Note: Descriptions are shown in the official language in which they were submitted.
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SOUND CONTROL UNDERLAYMENT AND FLOOR CONSTRUCTION
INCORPORATING THE SAME
Field
[0001] The subject application relates generally to vibration and
noise control
and in particular, to a sound control underlayment and a floor construction
incorporating the same.
Background
[0002] Insulating building structures to inhibit the transmission of
vibration and
noise from one region to another is common in many environments. For example,
vibration dampening pads, tiles and mats for use on floors to inhibit
vibration/noise
from traveling through floor surfaces are known.
[0003] Floor constructions employing a rubber underlayment interposed
between a concrete slab or wood subfloor and a finished floor covering such as
a
tile, stone, wood and vinyl floor covering are also known. During such an
installation,
depending on whether the floor construction comprises a concrete slab or wood
subfloor, either an adhesive or thinset mortar layer is applied to the upper
surface of
the concrete slab or wood subfloor and the rubber underlayment is laid over
the
concrete slab or wood subfloor. Once the adhesive or thinset mortar layer has
cured, depending on the finished floor covering to be laid over the rubber
underlayment, either an adhesive or thinset mortar layer is applied to the
upper
surface of the rubber underlayment and the finished floor covering is then
applied to
the upper surface of the rubber underlayment. Although the resulting floor
construction yields good vibration/noise dampening characteristics,
installation times
can be significant due to the need to wait for the adhesive and/or thinset
mortar
layers to cure. As will be appreciated, improvements in floor construction
designs
are desired.
[0004] It is therefore an object to provide a novel sound control
underlayment
and a floor structure incorporating the same.
Summary
[0005] Accordingly, in one aspect there is provided a sound control
underlayment for disposition between an unfinished floor surface and a floor
covering comprising a generally flat layer formed of resilient material and an
adhesive layer on at least one major surface of the flat layer.
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[0006] Other aspects of a sound control underlayment for
disposition between
an unfinished floor surface and a floor covering are provided. For example,
the
sound control underlayment of paragraph [0005], wherein the adhesive layer is
a
pressure sensitive adhesive layer.
[0007] The sound control underlayment of paragraph [0005] or [0006],
wherein the resilient material is rubber material.
[0008] The sound control underlayment of paragraph [0007],
wherein the
rubber material comprises recycled rubber content.
[0009] The sound control underlayment of any one of paragraphs
[0005] to
[0008], having a thickness in the range of 1mm to 25mm.
[0010] The sound control underlayment of any one of paragraphs
[0005] to
[0009], having an average dynamic stiffness in the range of 10MN/m3 to
200MN/m3.
[0011] According to another aspect there is provided a floor
construction
comprising a subfloor having an upper unfinished floor surface; a floor
covering
having an upper finished floor surface; and a sound control underlayment
interposed
between the subfloor and the floor covering, the sound control underlayment
comprising a generally flat layer formed of resilient material and an adhesive
layer on
at least one major surface of the resilient layer.
[0012] The floor construction of paragraph [0011], wherein the
sound control
underlayment is in accordance with any one of paragraphs [0006] to [0010].
[0013] The floor construction of paragraph [0011] or [0012],
wherein the
adhesive layer is in contact with the unfinished floor surface.
[0014] The floor construction of paragraph [0011] or [0012],
wherein the
adhesive layer is in contact with the floor covering.
[0015] The floor construction of paragraph [0011] or [0012], wherein the
adhesive layer is on opposed major surfaces of the resilient layer and the
adhesive
layers are in contact with both the unfinished floor surface and the floor
covering.
[0016] The floor construction of any one of paragraphs [0011] to
[0015],
wherein the subfloor is one of a concrete slab, a wood subfloor and an
oriented
strand board subfloor.
[0017] The floor construction of any one of paragraphs [0011] to
[0016],
wherein the floor covering is one of a ceramic tile floor covering, a vinyl
plank, tile or
sheet floor covering, a stone floor covering, an engineered wood floor
covering, a
laminate floor covering and a wood floor covering.
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[0018] According to another aspect there is provided a sound control
underlayment having opposed major unfinished floor and floor covering contact
surfaces for disposition between an unfinished floor surface and a floor
covering, the
sound control underlayment comprising a resilient layer and an adhesive layer
on at
.. least one major surface of the resilient layer.
[0019] The sound control underlayment of paragraph [0018], wherein the
adhesive layer is a pressure sensitive adhesive layer.
