Floor Panel Sound-Damping Layer with Liquid-to-Foam Adhesive
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Solution Overview
Problem
Existing floor panels with soundproofing layers often require adhesives to connect to the subfloor, leading to cavities that increase room noise, and there is a need for easy-to-produce and lay panels with good acoustic properties.
Innovation Solution
A method where a soundproofing material with a density of 800-1500 kg/m³ is applied to the carrier layer in liquid form, hardened before connection, and combined with a full-surface adhesive layer to avoid stress and ensure effective sound insulation, allowing for flexible installation without gluing, using viscoelastic polyurethane with fillers and a permanently elastic adhesive layer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If adhesive is used to connect the floor panel to the subfloor, then the connection strength is improved, but cavities are created between the floor panel and subfloor which increase room noise
Solution Approach 1:
The patent changes the physical state of the adhesive from liquid to foam form. The adhesive is applied in liquid form and then transforms into foam, expanding to fill cavities and voids between the floor panel and subfloor. This parameter change (from liquid to foam) allows the adhesive to simultaneously provide strong connection and eliminate noise-causing cavities.
Solution Approach 2:
The patent uses a composite material system consisting of polyurethane adhesive that forms a foam structure. This foam composite material combines the adhesive function with the sound-damping function, creating a multi-functional layer that both bonds the floor panel to the subfloor and fills cavities to reduce noise transmission.
2Ease of operation
If floating installation without adhesive is used, then ease of installation is improved, but cavities are created between floor panels and subfloor increasing room noise
Solution Approach 1:
The adhesive system is applied in liquid form and then automatically transforms into foam, self-expanding to fill cavities and voids without requiring additional manual intervention. This self-service mechanism eliminates the need for complex installation procedures while simultaneously addressing the noise problem that would otherwise require floating installation.
Solution Approach 2:
The patent utilizes phase transition of the adhesive material from liquid to foam state. This phase transition occurs after application, automatically filling cavities and eliminating noise pathways while maintaining the simplicity of the installation process. The phase change happens in-situ, providing both ease of installation and noise reduction.
3Stress or pressure
If soundproofing material is applied in liquid form and hardened before connection, then stress in the carrier plate is reduced, but the production process complexity increases
Solution Approach 1:
The soundproofing material is applied in liquid form to the carrier plate before the floor panel is connected to the subfloor. This preliminary action allows the material to set and harden in place, accommodating any volume changes without creating stress in the carrier plate. The sequence of operations is optimized to prevent stress formation.
Solution Approach 2:
The patent changes the physical state of the soundproofing material from liquid to solid through controlled hardening. This parameter change occurs before the connection step, allowing the material to stabilize and accommodate volume changes without transferring stress to the carrier plate structure.
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 method provides floor panels with excellent acoustic properties, reducing room noise by minimizing cavities and allowing flexible installation, with the soundproofing layer effectively reducing vibrations and accommodating uneven subfloors without adhesive reliance.
Implementation Method 1
Only after the liquid soundproofing material has hardened is the soundproofing layer connected to the carrier plate
Implementation Method 2
using viscoelastic polyurethane with fillers
Implementation Method 3
the soundproofing layer effectively reducing vibrations
Data Source
Figure 1
AI summary
The invention relates to a floor panel (1) for laying on a subfloor (2), comprising a carrier panel (10) with an upper side (11) and an underside (12), a decorative layer (20) provided on the upper side (11) of the carrier panel (10), a first edge with a first holding profile, a second edge with a second holding profile which can be connected to the first holding profile of a structurally identical floor panel, wherein the first holding profile and the second holding profile are designed such that, in the connected state, they are locked in a horizontal direction parallel to a laying plane and transversely to the first edge and in a vertical direction perpendicular to the laying plane, a sound-damping layer (40) composed of a sound-damping material (43) that is provided on the underside (12) of the carrier panel (10), wherein, in the use position of the floor panel (10), the sound-damping layer (40) has a substantially full-surface adhesive layer (44) on an outer side directed towards the subfloor (2), and a peelable protective layer (50) for the adhesive layer (44). There is provision according to the invention that a density of the sound-damping material (43) is between 800 and 1500 kg/m3, and that the sound-damping layer (40) has a carrier layer (41) for the sound-damping material (43) on an inner side directed towards the carrier panel (10). The invention also relates to a method for producing the floor panel (1).