IMPACT AND/OR SOUND DEADENING HYDRONIC SUB-FLOORING PANEL WITH UNDERLAYMENT ASSEMBLIES AND RELATED SYSTEMS AND METHODS

Abstract

A sub-flooring panel with improved impact and/or sound deadening (ISD) properties that is adapted to adjoin other sub-flooring panels to form a sub-flooring panel assembly, includes a base body having an upper surface formed with a groove for receiving a heating/cooling element, such as hydronic piping. A sub-flooring system with significantly improved ISD properties includes the sub-flooring panel assembly and an underlayment assembly which comprises a plurality of generally rigid stabilizing panels and pistons, each piston being adjustable in height, to support at least sub-flooring panels, and any sound trapping panels.

Description

CROSS-REFERENCE TO RELATED APPLICATION(S)

This application is a continuation in part of U.S. patent application Ser. No. 14/300,183, filed Jun. 9, 2014, which claims the benefit of U.S. Provisional Patent Application No. 61/834,384 filed Jun. 12, 2013, the entire contents of both applications are incorporated herein by reference.

FIELD OF INVENTION

The present invention relates to sub-flooring systems, including underlayment assemblies, and related methods, including heating (and/or cooling) sub-flooring systems and methods applying hydronics and hydronic structures.

BACKGROUND OF INVENTION

An “ondol” is an underfloor heating system used in traditional Korean architecture. The system typically included a cooking fire or stove in a kitchen that was surrounded by one or more rooms of the house built on a raised masonry floor two or three feet higher than the kitchen. Extending through the raised masonry floor were horizontal smoke passages that led to a standing chimney providing a draft through the passages. Heat from the fire or stove would travel through the horizontal smoke passages to heat the rooms of the house. The horizontal smoke passages were usually covered by stone slabs, clay or concrete, which formed the heated floor of the rooms, and a water-impervious layer, such as oiled paper, which formed the finished flooring on the heated floor.

It is appreciated that an efficient ondol system required a delicate balance between two conflicting factors. On the one hand, for fuel to burn well in the fire or stove, the passages should provide good air flow from the fire to the chimney. On the other hand, for effective heating of the rooms, hot air should linger in the passages as long as possible to warm the stone slabs, clay or concrete forming the heated floor. To accomplish this, the passages were lengthened for multiple passes under each room, thus preventing the hot air from exiting through the chimney too quickly. When the correct balance was achieved, a room could be kept warm all night by the stone slabs, clay or concrete heated by a fire that lasted only a couple of hours.

Evolution of Korean architecture led to multi-story housing and improved ondol systems. However, flue gases from burning wood or coal caused many deaths from carbon monoxide poisoning. As a result, flue gas systems have given way to electric heating elements and/or piping circulating heated water (or “hydronics”).

In a “poured floor” or “wet floor” system, electric heating elements or hydronic piping extend through a “light” (more porous) concrete floor that is poured above a concrete slab. The wet floor system has many drawbacks, including the 15-20 day curing period for both layers of concrete, the upper layer of which cannot be poured until the lower layer has completely cured. The curing period can also be extended significantly if the concrete is poured during rainy or winter season. In cold climate, the concrete can even freeze.

After curing, the concrete can absorb water which can significantly increase its weight and evaporate during warmer weather causing the finishing flooring or laminate to buckle and warp. Moreover, in high-rise buildings and multi-story residential buildings, concrete can create poor acoustics as sound and impact waves can travel through concrete between floors and echo throughout the building. In that regard, while impact and/or sound may involve different physical events with different physical effects, impact and/or sound deadening are used interchangeably and collectively herein as “impact and/or sound deadening” or “ISD.”

Laying a sub-floor and piping in a “poured floor” or “wet floor” system is labor and time intensive. Different stages of construction and installation of a poured or wet floor system require time, scheduling and a team of professional workers with an array of different skills and experience. If any part of the sub-floor, piping or heating element in a “poured floor” or “wet floor” system is subsequently damaged, the concrete sub-floor of the entire room or area must be cracked and removed in order to access and replace the damaged piping or heating element. The concrete sub-floor must then be repoured over the replacement piping or heating element.