[0020] The sound control underlayment of paragraph [0018] or [0019],
wherein the resilient layer is formed of rubber material.
[0021] The sound control underlayment of paragraph [0020], wherein the
rubber material comprises recycled rubber content.
[0022] The sound control underlayment of any one of paragraphs [0018]
to
[0021], having a thickness in the range of 1mm to 25mm.
[0023] The sound control underlayment of any one of paragraphs [0018]
to
.. [0022], having an average dynamic stiffness in the range of 10MN/m3 to
200MN/m3.
[0024] According to another aspect there is provided a floor
construction
comprising a subfloor having an upper unfinished floor surface; a floor
covering
having an upper finished floor surface; and the sound control underlayment of
any
one of paragraphs [0018] to [0023] interposed between the subfloor and the
floor
covering.
[0024a] According to another aspect there is provided a sound control
underlayment for disposition between an unfinished floor surface and a floor
covering, the sound control underlayment being formed into a roll prior to
installation
between the unfinished floor surface and the floor covering and being unrolled
for
installation between the unfinished floor surface and the floor covering, the
sound
control underlayment being in the form of a laminate having a thickness in the
range
of 1mm to 25mm, an average dynamic stiffness in the range of 10MN/m3 to
200MN/m3, and a type A durometer hardness in the range of 40 to 50, the
laminate
comprising a layer formed of resilient rubber material comprising recycled
rubber and
having generally flat, opposite major surfaces, a pressure sensitive adhesive
layer
on at least one major surface of the resilient rubber material layer, and a
release
layer overlying the adhesive layer, the release layer being peelable from the
adhesive layer to expose the adhesive layer during installation of the sound
control
underlayment.
Date recue/Date received 2023-05-04
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[0024b] According to another aspect there is provided a floor
construction
comprising: a subfloor having an upper unfinished floor surface; a floor
covering
having an upper finished floor surface; and a sound control underlayment
interposed
between the subfloor and the floor covering, the sound control underlayment
being in
.. the form of a laminate having a thickness in the range of 1mm to 25mm, an
average
dynamic stiffness in the range of 10MN/m3 to 200MN/m3,and a type A durometer
hardness in the range of 40 to 50, the laminate comprising a resilient layer
having
generally flat, opposite major surfaces and comprising recycled rubber and a
pressure sensitive adhesive layer on at least one major surface of the
resilient layer
adhered to one of the upper unfinished floor surface of the subfloor and a
lower
surface of the floor covering.
[00240 According to another aspect there is provided a sound control
underlayment having opposite major unfinished floor and floor covering contact
surfaces for disposition between an unfinished floor surface and a floor
covering, the
.. sound control underlayment being in the form of a laminate and comprising a
resilient layer comprising natural rubber, SBR rubber and/or recycled rubber
and a
pressure sensitive adhesive layer on at least one major surface of said
resilient
layer, wherein the sound control underlayment has a thickness in the range of
1mm
to 25mm, an average dynamic stiffness of 10MN/m3 to 200MN/m3 and a type A
.. durometer hardness in the range of 40 to 50.
Brief Description of the Drawings
[0026] Embodiments will now be described more fully with reference to
the
accompanying drawings in which:
[0026] Figure 1 is a side elevational view of a floor construction;
[0027] Figure 2 is a side elevational view of another floor
construction; and
[0028] Figure 3 is a side elevational view of yet another floor
construction.
Detailed Description of Embodiments
[0029] The foregoing summary, as well as the following detailed description
of
certain examples will be better understood when read in conjunction with the
appended drawings. As used herein, an element or feature introduced in the
singular and preceded by the word "a" or "an" should be understood as not
necessarily excluding the plural of the elements or features. Further,
references to
"one example" or "one embodiment" are not intended to be interpreted as
excluding
Date recue/Date received 2023-05-04
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the existence of additional examples or embodiments that also incorporate the
described elements or features. Moreover, unless explicitly stated to the
contrary,
examples or embodiments "comprising" or "having" or "including" an element or
feature or a plurality of elements or features having a particular property
may include
additional elements or features not having that property. Also, it will be
appreciated
that the terms "comprises", "has", "includes" means "including by not limited
to" and
the terms "comprising", "having" and "including" have equivalent meanings. It
will
also be appreciated that like reference characters will be used to refer to
like
elements throughout the description and drawings.
