent therein. While
numerous changes may be made by those skilled in the art, such
changes are encompassed within the spirit of this invention as
defined by the appended claims.
* * * * *