Noise Control Flooring System with Compressible Layer
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Solution Overview
Problem
Current noise control flooring systems, relying on entangled nets, face limitations in effectively reducing noise transmission due to energy transfer through material contact and air pressure build-up, and fail to achieve higher performance levels beyond code compliance.
Innovation Solution
A noise control flooring system incorporating a solid substrate, a compressible polymer-based carded fabric layer, an entangled net layer, and a separation layer that is air and vapor pervious but liquid impervious, where the compressible layer compresses into the entangled net, creating a resilient cushion and diffusing air pressure, thereby enhancing noise absorption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If an entangled net is used to create void space for noise control, then noise transmission is reduced, but energy transfer through material contact and air pressure build-up limits performance improvement
Solution Approach 1:
A compressible layer is introduced as an intermediary between the entangled net and the floating substrate. This layer mediates the interaction by compressing under load to maintain consistent void space, preventing both material contact and air pressure build-up while ensuring reliable noise control performance across varying installation conditions.
Solution Approach 2:
The system changes the physical state of the void space by introducing a compressible layer that dynamically adjusts the void space characteristics. Under load, the compressible layer compresses to maintain optimal void space thickness, transforming the static void space into a dynamically adaptable parameter that ensures consistent noise control performance.
2Object-affected harmful factors
If thicker entangled net products are used to improve noise control, then air pressure is better limited, but device complexity and installation difficulty increase
Solution Approach 1:
The compressible layer acts as a mediator that replaces the need for excessively thick entangled net products. It achieves the same air pressure limitation function in a thinner, more manageable package, simplifying the overall product while maintaining effective noise control.
Solution Approach 2:
Instead of uniformly increasing the thickness of the entire entangled net product, the invention applies a targeted compressible layer only where needed to limit air pressure build-up. This localized approach achieves the desired performance improvement without proportionally increasing overall product complexity and installation difficulty.
3Object-affected harmful factors
If material contact between floating substrate and subfloor is limited, then vibration wave transmission is reduced, but achieving higher performance levels beyond code compliance becomes difficult
Solution Approach 1:
The compressible layer serves as an intermediary that optimizes the decoupling between floating substrate and subfloor. It maintains sufficient separation to limit vibration wave transmission while providing consistent mechanical support, enabling reliable achievement of higher performance levels beyond basic code compliance.
Solution Approach 2:
The compressible layer introduces dynamic characteristics to the void space, allowing it to adapt to varying loads and installation conditions. This dynamic adjustment ensures consistent performance across different scenarios, enabling reliable achievement of higher performance levels rather than just meeting minimum code requirements.
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 system achieves improved noise reduction by increasing the resilience and thickness of the void space, limiting air pressure build-up and enhancing sound absorption across various frequencies, outperforming traditional systems by 3-5 points in IIC ratings and reducing sound levels by 4-6 dB from 125 Hz to 2500 Hz.
Implementation Method 1
the compressible layer compresses into the bottom side of the entangled net layer as a result of the loading from the floating substrate
Implementation Method 2
creating a small cushion under the filaments of the entangled net layer pressing back toward the overlying floating substrate layer
Implementation Method 3
The void limited touching of the two solid materials (subfloor and floating substrate) limited the energy transfer. The limited energy transfer consequently limited the ability of the vibration waves to pass through
Implementation Method 4
The second method is through the air pressure build up within the 'entangled net' product, 'convection'
Implementation Method 5
the separation layer is constructed of material that is air and vapor pervious while, at the same time, is substantially liquid impervious
Data Source
AI summary
A noise control flooring system is presented herein for reducing noise transmission in a building structure that contains the system. The system comprises a solid substrate layer, a compressible layer overlying at least a portion of the substrate layer, and an entangled net layer that overlies at least a portion of the compressible layer, wherein the net layer is comprised of multiple polymer filaments and air, together forming a void space. A separation layer overlies at least a portion of the entangled net layer. The separation layer carries a floating solid substrate layer thereupon. This solid substrate layer provides loading for causing the compressible layer to compress into the overlying entangled net layer.