[0030] In the following, various embodiments of a floor construction are
shown
and described that employ a sound control underlayment interposed between an
underlying unfinished floor surface and a floor covering. The sound control
underlayment is designed to inhibit or prevent the transmission of
sound/vibration/noise (hereinafter referred to as "sound" for convenience
only)
through the floor surface. Broadly, the sound control underlayment comprises a
generally flat or planar layer of resilient material having good vibration
deflection
characteristics and an adhesive layer on at least one major surface of the
resilient
material layer. Particular non-limiting examples of floor constructions
employing
sound control underlayments will now be described.
[0031] Turning now to Figure 1, a floor construction is shown and is
generally
identified by reference numeral 10. As can be seen, in this embodiment the
floor
construction comprises a subfloor in the form of a concrete slab 12 having an
upper
unfinished floor surface 14. A sound control underlayment 16 overlies the
upper
unfinished floor surface 14. A floor covering 18 overlies the sound control
underlayment 16 and has an upper surface defining the finished floor surface
20 of
the floor construction 10.
[0032] The sound control underlayment 16 comprises a layer 30 of
resilient
material. The resilient material is formed rubber material or other suitable
material
such as for example natural rubber, styrene-butadiene rubber (SBR), recycled
rubber etc. In this embodiment, the resilient material is formed of rubber
material
having 94% recycled rubber content. An adhesive layer 32 is laminated or
otherwise
applied onto one major surface of the resilient layer 30. In this embodiment,
the
adhesive layer 32 is a pressure-sensitive adhesive layer.
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[0033] The pressure sensitive adhesive layer 32 in this
embodiment
comprises an emulsion based acrylic double coated nonwoven tape that is
laminated
to the one major surface of the resilient layer 30. Those of skill in the art
will
however appreciate that other adhesives can be used. For example, if the sound
control underlayment 16 is to be used in damp or wet areas such as bathrooms
and
kitchens, waterproof adhesives may be employed.
[0034] The adhesive layer 32 is in direct contact with the upper
unfinished
floor surface 14 of the concrete slab 12 providing a quick and secure bond
between
the concrete slab 12 and the sound control underlayment 16. The sound control
underlayment 16 has a thickness of 2.0mm (5/64") and is mold, bacteria, fungi
and
water resistant.
[0035] In this embodiment, the floor covering 18 is a tile
(ceramic, stone etc.)
floor with the tiles 40 of the floor covering being secured to the upper
surface of the
sound control underlayment 16 via a thinset mortar layer 42.
[0036] During manufacture of the sound control underlayment 16, the
adhesive layer 32 is pre-adhered to a backing or release layer (not shown) and
the
adhesive layer 32 and resilient layer 30 are fed to a laminating machine,
which
applies the adhesive layer 32 to the resilient layer 30. The sound control
underlayment 16 is then rolled into a master roll. Sub-rolls of the sound
control
underlayment 16 are then cut from the master roll. The sub-rolls of sound
control
underlayment 16 when unrolled have a length of 10m (33ft) and a width of 1.50m
(591n). Those of skill in the art will appreciate that the sound control
underlayment
may be formed into rolls of different dimensions.
[0037] During installation, as the sound control underlayment 16
is unrolled
onto the unfinished floor surface 14, the backing or release layer is peeled
from the
adhesive layer 32 thereby to expose the adhesive layer 32 and allowing it to
be
brought into direct contact with the unfinished floor surface 14. As a result,
the
sound control underlayment 16 can be easily and quickly installed. Depending
on
the floor covering to be laid on the sound control underlayment 16, adhesive
or
thinset mortar is then applied on the upper surface of the sound control
underlayment 16 and the floor covering is laid on the sound control
underlayment
without delay to complete the floor construction 10.
[0038] Although the sound control underlayment 16 is described
and shown
as overlying a concrete slab 12, those of skill in the art will appreciate
that the sound
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control underlayment 16 can be applied to other subfloor constructions. For
example, the sound control underlayment 16 can be applied and adhered to
subfloors formed of plywood or other wood, oriented strand board (OSB) or
other
structural material.
[0039] Also, although the floor construction 10 is described as comprising
a
tile floor, those of skill in the art will appreciate that other floor
coverings such as
vinyl, (plank, tile, sheet, etc.) wood, stone, engineered wood, and laminate
floor
coverings may be applied to the upper surface of the sound control
underlayment 16
via adhesive, thinset mortar or other suitable bonding agent.