Accordingly, there is a need for a heating and/or cooling sub-flooring system which advantageously uses hydronics or hydronic principles for thermal conduction while minimizing or avoiding entirely the use of concrete. It is desirable that such sub-flooring system be easy to install, in terms of labor, time and the skills required of workers whether or not they are trained professionals. It is further desirable that such sub-flooring system, including underlayment assembly and/or sub-flooring panels, use environmentally-friendly components and that such sub-flooring system be adapted for use in multi-dwelling highrise buildings and multi-story residential buildings with significantly improved impact and/or sound deadening.

SUMMARY OF THE INVENTION

The present invention is directed to an ISD sub-flooring system, including a sub-flooring panel assembly and an underlayment assembly, that is environmentally-friendly and relatively inexpensive to manufacture and install in terms of material and labor. The sub-flooring system also provides significantly improved impact and/or sound deadening properties (collectively referred to herein as ISD properties).

A sub-flooring panel of the present invention is adapted to adjoin with other sub-flooring panels. The panel includes a base body having an upper surface formed with a groove for receiving a temperature control element, e.g., a hydronic heating and/or cooling piping adapted to pass fluid. The groove is lined with one or more thermally-conductive (TC) liners that come into contact with the piping after it is laid in the groove. The TC liners extend over surfaces of the base body for improving thermal transfer between the piping and the base body. A protective cap member covers the groove to protect the piping and provide a flat smooth surface generally continuous with the upper surface of the sub-flooring panel.

Each sub-flooring panel has side surfaces formed with tongue and groove connectors for releasably joining with adjacent sub-flooring panels to span an area. The sub-flooring panels are joined with the piping grooves aligned to form a predetermined groove pattern over the area so that a single continuous elongated piping can be placed in the grooves.

The underlayment assembly of the present invention includes layers of ISD material(s) and support structures, including stabilizing supports and at least one rigid board layer and at least one fiberboard layer. Depending on the layout of the sub-flooring panels, stabilizing supports are positioned at selected locations on a bottom slab structure, with the at least one rigid “balance” board and the at least one fiberboard positioned on the stabilizing supports. These layers may be affixed to each other by ISD adhesive and the like, and they may be affixed to the stabilizing supports by fasteners, such as screws or nails.

The stabilizing supports are advantageously portable, and adjustable in height for supporting the structures above it at any desired horizontal level, for example, to compensate for any tilting or unevenness of the bottom slab structure. Each stabilizing support has a tubular member containing a noncompressible, volume-filling particulate substance, and a piston inserted in the tubular member and resting on the surface of the particulate substance. The stabilizing supports further include ISD cushion pads and/or liners. The stabilizing supports also significantly increase the ISD properties of the underlayment assembly by providing a noncompressible layer of space that can both bear the weight load of the structures above while allowing the layer to be filled with a loose, volume-filling (“LVF”) substance with ISD properties, for example, natural fiber chips.

The present invention also includes methods of installing a sub-flooring system having a sub-flooring panel assembly and an underlayment assembly. The methods include forming a sub-flooring panel assembly by joining a plurality of sub-flooring panels with their piping grooves aligned, providing TC liners in the grooves and elsewhere on the panels, resting a piping on overlying TC liners along perforations positioned above the grooves and pressing on the piping with sufficient force to tear the perforations and drop into the grooves. Before the piping is laid in the grooves, an underlying TC liner may be placed in the groove or be wrapped on the piping so that the underlying TC liner accompanies the piping into the groove. With the piping installed in the grooves having direct and indirect contact with the overlapping TC liners, thermal transfer between the piping and the base body of the panel is increased.

