Sound suppressing flooring and method of manufacturing same

• US 20040140151A1
• Filed: 01/09/2004
• Published: 07/22/2004
• Est. Priority Date: 01/09/2003
• Status: Abandoned Application

• Current Assignee: FCF Limited
• Original Assignee: F C & C
• Inventors: Gallant, Mel
• Application Number:
  US10/753,312
• Publication Number:
  US 20040140151A1
• Time in Patent Office: Days
• US Class Current: 181/290
• CPC Class Codes: B32B 21/08 of synthetic resin
• CPC Class Codes: B32B 5/18 characterised by features of a layer of foamed material
• CPC Class Codes: E04F 15/02 Flooring or floor layers composed of a number of similar elements of webs E04F15/16
• CPC Class Codes: E04F 15/181 Insulating layers integrally formed with the flooring or the flooring elements
• CPC Class Codes: E04F 15/20 for sound insulation
• CPC Class Codes: E04F 15/206 Layered panels for sound insulation
• CPC Class Codes: E04F 2290/043 with a bottom layer for sound insulation

Abstract

A method of forming wood flooring. The flooring has foam applied to one side by adhesive. The adhesive is cured and a chemical bond forms between the wood and foam to provide a consolidated unit. This facilitates easier cutting of the consolidated product without dissociation of the foam from the wood. The result is an improved flooring product having sound suppression qualities.

Claims

1. A sound transmission reducing flooring article, comprising, in combination:

a wood member having opposed major faces, sides and ends; and

cross linked polyolefin foam material adhesively engaged to a major face of said major faces.

2. The article as set forth in claim 1, wherein said foam is closed cell foam.

4. The article as set forth in claim 1, wherein said engineered wood product comprises a laminated wood flooring product.

5. The article as set forth in claim 1, wherein said polyolefin foam has a width dimension comprising between 1% and 25% of the width of said wood member.

6. The article as set forth in claim 1, wherein said wood member comprises planking selected from the group consisting of maple, ash, oak, cherry, walnut, pine, cedar and birch.

7. The article as set forth in claim 1, wherein said foam is adhesively engaged with a curable adhesive.

8. The article as set forth in claim 7, wherein said adhesive comprises an ultraviolet curable adhesive.

9. The article as set forth in claim 7, wherein said cross linked polyolefin foam material has a textured surface.

10. The article as set forth in claim 1, wherein said adhesive forms a chemical bond with said foam to integrate said foam with said wood member.

11. The article as set forth in claim 1, wherein said flooring article includes a plurality of spaced apart air cells.

3. The article as set forth in claim 3, wherein said wood member comprises an engineered wood product.

12. A sound transmission reducing flooring article, comprising, in combination:

a wood member having opposed major faces, sides and ends;

a textured, cross linked polyolefin foam material adhesively engaged to a major face of said major faces; and

a plurality of spaced apart air cells between said major face of said wood member and said cross linked polyolefin foam material adhesively engaged to said major face.

13. The article as set forth in claim 12, wherein said foam is closed cell foam.

14. The article as set forth in claim 12, wherein said wood member comprises an engineered wood product.

15. The article as set forth in claim 14, wherein said engineered wood product comprises a laminated wood flooring product.

16. A method of forming a wood flooring member, comprising:

providing a source of wood suitable for use as flooring;

providing a foam material for fixation to said wood;

applying an adhesive material to one side of the flooring to effect chemical fusion between said flooring and said foam; and

cutting said wood having said foam consolidated there with into segments for flooring.

17. The method as set forth in claim 16, further including the step of pressurizing said segments to remove gas trapped between said foam and said wood.

18. The method as set forth in claim 17, wherein said heat treating includes exposing edges of said segments to heat for sealing said edges.

19. The method as set forth in claim 17, further including the step of heat treating cut segments.

20. The method as set forth in claim 16, further including the step of texturing said foam material prior to fixation to said wood.