[0040] For example, Figure 2 shows another floor construction generally
identified by reference numeral 110. In this embodiment, the floor
construction 110
comprises a wood subfloor 112 supported by joists J and having an upper
unfinished
floor surface 114. The sound control underlayment 16 overlies the upper
unfinished
floor surface 114 with its adhesive layer 32 in direct contact with the upper
unfinished
floor surface 114. The floor covering 18 overlies the sound control
underlayment 16
and has an upper surface defining the finished floor surface 20 of the floor
construction 110. In this embodiment, the floor covering 18 is a vinyl sheet
140 that
is secured to the upper surface of the sound control underlayment 16 via an
adhesive layer 142.
[0041] As will be appreciated, the above floor constructions provide
benefits or
advantages. The provision of the sound control underlayment 16 reduces
transmission of impact sound and vibration through the floor constructions as
compared to conventional floor constructions. The adhesive layer 32 of the
sound
control underlayment 16 allows the sound control underlayment to be installed
quickly on the unfinished floor surface. Once installed, the floor covering
can be
applied on the sound control underlayment without delay allowing the finished
floor
construction to be completed quickly as compared to conventional floor
constructions.
[0042] In the embodiments described above, the sound control
underlayment
16 is applied to the subfloor with the adhesive layer 32 facing down so that
the
adhesive layer bonds the sound control underlayment 16 to the subfloor. The
sound
control underlayment 16 however, does not need to be installed in this
orientation.
[0043] If desired, the sound control underlayment 16 can be applied
to the
subfloor with the adhesive layer facing up so that the sound control
underlayment
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floats on the subfloor and provides an upper adhesive layer 32 facilitating
installation
of the floor covering.
[0044] For example, Figure 3 shows a floor construction 210
comprising a
wood subfloor 112 supported by joists J. The sound control underlayment 16
overlies the upper unfinished floor surface 114 of the subfloor 112 with the
adhesive
layer 32 of the sound control underlayment 16 facing up. A vinyl floor
covering 18
overlies and is adhered to the sound control underlayment 16.
[0045] In above embodiments, the sound control underlayment 16 is
described as having a resilient layer formed of rubber material with 94%
recycled
rubber content. Those of skill in the art will appreciate that the percentage
content of
recycled rubber may be varied. Also, as mentioned above other suitable
resilient
materials may be employed.
[0046] In above embodiments, the sound control underlayment 16 is
described as having a thickness of 2mm. Those of skill in the art will
appreciate that
the thickness of the sound control underlayment may be varied depending on the
particular floor construction environment in which the sound control
underlayment is
being installed. For example, the thickness of the sound control underlayment
may
be in the range of lmm to 15mm. As will be appreciated, as the thickness of
the
sound control underlayment increases, during manufacture, the length of the
sound
control underlayment rolled into sub-rolls is reduced.
[0047] Depending on floor construction environment (i.e. heavy
commercial to
light commercial to residential), the average dynamic stiffness and hardness
of the
sound control underlayment may be varied. The average dynamic stiffness of the
sound control underlayment 16 is typically in the range of from 10MN/m3 to
200MN/m3. For example, in heavy commercial environments, the sound control
underlayment may have an average dynamic stiffness of 157MN/m3 and a type A
harness of 40 durometer. In moderate commercial environments, the sound
control
underlayment may have an average dynamic stiffness of 105MN/m3 and a type A
harness of 40 durometer. In light commercial/residential environments, the
sound
control underlayment may have an average dynamic stiffness in the range of 64
MN/m3 to 54 MN/m3 and a type A harness of 40 or 50 durometer.
[0048] In the above embodiments, the sound control underlayment is
described as having an adhesive layer on one major surface of the resilient
layer that
is either in direct contact with the subfloor or the floor covering. If
desired, adhesive
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layers may be laminated on or otherwise applied to opposed major surfaces of
the
resilient layer so that adhesive layers are in direct contact with both the
subfloor and
the floor covering.
[0049] Those of skill in the art will appreciate that the sound
control
.. underlayment can also act as a waterproof barrier between the subfloor and
the floor
covering.
[0050] Although embodiments have been described above and are shown
in
the accompanying drawings, it will be appreciated by those skilled in the art
that
variations and modifications may be made without departing from the scope
defined
by the appended claims, and the scope of the claims should be given the
broadest
interpretation consistent with the specification as a whole.
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