The methods also include installing the underlayment assembly prior to installing the sub-flooring panel assembly. Installing the underlayment assembly includes installing and assembling stabilizing supports at selected locations on a slab structure relative to layouts of the sub-flooring panels, balance boards and/or fiberboards, for example, under their corner areas. Tubular members of the supports are affixed to their respective selected locations on the slab structure. The particulate substance is placed in the tubular members. The pistons are inserted into their respective tubular members and positioned on the particulate substance in the tubular members. The height of each piston is advantageously adjustable by methods including increasing or decreasing the amount of particulate substance contained in its respective tubular member, adding or removing ISD pads, and/or replacing the piston with a taller or shorter piston. The balance boards and/or fiberboards are placed on the stabilizing supports, followed by the assembly of sub-flooring panels.

The present invention further includes alternate embodiments of underlayment assemblies. In some embodiments, an underlayment assembly includes one or more generally rigid stabilizing panels, multiples of each are arranged in a side-by-side configuration to form a layer above a supporting surface, such as a slab. Each stabilizing panels has an upper portion, a lower portion and one or more pistons. The pistons are adapted to be supported in one or more first recesses formed in the upper portion, wherein the height of each piston is adjustable by the arrangement and/or amount of particulate substance contained in each first recess. The lower portion may have one or more second recesses adapted to form one or more insulation air pockets. One or more pistons may have a respective inner cavity, each adapted to form an insulation air pocket.

In more detailed embodiments, the first and second recesses of a respective stabilizing panel are generally in vertical alignment with each other. Moreover, each piston may have an inner cavity generally in vertical alignment with respective first and second recesses.

In more detailed embodiments, each stabilizing panel includes at least one tubular member configured to circumferentially line a respective first recess and to circumferentially contain particulate substance in the respective first recess.

In some embodiments, the underlayment assembly further includes one or more generally rigid sound trapping panels, each having at least one recess adapted to form at least one insulation air pocket. The one or more sound trapping panels may be arranged in a side-by-side configuration to fonts a layer of sound trapping panels, for example, between the layer of stabilizing panels and the sub-flooring panels. Each sound trapping panels is raised and supported by the one or more pistons above the layer of stabilizing panels. The underlayment assembly may include one or more layers of sound trapping panels, wherein the air pockets of the layers of sound trapping panels are vertically offset.

The present invention also includes a method of installing an underlayment assembly, comprising providing a support surface, providing a first amount of particulate substance on the support surface; positioning at least one stabilizing panel on the first amount of particulate substance, the at least one stabilizing panel having an upper portion, a lower portion and at least one piston, the upper portion having at least one first recess; providing a second amount of particulate substance in the at least one first recess; and positioning the at least one piston above the second amount of particulate substance.

The method may further include placing a tubular member in the at least one first recess before providing a second amount of particulate substance in the at least one first recess, and also providing at least one sound trapping panel on the at least one stabilizing panel.

BRIEF DESCRIPTION OF THE DRAWINGS

These and other features and advantages of the present invention will be better understood by reference to the following detailed description when considered in conjunction with the accompanying drawings wherein:

FIG. 1 is a partially-exploded perspective view of a sub-flooring panel, with a portion of piping and a protective cap member, of the present invention, in accordance with one embodiment.

FIG. 1A is a partially exploded perspective view of the sub-flooring panel of FIG. 1 prior to receiving the portion of piping.

FIG. 1B is a detailed view of the sub-flooring panel, including a tongue member, of Section B in FIG. 1.

FIG. 2 is another partially-exploded perspective of the sub-flooring panel of FIG. 1

FIG. 3 is an end cross-sectional view of the sub-flooring panel of FIG. 1, taken along line A-A.

FIG. 4 is an end cross-sectional view of a sub-flooring panel, with a portion of piping and a protective cap member of the present invention, in accordance with another embodiment.

FIG. 5A is a top plan view of a sub-flooring panel assembly of the present invention, in accordance with an embodiment, shown with an overall resulting groove pattern and a piping received therein.

FIG. 5B is a top plan view of a sub-flooring panel assembly of the present invention, in accordance with another embodiment, shown with an overall resulting groove pattern.

FIG. 6 is a side cross-sectional view of three adjoined sub-flooring panels forming a sub-flooring panel assembly of the present invention, in accordance with one embodiment.

