U.S. patent number RE41,945 [Application Number 11/782,999] was granted by the patent office on 2010-11-23 for impact sound insulation.
This patent grant is currently assigned to Ecore International Inc.. Invention is credited to Paul Charles Downey.
United States Patent |
RE41,945 |
Downey |
November 23, 2010 |
Impact sound insulation
Abstract
A substrate for use in a flooring system which has a subfloor
and a decorative upper layer. The substrate is made in a continuous
sheet which has a bottom surface, a top surface, side surfaces and
end surfaces. The top surface and the oppositely facing bottom
surface are essentially parallel to each other and are spaced apart
by the thickness of the substrate. Voids are provided in the
substrate, the voids are provided between particles of rubber or
other similar material. When the substrate is positioned between
the subfloor and the decorative top layer, the particles of rubber
provide the strength required to prevent deformation of the
substrate in the direction of the thickness and the voids
contribute to the sound dampening characteristics required to
provide decibel reduction across the thickness of the
substrate.
Inventors: |
Downey; Paul Charles (Toronto,
CA) |
Assignee: |
Ecore International Inc.
(Lancaster, PA)
|
Family
ID: |
25460593 |
Appl.
No.: |
11/782,999 |
Filed: |
July 25, 2007 |
Related U.S. Patent Documents
|
|
|
|
|
|
|
Application
Number |
Filing Date |
Patent Number |
Issue Date |
|
Reissue of: |
09931320 |
Aug 16, 2001 |
06920723 |
Jul 26, 2005 |
|
|
Current U.S.
Class: |
52/144; 52/408;
181/284; 52/403.1; 428/492 |
Current CPC
Class: |
A63C
19/04 (20130101); E04F 15/206 (20130101); E04F
15/20 (20130101); Y10T 428/31826 (20150401) |
Current International
Class: |
E04B
1/82 (20060101); E04F 15/22 (20060101) |
Field of
Search: |
;52/144,145,403.1,480,408,411,746.1,747.11 ;181/284,285,286
;428/327,329,492 |
References Cited
[Referenced By]
U.S. Patent Documents
Foreign Patent Documents
|
|
|
|
|
|
|
41 41 023 |
|
Jun 1993 |
|
DK |
|
1120827 |
|
Jul 1968 |
|
GB |
|
2 379 934 |
|
Mar 2003 |
|
GB |
|
WO 93/12283 |
|
Jun 1993 |
|
WO |
|
WO 2004/058416 |
|
Jul 2004 |
|
WO |
|
Other References
Brochure: Amorim Industrial Solutions Acousticork Products. cited
by other .
Brochure: The Noble Company Nobleseal.RTM. SIS (Sound Isolation
Sheet). cited by other .
Test Data from 2000-2007 with 901 pages. cited by other .
Transcript of Deposition of Paul C. Downey, Apr. 24, 2008, pp.
46-49, 54-57, 106-109, and 134-137, Art Dodge, vol. II, Apr. 25,
2008, pp. 109-112, 117-128, 153-156, 165-180, 209-212, and 265-268,
Dodge-Regupol, Inc. v. RB Rubber Products, Inc., Case No.
3:06-CV-00236-UN2. cited by other .
Transcript of Deposition of Paul C. Downey, vol. II, Apr. 24, 2008,
pp. 199, 216-219, 272-275, 288-295, 364-367, and 468-471;
Dodge-Regupol, Inc. v. RB Rubber Products, Inc., Case No.
3:06-CV-00236-UN2. cited by other .
Transcript of Deposition of Art Dodge, vol. II, Apr. 25, 2008, pp.
109-112, 117-128, 153-156, 165-180, 209-212, and 265-268;
Dodge-Regupol, Inc. v. RB Rubber Products, Inc., Case No.
3:06-CV-00236-UN2. cited by other .
Exhibit 3 to the Deposition of Art Dodge, vol. II, Apr. 25, 2008,
Dodge-Regupol, Inc. v. RB Rubber Products, Inc., Case No.
