Profiled Bonding Layer for Footfall Sound Deadening

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Solution Overview

Problem

Existing solutions for footfall and ambient sound deadening in panels, such as those made from wood materials, are costly and inconvenient, especially when applied to panels with coated or decorative surfaces, as they require processing different surfaces and may not be feasible for all panel types.

Innovation Solution

A panel design featuring a bonding layer with an uneven surface on its lower side, coated with a polymer damping layer, which is either applied during manufacturing or installation, effectively reduces sound transmission by converting vertical vibrations into horizontal motion, enhancing both footfall and ambient sound deadening across a wide frequency range.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Object-affected harmful factors

If separate layers of light materials are laid under panels or panels are provided with footfall deadening on the lower side, then footfall and ambient sound deadening is improved, but device complexity and manufacturing cost increase

Engineering Contradiction:

Improvefootfall and ambient soundVSAvoidpanel structure

Core Design Contradiction:

Object-affected harmful factorsVSDevice complexity

Solution Approach 1:

The patent combines the bonding layer and damping layer into a single integrated component. The bonding layer is profiled to create an uneven surface that directly contacts the panel, while the damping layer is applied over this profiled surface. This merging eliminates the need for separate footfall deadening layers and reduces overall structural complexity while maintaining sound deadening effectiveness.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The bonding layer serves multiple functions: it bonds the panel to the substrate, provides an uneven surface for vibration conversion, and works in conjunction with the damping layer to provide both footfall and ambient sound deadening. This multi-functionality reduces the number of separate components needed.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Object-affected harmful factors

If panels are coated with footfall deadening or ambient sound deadening coatings, then sound deadening is improved, but ease of manufacture decreases due to additional processing steps

Engineering Contradiction:

Improvesound transmissionVSAvoidpanel production

Core Design Contradiction:

Object-affected harmful factorsVSEase of manufacture

Solution Approach 1:

The bonding layer is profiled with an uneven surface before the damping layer is applied. This preliminary action of creating the profiled surface allows the damping layer to be applied in a single step without requiring subsequent processing, simplifying manufacturing while ensuring effective sound deadening.

Inventive Principle:

Principle #10Preliminary action

3Object-affected harmful factors

If thick damping layers are used to achieve effective sound deadening, then sound reduction is improved, but panel thickness and material usage increase

Engineering Contradiction:

Improvesound spreading and loudnessVSAvoidpanel thickness

Core Design Contradiction:

Object-affected harmful factorsVSLength of stationary object

Solution Approach 1:

The damping layer is applied specifically over the profiled bonding layer where it is most needed for sound deadening. The profiled structure creates local variations in contact and vibration absorption, allowing effective sound reduction with thinner overall material usage compared to uniform thick layers.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The profiled bonding layer changes the contact parameters between the panel and substrate, creating an uneven surface that converts vertical vibrations to horizontal motion. This parameter change in the bonding interface allows the damping layer to be thinner while maintaining effective sound deadening performance.

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 solution achieves up to 40% reduction in sound spreading and loudness, allowing for a thin damping layer that saves material and maintains a low panel thickness, while being easy to apply and adaptable to various panel types, including those with decorative surfaces.

Implementation Method 1

converting the vertical deflection of the panel, for example by a step hitting the upper side of the panel, to a horizontal motion of the bonding layer

Methodology Applied

Scientific EffectVibration conversion: Vibration

Implementation Method 2

a damping layer composed of polymer... the spreading of the ambient sound and the loudness can be damped

Methodology Applied

Scientific EffectDamping: Damping

Data Source

PatentUS8795814B2Panel with footfall and ambient sound deadening, covering composed of panels, sound reducing coating, process for its production and apparatus for this purpose

Publication Date: 2014.08.05 SWISS KRONO TEC AG

AI summary

A panel has an upper side facing the room in the use position and a lower side facing the floor. The lower side is coated, at least in sections, with a bonding layer composed of polymer. The bonding layer has an uneven surface on the outer side facing away from the panel, and has been coated at least in sections with a damping layer composed of polymer. A covering composed of panels, a process and an apparatus for producing the panels are also described.