FIG. 7 is a top plan view of a sub-flooring panel of the present invention, in accordance with one embodiment.

FIG. 8 is a top plan view of a sub-flooring panel of the present invention, in accordance with another embodiment.

FIG. 9 is a top plan view of a sub-flooring panel of the present invention, in accordance with another embodiment.

FIG. 10 is a top plan view of a sub-flooring panel of the present invention, in accordance with another embodiment.

FIG. 11 is a top plan view of a sub-flooring panel of the present invention, in accordance with another embodiment.

FIG. 12A is an end cross-sectional view of a sub-flooring system of the present invention, in accordance with an embodiment.

FIG. 12B is an end cross-sectional view of a sub-flooring system of the present invention, in accordance with another embodiment.

FIG. 12C is an end cross-sectional view of a sub-flooring system of the present invention, in accordance with another embodiment.

FIG. 12D is a top plan view of an underlayment assembly of the present invention, in accordance with an embodiment.

FIG. 13A is a side cross-sectional view of a periphery portion of an installed sub-flooring system of the present invention, in accordance with one embodiment.

FIG. 13B is a side cross-sectional view of an interior portion of an installed sub-flooring system of the present invention, in accordance with one embodiment.

FIG. 14 is an exploded perspective view of an underlayment stabilizing support of the present invention, in accordance with one embodiment.

FIG. 14A is a perspective view of a tubular member of the stabilizing support of FIG. 14, in accordance with another embodiment, with a portion broken away for clarity.

FIG. 14B is a perspective of a tubular member in accordance with yet another embodiment, with a portion broken away for clarity.

FIG. 15 is a perspective view of the stabilizing support of FIG. 14, as assembled.

FIG. 16 illustrated suitable cross-sectional shapes for a tubular member and a piston of the stabilizing support.

FIG. 17 is a side cross-sectional view of a periphery portion of an installed sub-flooring system of the present invention, in accordance with another embodiment.

FIG. 18 is a side cross-sectional view of an interior portion of an installed sub-flooring system of the present invention, in accordance with another embodiment.

FIG. 19 is an exploded perspective view of a portion of a stabilizing panel, including an upper portion, a lower portion and a piston of FIG. 18.

FIG. 20 is a perspective view of a sound trapping panel of the present invention, in accordance with one embodiment.

FIG. 21 is a schematic top plan view of an underlayment assembly of the present invention, including a sound trapping panel and above stabilizing panels, in accordance with an embodiment.

FIG. 22 is a side cross-sectional view of sound trapping panels stacked in a vertically offset configuration.

DETAILED DESCRIPTION OF THE INVENTION

ISD Sub-Flooring Panel

FIG. 1, FIG. 2 and FIG. 3 illustrate an embodiment of a ISD sub-flooring hydronic panel 10 adapted to provide temperature control, including radiant heat, into a room or an area lined with a plurality of sub-flooring hydronic panels on which finishing flooring or laminate may be laid. The sub-flooring panel 10 is shown with portions broken and not necessarily to scale to facilitate a description thereof, as follows. The panel 10 has a base body 11 which is generally rectangular and has dimensions extending in the x, y and z directions. The body 11 has a plurality of surfaces, including an upper surface 12 and a lower surface 14, each in an x/y plane, a front surface 16, and a back surface 18 (not shown), each in a y/z plane, and two side surfaces 20 and 22, each in an x/z plane. The body 11 may be constructed of any suitable material that is thermally-conductive and load-bearing, for example, oriented strand board (OSB), plywood, medium density fiberboard (MDF), particleboard, pre-fabricated agricultural residues, wood, pre-fabricated “light” concrete, plastics or any combinations thereof. As understood by one of ordinary skill in the art, OSB is an engineered wood formed by layering strands (flakes) of wood in specific orientations. OSB has high mechanical properties which make it suitable for load-bearing applications in construction.