3:06-CV-00236-UN2. cited by other .
Exhibit 4 to the Deposition of Art Dodge, vol. II, Apr. 25, 2008,
Dodge-Regupol, Inc. v. RB Rubber Products, Inc., Case No.
3:06-CV-00236-UN2. cited by other .
Exhibit 5, p. 4 of 6, to the Deposition of Art Dodge, vol. II, Apr.
25, 2008, Dodge-Regupol, Inc. v. RB Rubber Products, Inc., Case No.
3:06-CV-00236-UN2. cited by other .
Exhibit 6 to the Deposition of Art Dodge, vol. II, Apr. 25, 2008,
Dodge-Regupol, Inc. v. RB Rubber Products, Inc., Case No.
3:06-CV-00236-UN2. cited by other .
Exhibit 17, p. 4 of 4, to the Deposition of Art Dodge, vol. II,
Apr. 25, 2008, Dodge-Regupol, Inc. v. RB Rubber Products, Inc.,
Case No. 3:06-CV-00236-UN2. cited by other .
Exhibit 18 to the Deposition of Art Dodge, vol. II, Apr. 25, 2008,
Dodge-Regupol, Inc. v. RB Rubber Products, Inc., Case No.
3:06-CV-00236-UN2. cited by other .
Exhibit 19 to the Deposition of Art Dodge, vol. II, Apr. 25, 2008,
Dodge-Regupol, Inc. v. RB Rubber Products, Inc., Case No.
3:06-CV-00236-UN2. cited by other .
Exhibit 20 to the Deposition of Art Dodge, vol. II, Apr. 25, 2008,
Dodge-Regupol, Inc. v. RB Rubber Products, Inc., Case No.
3:06-CV-00236-UN2. cited by other .
Exhibit 21 to the Deposition of Art Dodge, vol. II, Apr. 25, 2008,
Dodge-Regupol, Inc. v. RB Rubber Products, Inc., Case No.
3:06-CV-00236-UN2. cited by other .
Brochure: PlayGuard.RTM. Playground Safety Surfacing. By Dodge
Regupol, Inc..RTM. pp.DR01066-DR01071 Jul. 2005. cited by other
.
Brochure: Pavesafe-Equine Safety Surfacing systems. By
Dodge-Regupol, Inc..RTM. pp.DR01072-DR01075 Apr. 2003. cited by
other .
Brochure: Innovators in Fitness and sport Surfacing. By
Dodge-Regupol, Inc..RTM. pp. DR01076-DR01079 Aug. 2002. cited by
other .
Brochure: Everlast-Performance Flooring. Manufactured by :
Dodge-Regupol, Inc..RTM. pp. DR01080-DR01091 Jul. 2006. cited by
other .
Letter dated Mar. 5, 2008 from Harness Dickey. Re: Dodge-Regupol,
Inc. v. RB Rubber Products, Inc. Case No. 3:06cv236. cited by other
.
Case 3:06-cv-00236-JEJ, Document 48, (Markman Order) Filed Mar. 9,
2007, pp. 1-12. cited by other .
U.S. District Court. Middle District of Pennsylvania (Scranton)
Civil Docket for Case # 3:06-cv-00236-JEJ. 9 pages, date filed Jan.
31, 2006. cited by other .
Deposition of Paul Downey, Jun. 27, 2007. pp. 1-198, Index, pp.
1-20. cited by other .
Deposition of Paul Downey, Jun. 27, 2007, Exhibits 1, 3-7, 9-12.
cited by other .
Deposition of Paul Downey, Apr. 24, 2008, vol. II-pp. 199-275.
cited by other .
Downey Exhibits, 13-42, Jun. 27, 2007. cited by other .
Deposition of Arthur Dodge, Jun. 27, 2007, pp. 1-75 .Index, pp.
1-10. cited by other .
Dodge Exhibits, 1-2, Jun. 27, 2007. cited by other .
Videotaped Deposition of Art Dodge, Apr. 25, 2008. vol. II--pp.
76-318. Index, pp. 1-21. cited by other .
