Acoustic Flooring Panel With Compressible Sound-Absorbing Layer
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Solution Overview
Problem
Hard surface floor coverings exhibit poor acoustic performance due to their rigidity, which leads to high-pitch noise and limited sound attenuation, especially for impact and reflected sounds, despite efforts to improve sound management through underlays and acoustic pads.
Innovation Solution
A flooring panel design incorporating a decorative top layer with a compressible natural material layer between the core and decorative layer, utilizing materials like felt, cotton, wool, mycelium, or cork, along with closed cell flexible foam, to absorb and transform impact kinetic energy, reducing generated sound amplitude and pitch.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If hard surface floor coverings are used to provide rigidity and strength, then structural strength is improved, but acoustic performance deteriorates due to high-pitch noise and limited sound attenuation
Solution Approach 1:
The patent applies composite materials by combining a rigid core layer with a compressible natural material layer. The core layer provides structural strength and rigidity, while the compressible layer (made from materials like cork, wool, cotton, or felt) absorbs impact sound and reduces high-pitch noise. This composite structure resolves the contradiction by integrating both hard and soft materials to achieve simultaneous structural integrity and acoustic performance.
Solution Approach 2:
The patent applies local quality by creating different zones within the flooring panel with distinct properties. The core layer maintains high rigidity for structural support, while the compressible layer provides localized sound absorption where needed. This spatial differentiation of material properties allows the flooring to exhibit both strength and acoustic comfort in different regions of the same panel.
2Ease of operation
If the rigidity of floor coverings is increased to enable floating installation, then ease of operation is improved, but sound attenuation capability deteriorates
Solution Approach 1:
The patent uses composite materials to reconcile the conflict between rigidity for floating installation and sound attenuation. The core layer provides the necessary rigidity (>3500 MPa) for floating installation and interlocking mechanisms, while the compressible natural material layer absorbs impact energy and attenuates sound. This composite approach allows the flooring to be installed as a floating floor while simultaneously reducing transmitted impact sound.
Solution Approach 2:
The patent applies parameter changes by modifying the physical properties of the flooring structure. The core layer maintains high rigidity modulus for floating installation, while the compressible layer introduces controlled compliance through its lower rigidity. This parameter differentiation enables the flooring to satisfy both installation requirements and acoustic performance criteria.
3Device complexity
If the thickness of floor coverings is limited to 3-15 mm, then device complexity is reduced, but sound attenuation performance deteriorates
Solution Approach 1:
The patent applies local quality by concentrating sound absorption functionality in the compressible natural material layer, which is optimized for acoustic performance. Even within the limited thickness constraint, this specialized layer provides effective sound attenuation through its compressible structure, while the core layer maintains structural integrity. The localized optimization of material properties compensates for the overall thinness of the panel.
Solution Approach 2:
The patent uses composite materials to maximize sound attenuation within limited thickness. The combination of rigid core and compressible layer creates a multi-functional structure where each material contributes its strengths. The compressible natural material layer, though thin, provides disproportionate sound attenuation value due to its energy-absorbing properties, enabling effective acoustic performance without increasing overall panel thickness.
4Object-generated harmful factors
If traditional underlays or acoustic pads are added to improve sound performance, then acoustic performance is improved, but device complexity increases
Solution Approach 1:
The patent applies merging by integrating the sound absorption function directly into the flooring panel structure through the compressible natural material layer. Instead of requiring separate underlays or acoustic pads, the sound attenuation capability is combined with the decorative top layer and core layer into a single unified panel. This integration reduces device complexity by eliminating additional components while maintaining acoustic performance.
Solution Approach 2:
The patent applies universality by designing the compressible natural material layer to serve multiple functions simultaneously. This layer provides both aesthetic value as part of the decorative top layer and acoustic functionality for sound attenuation. The multi-functionality eliminates the need for separate acoustic treatment layers, thereby reducing overall device complexity while achieving both structural and acoustic objectives.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The combination achieves significant sound attenuation, with up to 26 dB reduction in generated sound amplitude and 5 octaves lower pitch, outperforming traditional constructions with thinner and more flexible designs.
Implementation Method 1
the compressible layer comprises at least one compressible natural material
Implementation Method 2
a compressible layer which comprises at least one compressible natural material
Implementation Method 3
by means of friction between the air particles and its pore walls, reduces the amplitude of certain frequencies of the sound waves passing through the flooring
Implementation Method 4
This type of underlay provides a low density, porous buffer layer
Data Source
AI summary
The invention relates to a flooring panel suitable for constructing a floor covering, which panel comprises a core layer and a decorative top layer and a layer situated between the core layer and the decorative top layer which enables improves sound performance.