On the upper surface 12 of the body 11, an elongated recessed formation or piping groove 24 is provided. In the illustrated embodiment of FIG. 1, FIG. 2 and FIG. 3, the groove 24 has multiple and at least two different depths in the z-axis so as to allow a variety of components, including heating and/or cooling components to be situated within the groove 24 generally below the plane of the upper surface 12. Such components include, for example, a heating element such as a flexible electric heating cord or a flexible hydronic piping 26 for passing heated fluid through a lumen 28, and a protective filler or cap member 36. These components are laid in the aligned grooves 24 of a plurality of adjoined flooring panels 10 spanning the room or an area. One or more thermally-conductive (TC) sheet liners are placed in direct contact with the piping 26 to improve the thermal transfer throughout the panel 10. In the illustrated embodiment, a first underlying TC liner 30 lines the groove 24, and first and second overlying TC liners 32 line a respective side of the groove and the upper surface 12. Each of the three TC liners is in physical contact with a portion of the piping 26, and each of the overlying liner 32 is in contact with the underlying liner 30.

With reference to FIG. 2, the piping groove 24 has a first greater depth D1 with a lesser width W1, and a second lesser depth D2 with greater width W2 that spans on opposite sides of the groove 24. With the width W1 being less than the width W2, a step 40 is formed with a run 41 and a rise 42 on each side of the groove 24. The portion of the groove 24 below the run 41 forms the trough 25, whose cross-sectional shape and size correspond to those of the piping 26. In the illustrated embodiment, the cross-sectional shape of the piping 26 is circular, so the trough 25 has a bottom portion 25B with a semi-circular cross-sectional shape that conforms to the bottom of the piping 26. Such correspondence and conformity improve surface contact between the piping 26 and any liner lining the trough 25. The trough 25 has an unrestrictive (e.g., rectangular) cross-sectional top portion 25R so that the piping 26 can be easily lowered or dropped into the trough 25. In the illustrated embodiment, the depth D1 is greater than the outer diameter of the piping 26 and ranges between about 120% and 130%, and preferably about 125%, of the outer diameter of the piping 26. Above the trough 25, at the lesser depth D2 and with the greater width W2, the groove 24 also has a unrestrictive (e.g., rectangular) cross-sectional portion 24R, between the upper surface 12 and the trough 25.

As shown in FIG. 1 and FIG. 2, lining the trough 25 is the underlying TC liner 30 which conforms to the trough 25 so that it has a semi-circular cross-sectional bottom portion 30B that advantageously conforms to a bottom portion of the piping 26. The TC liner 30 has a sufficient width such that it provides flat side portions 30T that extend upwardly along each side of the top portion 25T of the trough 25. The TC liner 30 may be affixed in the trough 25 by an ISD adhesive or glue, a layer or coating of which may be applied on the surface of the trough 25.

As also shown in FIG. 1 and FIG. 2, each of the two overlying TC liners 32 (one on each side of the TC liner 30) has a bottom portion 32B, a run-portion 32RUN, a rise-portion 32RISE and a top portion 32T, delineated by a first elongated bend 33A between the portions 32RISE and 32T, and a second elongated bend 33B between the portions 32RUN and 32B. Each bend may be, for example, a right angle bend which conforms to a respective corner 38 on each side of the groove 24 above and below the run 41 and rise 42. Each bottom portion 32B of the overlying TC liner 32 advantageously contacts (by overlying or Underlying) a respective top flat side portion 30T of the underlying TC liner 30 for direct heat transfer from the underlying TC liner 30 to each overlying TC sheet liner 32. Each run-portion 32RUN lies on a respective run 41 and each rise-portion 32RISE lies against a respective rise 42. Each top portion 32T lies on a respective portion of the upper surface 12 on opposite sides of the groove 24. The top portions 32T may cover only portions of the upper surface 12 or in its entirety, depending on the desire or need. ISD adhesive 44 or the like (FIG. 1) can be applied to the undersides of the TC liners 32 before the liners are applied and to the panel 10, or it can be applied to the run 41, the rise 42 and portions of the upper surface 12.