Dodge Deposition 2008. Exhibits 3-27, Jun. 27, 2007. cited by
other.
|
Primary Examiner: Chilcot, Jr.; Richard E
Assistant Examiner: Wendell; Mark R
Attorney, Agent or Firm: Oblon, Spivak, McClelland, Maier
& Neustadt, L.L.P.
Claims
What is claimed is:
1. A flooring system comprising: a subfloor; a decorative top
layer; a substrate having a top surface and an oppositely facing
bottom surface, the bottom surface positioned proximate the
subfloor and the top surface is positioned proximate the decorative
top layer, the substrate having a thickness of about 10 mm and
voids which extend between the top surface and the bottom surface,
the substrate is manufactured from rubber in sheets which are cut
to the desired configuration; whereby the substrate has the
strength characteristics to support the decorative layer and
prevent damage thereto and the sound dampening characteristics to
provide decibel reduction through the substrate.
2. The flooring system as recited in claim 1 wherein the density of
the substrate is less than 1000 kilograms per meter cubed.
3. The flooring system as recited in claim 1 wherein the substrate
has the strength characteristics required to support the decorative
layer while having sufficient resiliency to allow the substrate to
be delivered in rolls.
4. The flooring system as recited in claim 1 wherein the substrate
is fixed to the subfloor by means of an adhesive.
5. The flooring system as recited in claim 1 wherein the substrate
is fixed to the decorative top layer by means of an adhesive.
6. The flooring system as recited in claim 1 wherein the substrate
is made from an SBR rubber material.
7. The flooring system as recited in claim 1 wherein the sound
damping characteristics exhibit a decibel reduction of
approximately 20 dB for a substrate with a thickness of 5 mm.
8. A substrate for use in a flooring system which has a subfloor
and a decorative upper layer, the substrate comprising of: a
continuous sheet having a bottom surface configured for frictional
interface with the subfloor, a top surface configured for receiving
the decorative upper layer, side surfaces and end surfaces, the top
surface and the oppositely facing bottom surface are essentially
parallel to each other and are spaced apart by the thickness of the
substrate, the thickness of the substrate being about 10 mm; an
adhesive located on the bottom surface for fixing the substrate to
the subfloor; voids are provided in the substrate, the voids are
provided between particles of material of the substrate, such that
the particles of material provide the strength required to prevent
deformation of the substrate in the direction of the thickness and
the voids contribute to the sound dampening characteristics
required to provide decibel reduction across the thickness of the
substrate; and the top surface has an adhesive for fixing the
substrate to the decorative upper layer.
9. The substrate for use in a flooring system as recited in claim 8
wherein the continuous sheet is cut to the appropriate length to
fit the space requirements.
10. The substrate for use in a flooring system as recited in claim
8 wherein the density of the substrate is less than 1000 kilograms
per meter cubed.
11. The substrate for use in a flooring system as recited in claim
8 wherein the substrate has the strength characteristics required
to support the decorative layer while having sufficient resiliency
to allow the substrate to be delivered in rolls.
12. The substrate for use in a flooring system as recited in claim
8 wherein the substrate is made from an SBR rubber material.
13. The substrate for use in a flooring system as recited in claim
8 wherein the sound dampening characteristics exhibit a decibel
reduction of approximately 20 dB for a substrate with a thickness
of 5 mm.
14. The flooring system as recited in claim 1 wherein the rubber is
formed in a cylindrical member and the sheets are cut from the
cylindrical member.
15. The substrate for use in a flooring system as recited in claim
8 wherein the continuous sheet is cut from a cylindrical
member.
16. The substrate for use in a flooring system as recited in claim
8 wherein the substrate includes a binder and particles of rubber,
the binder and the particles of rubber being partially severed at
the top surface and the bottom surface of the continuous sheet.
