Multi-layer acoustical flooring tile and method of manufacture

Abstract

An acoustical vinyl tile having an integral acoustical layer is disclosed. The vinyl tile includes a vinyl portion and an acoustical portion. The acoustical portion comprises a plurality of individual layers, the combination of which is customized to the particular sub-floor structure to which the tile will be adhered or overlain. The individual layers of the acoustical portion can include any of a variety of combinations of rubber, cork, polyurethane foam, and the like. The resulting tile meets one or more of ASTM E 2179, ASTM E 989, ASTM E 492, and ASTM E1007 IIC sound requirements. A method of designing the disclosed tile to suit a particular flooring application is also disclosed. Other embodiments are described and claimed.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS[0001]This is a non-provisional of pending U.S. Provisional Patent Application Ser. No. 61 / 808,670, filed Apr. 5, 2013, and also claims priority to pending U.S. Non-Provisional Patent Application Ser. No. 13 / 468,103, filed May 10, 2012, the entirety of which applications are expressly incorporated by reference herein.FIELD OF THE DISCLOSURE[0002]The present disclosure relates to vinyl flooring systems in general, and more particularly, to an improved vinyl tile having enhanced acoustical properties coupled with improved long term stability.BACKGROUND OF THE DISCLOSURE[0003]Vinyl flooring has been a popular floor covering material for many years. Vinyl flooring is typically available in either tile or sheet form for both commercial and residential use. As finished flooring material, vinyl tile has been used extensively in commercial, institutional and public building applications, such as, for example, malls, schools, healthcare facilities, conv...

AI Technical Summary

Benefits of technology

[0009]The disclosed system and method include an improved vinyl tile having enhanced stability, resilience and acoustical properties. The disclosed vinyl tile incorporates an acoustical layer made up of a plurality of individual sublayers. The composition and arrangement of the sublayers can be adjusted to provide desired sound dampening properties that are customized to a particular flooring structure.

[0010]In some embodiments, a sound dampening material is bonded to a vinyl tile slab prior to cutting the product into tiles or planks The formulation of the acoustical sound dampening material may be selected to be compatible with the adhesive used to fix the material to the vinyl tile slab. Such a formulation may ensure a good long term bond between the sound dampening material and the vinyl tile slab. The acoustical sound dampening material may also be selected to be compatible with the vinyl tile slab material, which may reduce or eliminate discoloration of the vinyl tile over the lifetime of the flooring system. Embodiments of the disclosed tile incorporate the aforementioned chemical compatibility while still providing desired acoustical properties. The disclosed vinyl tiles may find application in multi-family housing developments, which as previously noted, can benefit greatly from the associated sound dampening properties.

Problems solved by technology

Vinyl flooring can also have limited acoustical properties, in that the material offers some rebound or resilience upon compression (i.e., when walked on).

Because current vinyl tile systems employ a standard base layer, they are incapable of dampening sound optimally across a variety of floor / ceiling structure types.

For example, while a typical tile may provide reasonable acoustical dampening when applied over a poured concrete floor, it may not provide acceptable dampening when applied over a wood beam-supported floor.

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