As illustrated in FIG. 1, each corner 38 in the piping groove 24 may be optionally beveled to minimize damage to overlying TC liners 32. Without beveling, the corners may pose the risk of tearing the overlying liners during panel installation and use. The folds 33A and/or 33B of overlying TC liners 32 may be rounded in conformity with the beveled corners 38.

To fill in the top cross-sectional portion 24R of the groove 24 and protect the piping 26, the protective filler or cap member 36 with a generally conforming configuration to the top groove portion 24R is placed in the groove 24 with its side portions 46 resting on the rises 42 on each side of the groove 24. In the illustrated embodiment, the top groove portion 24R has a generally rectangular cross sectional configuration, so the cap member 36 also has a generally rectangular cross-sectional configuration. Moreover, the thickness of the cap member 36 is no greater and generally equal to the depth D2 so that a top surface 48 of the cap member is generally even and co-planar with the top surface 12 of the body 11. As shown in FIG. 3 and FIG. 4, the cap member 36 has a width that is less than the width W1 of the groove 24, which provides small lateral space gaps 57 between it and the rises 42 on each side of the groove 24. The lateral gaps 57 accommodate any expansion and shrinkage of the cap member 36 and the body 11 due to temperature and humidity fluctuations so the cap member 36 can sit evenly on the runs 41 and not protrude above the upper surface 12 of the sub-flooring panel 10. Bottom corners 36C of the cap member 36 may be beveled to minimize damage to the overlying TC liners lining the groove 24. Adhesive 44 (FIG. 1) may be applied to affix cap member 36 to the runs 41, and/or a cushioning pad (FIG. 12A) may be applied between the cap member and the runs 42 to minimize the cap member rattling. It is understood that a protective cap member 36 may be placed in and occupy every groove 24 of an assembly of adjoined sub-flooring panels whether or not the groove 24 includes a piping 26.

The piping 26 may be constructed of any suitable material, for example, cross-linked polyethylene (PEX or PEX-AL-PEX), that is fluid-tight and can tolerate exposure to high or low temperatures of fluid passing therethrough and be thermally conductive. The TC sheet liners 30 and 32 may be constructed of any suitable material, for example, aluminum, copper, or any combinations thereof. It is understood that a single TC sheet liner may be used in place of the TC liners 30 and 32; however, installation of the single TC sheet liner into the groove 24 may require additional care and labor compared to installation of the TC sheet liners 30 and 32.

The cap member 36 may be constructed of any suitable material, for example, oriented strand board (OSB) medium-density fiberboard (MDF), particle board, plywood, pre-fabricated agricultural residues, plastics, wood, aluminum, or any combinations thereof. MDF is an engineered wood product formed by breaking down hardwood or softwood fibers into fiberboards, often in a defibrator, combining it with wax and a resin binder, and forming panels by applying high temperature and pressure. MDF is generally denser than plywood. It is made up of separated fibers, but can be used as a building material similar in application to plywood. It is typically stronger and much denser than particle board.

It is noted that the sub-flooring panel of FIG. 3 is shown with the piping 26 and the cap member 36 in place in the piping groove 24. That is, the piping and the cap member are typically placed in the piping groove 24 after the sub-flooring panel 10 has been installed in a room or an area and joined with other sub-flooring panels to form a sub-flooring panel assembly. In contrast, the sub-flooring panel of FIG. 1A illustrates a sub-flooring panel prior to receiving the piping 26 and the cap member 36. As shown, the overlying TC sheet liners 32 affixed to the upper surface 12 and straddling the piping groove 24 can be initially a single intact sheet with a series of perforations 61 generally centered over the groove 24. When the piping 26 is being laid in the piping groove 24, the piping 26 is pushed into the groove 24 which advantageously tears or otherwise separates the TC liner 32 along the perforation 61 into at least two pieces that line opposing sides of the groove 24. In contrast, the underlying TC liner 30 may be placed at the bottom of the trough 25 before the piping 26 is laid therein, or alternatively, the liner 30 may be wrapped on the bottom portion of the piping 26 before the piping is pushed into the groove 24 such that the piping and the underlying TC liner 30 are simultaneously laid in the trough 25.