.Iadd.17. A flooring system comprising: a subfloor; a decorative
top layer; and a rubber substrate having a density of below 1000
kilograms per meter cubed and a top surface and an oppositely
facing bottom surface, the bottom surface positioned proximate the
subfloor and the top surface positioned proximate the decorative
top layer, the substrate having voids which extend between the top
surface and the bottom surface, wherein the substrate: is
manufactured from rubber in sheets which are cut to the desired
configuration, has strength characteristics to support the
decorative layer and prevent damage thereto, and wherein the
flooring system: has sound dampening characteristics to provide
decibel reduction through the substrate of about 20 dB for a
substrate having a thickness of 5 mm and about 25 dB for a
substrate having a thickness of 10 mm; and wherein the substrate is
fixed to the decorative top layer by means of an adhesive.
.Iaddend.
.Iadd.18. The flooring system as recited in claim 17, wherein the
substrate has the strength characteristics required to support the
decorative layer while having sufficient resiliency to allow the
substrate to be delivered in rolls. .Iaddend.
.Iadd.19. The flooring system as recited in claim 17, wherein the
substrate is fixed to the subfloor by means of an adhesive.
.Iaddend.
.Iadd.20. The flooring system as recited in claim 17, wherein the
substrate comprises an SBR rubber material. .Iaddend.
.Iadd.21. The flooring system as recited in claim 17, wherein said
rubber substrate comprises rubber and polyurethane. .Iaddend.
.Iadd.22. A method for installation of a flooring system comprising
a subfloor, a rubber substrate, and a decorative top layer, said
method comprising: cutting a continuous sheet of said rubber
substrate to a desired length; and positioning the substrate over a
subfloor, wherein the rubber substrate has a density of below 1000
kilograms per meter cubed and a top surface and an oppositely
facing bottom surface, the rubber substrate having voids which
extend between the top surface and the bottom surface and strength
characteristics to support a decorative layer and prevent damage
thereto, said flooring system having sound dampening
characteristics to provide decibel reduction through the substrate
of about 20 dB for a substrate having a thickness of 5 mm and about
25 dB for a substrate having a thickness of 10 mm; and wherein the
substrate is fixed to the decorative top layer by means of an
adhesive. .Iaddend.
.Iadd.23. The method as recited in claim 22, wherein the substrate
has the strength characteristics required to support the decorative
layer while having sufficient resiliency to allow the substrate to
be delivered in rolls. .Iaddend.
.Iadd.24. The method as recited in claim 22, wherein the substrate
is fixed to the subfloor by means of an adhesive. .Iaddend.
.Iadd.25. The method as recited in claim 22, wherein the substrate
comprises an SBR rubber material. .Iaddend.
.Iadd.26. The method as recited in claim 22, wherein said rubber
substrate comprises rubber and polyurethane. .Iaddend.
.Iadd.27. The method according to claim 22, further comprising
positioning a decorative layer on the rubber substrate.
.Iaddend.
.Iadd.28. The method according to claim 27, wherein the positioning
a decorative layer includes positioning the decorative layer
directly on the rubber substrate. .Iaddend.
.Iadd.29. The method according to claim 22, further comprising
providing the continuous sheet of rubber substrate in the form of a
rolled sheet. .Iaddend.
.Iadd.30. The method according to claim 29, wherein the providing
the continuous sheet of rubber substrate in the form of a rolled
sheet includes providing a rolled sheet that is four feet wide.
.Iaddend.
.Iadd.31. The method according to claim 29, wherein the providing a
continuous sheet of a rubber substrate includes providing a
non-vulcanized rubber substrate. .Iaddend.
.Iadd.32. A rubber substrate for use in a flooring system which has
a subfloor and a decorative upper layer, the substrate comprising:
a continuous rubber sheet having a density of less than 1000
kilograms per meter cubed comprising rubber and polyurethane and
having a bottom surface configured for frictional interface with
the subfloor, a top surface configured for receiving the decorative
upper layer, side surfaces and end surfaces, the top surface and
the oppositely facing bottom surface being essentially parallel to
each other and spaced apart by the thickness of the substrate, the
rubber sheet being nonvulcanized and having adhesive located on the
bottom surface thereof for fixing the substrate to the subfloor;
wherein voids are provided in the rubber sheet between particles of
rubber such that the particles provide the strength required to
prevent deformation of the substrate in the direction of the
thickness and the voids contribute to the sound dampening
characteristics required to provide decibel reduction across the
thickness of the substrate; and the top surface has an adhesive for
fixing the substrate to the decorative upper layer. .Iaddend.
