Hybrid Acoustic Floor Panel With Foam Layer Noise Control

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Solution Overview

Problem

Existing multilayer floor panels made of synthetic polymer materials face challenges in achieving compatible layer combinations that provide both acoustic properties, such as sound attenuation and structural integrity, while meeting industrial standards.

Innovation Solution

A floor panel design comprising a rigid base slab of thermoplastic material with a flexible decorative top structure, featuring a footfall sound reducing foam layer between the wear layer and the base slab, which is bonded using a hotmelt adhesive, and optimized thickness and hardness combinations to enhance sound attenuation and structural properties.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Stability of the object's composition

If a foamed layer of thermoplastic material is used in the substrate, then dimensional stability is improved and reinforcement layer effectiveness is enhanced, but acoustic properties (sound attenuation) deteriorate

Engineering Contradiction:

Improvedimensional stabilityVSAvoidimpact noise

Core Design Contradiction:

Stability of the object's compositionVSObject-affected harmful factors

Solution Approach 1:

The substrate is divided into two distinct functional layers: a dense thermoplastic base layer providing dimensional stability and a separate foam layer providing acoustic insulation. This segmentation allows each layer to optimize its specific function without compromising the other, resolving the contradiction between stability and noise reduction.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The substrate uses a composite structure combining thermoplastic material and foam material with different densities and acoustic properties. This composite approach enables simultaneous achievement of dimensional stability (from the thermoplastic layer) and sound attenuation (from the foam layer), directly resolving the technical contradiction.

Inventive Principle:

Principle #40Composite materials

2Object-affected harmful factors

If a soft core of plastic is used in the floor panel, then acoustic properties are improved, but structural integrity and wear resistance deteriorate

Engineering Contradiction:

Improveimpact noiseVSAvoidstructural integrity

Core Design Contradiction:

Object-affected harmful factorsVSStrength

Solution Approach 1:

The floor panel is segmented into distinct layers with the wear layer/top structure providing structural integrity and the foam layer providing acoustic insulation. This segmentation allows the soft foam core to reduce noise while the harder top layers maintain strength and wear resistance.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The floor panel employs a composite multi-layer structure combining materials with different mechanical and acoustic properties. The thermoplastic base slab and wear layer provide structural strength, while the foam layer contributes acoustic insulation, achieving both structural integrity and noise reduction simultaneously.

Inventive Principle:

Principle #40Composite materials

3Object-affected harmful factors

If multiple foam layers are added to enhance sound attenuation, then acoustic properties are improved, but manufacturing complexity and cost increase

Engineering Contradiction:

Improveimpact noiseVSAvoidlayer structure complexity

Core Design Contradiction:

Object-affected harmful factorsVSDevice complexity

Solution Approach 1:

Instead of adding multiple foam layers, the invention uses a single foam layer with optimized thickness (at least 1 mm, preferably 1.2 mm or more) to achieve sufficient sound attenuation (20 dB or more). This partial action approach achieves the required acoustic performance with minimal structural complexity.

Inventive Principle:

Principle #16Partial or excessive action

Solution Approach 2:

The invention optimizes the thickness parameter of the single foam layer to achieve the desired acoustic performance. By adjusting the foam layer thickness to at least 1 mm (preferably 1.2 mm or more), the patent achieves 20 dB or more sound attenuation without needing multiple layers, thus maintaining manufacturing simplicity.

Inventive Principle:

Principle #35Parameter changes

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 design achieves significant sound attenuation of 20 dB or more, improved structural integrity, and enhanced wear resistance, while maintaining compatibility with industrial standards.

Implementation Method 1

bonded using a hotmelt adhesive

Methodology Applied

Scientific EffectHotmelt adhesive bonding: Heating

Implementation Method 2

at least one footfall sound reducing foam layer arranged between the wear layer and the base slab

Methodology Applied

Scientific EffectAcoustic absorption: Acoustic Absorption

Implementation Method 3

footfall sound reducing foam layer

Methodology Applied

Scientific EffectVibration damping: Damping

Data Source

PatentUS12485654B2Hybrid acoustic floor panel

Publication Date: 2025.12.02 TARKETT GDL

AI summary

A floor panel includes a rigid base slab of thermoplastic material and a flexible decorative top structure fixed on the base slab, the top structure including a wear layer for forming a walking surface of the floor panel, and the top structure including at least one footfall sound reducing foam layer arranged between the wear layer and the base slab.