.Iadd.33. The substrate for use in a flooring system as recited in
claim 32, wherein the continuous sheet is cut to the appropriate
length to fit the space requirements. .Iaddend.
.Iadd.34. The substrate for use in a flooring system as recited in
claim 32, wherein the substrate has the strength characteristics
required to support the decorative layer while having sufficient
resiliency to allow the substrate to be delivered in rolls.
.Iaddend.
.Iadd.35. The substrate for use in a flooring system as recited in
claim 32 wherein the substrate comprises an SBR rubber material.
.Iaddend.
.Iadd.36. A method for installing a flooring system comprising a
subfloor, a decorative top layer, and a substrate having a top
surface and an oppositely facing bottom surface, said method
comprising: positioning the bottom surface of the substrate
proximate the subfloor, the substrate having voids which extend
between the top surface and the bottom surface, the substrate being
manufactured from rubber in sheets which are cut to the desired
configuration and having strength characteristics to support the
decorative layer and prevent damage thereto and sound dampening
characteristics to provide decibel reduction through the substrate;
and positioning the decorative top layer proximate the top surface
of the substrate, wherein the substrate is fixed to the decorative
top layer by means of an adhesive..Iaddend.
.Iadd.37. The method as recited in claim 36, wherein the density of
the substrate is less than 1000 kilograms per meter cubed.
.Iaddend.
.Iadd.38. The method as recited in claim 36, wherein the substrate
has the strength characteristics required to support the decorative
layer while having sufficient resiliency to allow the substrate to
be delivered in rolls. .Iaddend.
.Iadd.39. The method as recited in claim 36, wherein the substrate
is fixed to the subfloor by means of an adhesive. .Iaddend.
.Iadd.40. The method as recited in claim 36, wherein the substrate
comprises an SBR rubber material. .Iaddend.
.Iadd.41. The method as recited in claim 36, wherein the sound
dampening characteristics exhibit a decibel reduction of about 20
dB for a substrate with a thickness of 5 mm. .Iaddend.
.Iadd.42. The method as recited in claim 36, wherein the substrate
comprises rubber and polyurethane. .Iaddend.
.Iadd.43. The method as recited in claim 36, wherein the voids are
provided between particles of rubber. .Iaddend.
.Iadd.44. The method as recited in claim 36, wherein said substrate
comprises rubber and polyurethane. .Iaddend.
.Iadd.45. The method according to claim 36, further comprising
providing the substrate in the form of a rolled sheet.
.Iaddend.
.Iadd.46. The method according to claim 45, wherein the rolled
sheet is four feet wide. .Iaddend.
.Iadd.47. The method as recited in claim 36, wherein the sound
dampening characteristics exhibit a decibel reduction of about 25
dB for a substrate with a thickness of 10 mm. .Iaddend.
.Iadd.48. The method as recited in claim 36, wherein the flooring
system has sound dampening characteristics providing a decibel
reduction of about 20 dB for a substrate having a thickness of 5 mm
and about 25 dB for a substrate having a thickness of 10 mm.
.Iaddend.
.Iadd.49. The method according to claim 36, wherein the positioning
a decorative layer includes positioning the decorative layer
directly on the substrate. .Iaddend.
.Iadd.50. The method according to claim 36, wherein the substrate
is a non-vulcanized substrate. .Iaddend.
Description
FIELD OF THE INVENTION
The invention is directed to sound insulating material for use in
flooring. In particular, a sound insulating material which exhibits
the strength characteristics required to properly support the
decorative top layer of the flooring.
BACKGROUND OF THE INVENTION
Ceramic, masonry, and wood tiles have been used for many years in
the construction industry. These materials are used for many
reasons including strength, durability, and appearance. However,
despite their numerous desirable qualities, these materials
typically exhibit poor acoustic properties. Poor sound or acoustic
properties are extremely undesirable in all structure, but in
particular in high-rise buildings which are used as office
buildings, hotels, apartments, and the like. As the occupants of
one floor do not want to be disturbed from the occupants of the
floor above, it is typical to add insulating material between the
subfloor and the decorative tiles. In fact, standards have been
developed and modified to insure that sound is not transmitted. The
ASTM Impact Sound related tests are E492-90 and E 989-89. Where
noise codes exist, generally IIC50 is specified. These apply to
either finished floors of wood, ceramic, tile, stone, marble,
vinyl, carpet, laminate, or floating floors of gypsum, lightweight
concrete, mortar beds, plywood, and backer board.
While the insulating material of the prior art dampens the impact
sound transmission, several disadvantages have been associated with
the use of the insulating material. There are currently a variety
of impact sound insulating materials which achieve the impact sound
dampening required. It is typical for these materials to utilize
numerous air-filled cells, such as foams, a honeycomb construction,
one or more fibrous layers, or a combination of these
constructions. All of these have problems associated therewith.
Increased thickness associated with these materials is a
significant problem. The thicker the material, the greater
thickness of the floor. Moreover, the increased thickness of the
floor increases the overall height required for the building,
thereby significantly increasing the cost of materials and
construction.
Additionally, as many of the materials are designed to reduce
impact sound, the structural stability of the material is weak. In
other words, the material can easily be compressed when a force is
applied thereto. Consequently, while the materials described above
work well in ceilings and walls, structural support must be added
in order for the insulating materials to be used in flooring
systems. Without the support, the tiles would crack and deform as
pressure is applied. The introduction of the support layer further
adds to the height requirements, resulting in greater expense.
It would, therefore, be beneficial to provide an insulating member
which provides the acoustic properties required while providing the
structural support necessary to support the tiles. It would also be
beneficial to provide the properties needed while minimizing the
height required for the insulating member.
SUMMARY OF THE INVENTION
An object of the present invention is to provide an insulating
material for use with decorative flooring tile and the like which
minimizes the height required. Another object of the invention is
to provide an insulating material which has the acoustic properties
and the strength characteristics required to be used in a flooring
system.
These and other objects are accomplished by the flooring system
described herein. The flooring system has a subfloor, a decorative
top layer, and a substrate provided therebetween. The substrate has
a top surface and an oppositely facing bottom surface. The bottom
surface positioned proximate the subfloor and the top surface is
positioned proximate the decorative top layer. Voids are provided
in the substrate which extend between the top surface and the
bottom surface. The substrate is manufactured from rubber in sheets
which are cut to the desired configuration. The substrate has the
strength characteristics to support the decorative layer and
prevent damage thereto and the sound dampening characteristics to
provide decibel reduction through the substrate.
The invention is also directed to a substrate for use in a flooring
system which has a subfloor and a decorative upper layer. The
substrate is made in a sheet which has a bottom surface, a top
surface, side surfaces and end surfaces. The top surface and the
oppositely facing bottom surface are essentially parallel to each
other and are spaced apart by the thickness of the substrate. Voids
are provided in the substrate, the voids are provided between
particles of rubber or other similar material. When the substrate
is positioned between the subfloor and the decorative top layer,
the particles of rubber provide the strength required to prevent
deformation of the substrate in the direction of the thickness and
the voids contribute to the sound dampening characteristics
required to provide decibel reduction across the thickness of the
substrate.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a substrate according to the
present invention.
FIG. 2 is an enlarged cross sectional view of the substrate of FIG.
1.
FIG. 3 is a cross sectional view of a flooring system in which the
substrate of FIG. 1 is incorporated.
DETAILED DESCRIPTION OF THE EMBODIMENT SHOWN
Referring to FIG. 3, a flooring system 2 according to the present
invention is shown. The flooring system 2 has a base or subfloor 4.
The subfloor 4 is an integral part of the building or structure and
can be in the form of a concrete slab, plywood floor, or any other
known material commonly used in the building industry. Positioned
above the subfloor is a sound absorbing substrate 6 and decorative
top layer 7. The sound absorbing substrate 6 may be affixed to the
subfloor 4 and/or the decorative top layer 7 by means of mastic or
glue layers 20. As the use of mastics or glues are well known in
the industry, a further explanation of the glue will not be
provided.
The decorative top layer may be wood, linoleum, ceramic tile,
carpet, or any other known flooring. Individual components of the
decorative top layer 7 are positioned in place and secured to each
other by frictional engagement, glue, grout, or other conventional
means. As decorative flooring is commonly used, a further
explanation of the specifics relating to the decorative top layer 7
will not be provided.
Referring to FIGS. 1 and 2, the substrate 6 has a bottom surface 8,
a top surface 10, side surfaces 12 and end surfaces 14. The top
surface 10 and the oppositely facing bottom surface 8 are
essentially parallel to each other and are spaced from each other
by a distance or thickness t. The side surfaces 12 are spaced from
each other and are essentially parallel to each other. End surfaces
14 are cut to conform to the shape required for the particular
application. As the substrate is manufactured in continuous sheets,
the length of the substrate will be governed by the particular
installation. This provides maximum flexibility to the installer of
the substrate. The use of a continuous sheet of substrate provides
advantages which will be more fully described below. Voids 16 are
provided in the substrate 6 and are randomly positioned in the
substrate. The size and configuration of respective voids is also
random.
In the embodiment shown the substrate 6 is manufactured from
recycled rubber. During the manufacturing process SBR and natural
rubber are mixed with a polyurethane and cured under moderate
temperature to form a large cylindrical member of the rubber. In
order to provide a continuous sheet of the substrate 6, the
substrate 6 is cut from a cylindrical member. As the cylindrical
member is rotated, blades engage an outside layer of the
cylindrical member and cause the outside layer to be cut away from
the cylindrical member, thereby forming a continuous sheet of the
substrate 6. This process of manufacturing the substrate is
significantly different than the vulcanized method generally used
to manufacture substrates of this type. Therefore, the substrate of
the present invention has greater resiliency, as will be more fully
discussed below. Although the embodiment shown has a large
percentage of SBR rubber therein, the substrate 6 can be made of
SBR rubber, other rubbers, or any combination thereof.
During installation of the flooring system, at least one continuous
sheet of the substrate 6 is brought to the job and cut to the
appropriate length. As the rubber material of the present invention
has not been vulcanized, the rubber material has the flexibility
required to allow the rubber material to be delivered in rolls of
sheets. With the substrate 6 cut to the proper length, the
substrate is positioned over and covers the subfloor 4. As each
sheet of the substrate 6 is generally four feet wide, several
sheets of substrate may be required to fully cover the subfloor 4.
The use of continuous sheets eliminates many of the seams found in
the prior art. Previously, individual pieces of some type of
substrate would be positioned on the subfloor. The use of many
rectangular pieces requires many seams which are difficult to align
precisely, thereby causing gaps to be provided therebetween. The
use of the sheets minimizes this problem.
The substrate 6 may or may not be glued or secured to the subfloor
4. If glue or adhesive 20 or the like is to be used, the glue is
generally applied to the subfloor prior to the substrate being
finally positioned thereon. As the substrate 6 is in the form of
continuous sheets, the weight of the sheets and their frictional
interface with the subfloor is generally sufficient to maintain the
substrate in position, thereby eliminating the need for glue 20 or
the like.
With the substrate 6 properly positioned on the subfloor 4, the
decorative top layer 7 can be installed. Depending on the material
used for the decorative top layer, the material may or may not be
glued or secured to the substrate. If glue or adhesive 20 is to be
used, the glue is generally applied in small areas and the
decorative top layer is installed thereon. This process is repeated
until the entire decorative top layer is installed.
In the embodiment shown, the substrate 6 has a density of below
1000 kilograms per meter cubed and a decibel reduction of
approximately 20 dB for a substrate having a thickness of 5 mm and
25 dB for a substrate having a thickness of 10 mm. However, the
density and thickness of the substrate 6 may be varied according to
the particular application. Consequently, the density and material
of the substrate are important to the overall effectiveness of the
flooring system. The flooring system must have the structural
integrity to prevent cracking or breaking of the decorative upper
layer. Generally, in order to achieve the maximum structural
integrity, the substrate should be as rigid as possible. In fact in
many of the previous flooring systems, extra support members are
provided to enhance the rigidity characteristics of the substrate.
However, the substrate must also have the ability to dampen the
sound and provide the appropriate decibel reduction. In order to
achieve this result, the prior art teaches of sound dampening
materials used in the substrate. These materials generally have air
voids and the like to dampen the sound, which lessens the rigidity
of the substrate. Therefore, prior art substrates are either
extremely thick or require the use of a separate support member to
provide the strength and/or sound dampening characteristics
required.
In contrast, the substrate 6 of the present invention is configured
to achieve the sound dampening and strength requirements with a
relatively thin cross section and without the need for an
additional support member. As the substrate 6 is manufactured as
described above, the rubber provides the structural integrity
required. Although the substrate is flexible, when a force is
applied to the top surface 10 of the substrate 6, the rubber
particles 30 will compress only a relatively small amount.
Therefore, as the compression of the substrate in the y direction
is not great, the movement of the decorative upper layer 7 in the y
direction is also not significant. Consequently, the likelihood of
damage to the upper layer because of cracking and the like is
essentially eliminated. However, the substrate 6 also has the sound
dampening characteristics required. As the manufacturing process
provides random voids 16 between the particles of rubber, the
configuration of the substrate 6 dampens the sound.
The use of substrate 6 has various advantages over the prior art.
Unlike other materials used to dampen sound, the rubber sheets are
highly elastic with long lasting flexibility. The material does not
wear, harden, or grow bittle over time. Consequently, as the
substrate maintains its integrity and characteristics over time,
the decorative top layer 7 does not wear as quickly and thereby
extends the life of the top layer 7.
The rubber substrate 6 is also moisture insensitive compared to
other materials such as cork. Therefore, in environments where the
floor system is exposed to liquids, the performance of the rubber
substrate 6 will be unaffected by the liquid and will not degrade
over time.
As described, the use of sheets provides a solid surface on which
the top layer is positioned. In previous systems, the substrate
would be made from numerous squares (or rectangles) which would be
positioned in abutting relationship. If any of the individual
pieces were not properly aligned, a gap or space would be provided
between the pieces. While the top layer positioned over the spaces,
the spaces would not properly support the top layer, creating a
weak area in which the top layer could crack over time.
The use of the rubber substrate 6 also allows radiant heat to be
positioned in the floor. As the rubber is stable over a range of
temperatures, the present invention can be used with radiant heat
systems. Many other sound dampening materials would not be
adaptable with radiant heat.
As the substrate does not require additional support members and as
the thickness of the substrate can be minimized to accommodate the
particular application, the use of the substrate minimizes the
overall height of the flooring system. This can be an extremely
important factor in reducing the cost to construct a building or
the like. When compared with conventional flooring system currently
used, the use of the flooring system described herein can eliminate
approximately 13 to 14 millimeters of height. As the thickness of
the substrate is minimized and as no additional members are
required, the use of the substrate 6 reduces the space required.
This reduction of height required for the flooring system is
particularly significant in multi-story or high rise buildings. In
these buildings, a reduction of a meter or less in height reduces
the amount of building material used and is a significant cost
savings.
The foregoing illustrates some of the possibilities for practicing
the invention. Many other embodiments are possible within the scope
and spirit of the invention. It is, therefore, intended that the
foregoing description be regarded as illustrative rather than
limiting, and that the scope of the invention is given by the
appended claims together with their full range of equivalents.
* * * * *