As understood by one of ordinary skill in the art, the sub-flooring panel 10 may assume in a variety of shapes and sizes. The illustrated embodiment is of a panel 10 with a rectangular shape with a length L, a width W and a thickness T. In one embodiment, the length L may range between about 600 mm and 1,200 mm. The width W may range between about 300 mm and 600 mm. The thickness T may range between about 20 mm and 30 mm. In a more detailed embodiment, the panel 10 has a length L of about 1,200 mm, a width W of about 600 mm, and a thickness T ranging between about 20 mm and 30 mm. The measurements, especially, the width W, should be made with care, or the grooves 24 of adjoining sub-flooring panels will not be aligned. As such, the width W is preferably measured from one outer edge of the upper surface 12 to the opposing outer edge.

As for the piping groove 24, the depth D1 is about 20.0 mm, the depth D2 is about 4.0 mm, the width W1 is about 16.5 mm, and the width W2 is about 24.5 mm. The run 41 has a width of about 4.0 mm and the rise 42 has a width of about 4.0 mm. The piping 26 may have an outer diameter ranging between about 14.0 mm and 20.0 mm, and preferably about 16.0 mm. Each of the thermally-conductive sheet liner 30 and 32 has a thickness ranging between about 0.1 mm and 0.3 mm, and preferably a thickness of about 0.2 mm. The cap member 36 has a width less than the width W2, for example, of about 22.5 mm, so as to allow for expansion and shrinkage of materials due to temperature and humidity.

FIG. 4 illustrates another embodiment of the sub-flooring panel of the present invention, wherein the piping groove 24 includes its upper rectangular portion 24R and the bottom portion 25B of the trough 25 without the trough upper portion 25R, such that an upper portion of the piping 26U is above the trough bottom portion 25B, with the upper portion of the piping being above the runs 41. Moreover, a lower surface of the cap member 36 facing the piping 26 has a recessed formation 54 in which the upper portion of the piping 26 is received. The recessed formation 54 has a depth DD that is a percentage of the diameter of the piping 26. In the disclosed embodiment, the percentage ranges between about 20%-50%, and preferably between about 30% to 40%. The recessed formation 54 enables the cap member 36 to encase and conform to the upper portion of the piping 26 and reduce air gaps between the piping 26 and the cap member 36 thereby providing better conformity and contact between the lower surface of the cap member 36 and the piping 26 for greater thermal conduction from the piping 26 to the cap member 36, and any TC liner in between. In that regard, an additional or third TC sheet liner 35 is inserted between the piping 26 and the cap member 36, whereupon the liner 35 adopts a configuration that conforms to the convexity of the piping 26 and the concavity of the recessed formation 54. For thermal conduction throughout the sub-flooring panel, the TC liner 35 has a sufficient width dimension such that it spans across the piping 26 with excess opposing side portions to overlap at least a portion of the TC liners 32 lining the runs 41 on each side of the groove 24.

For any embodiments of the present invention, the sub-flooring panel 10 may further include a layer or coating of waterproofing or water-resistant sealant that is applied to the groove 24, including the trough 25, the rises 41 and the runs 42. The sealant may be also be applied to any other surfaces of the panel, including the upper, front, back and side surfaces 12, 14, 16, 18, 20 and 22, as needed or desired.

ISD Sub-Flooring Panel Assembly

In accordance with a feature of the present invention, a plurality of sub-flooring panels 10 may be joined along the front, back and side surfaces 12, 14, 16 and 18 to form an assembly 100 of sub-flooring panels, as shown in FIG. 5A and FIG. 5B. In that regard, each of these surfaces may be provided with a feature that releasably joins adjacent sub-flooring panels. With reference to FIG. 1 and FIG. 2, the sub-flooring panel provides “tongue-and-groove” connectors by having at least one side surface formed with a recessed groove connector 52 and at least another side surface formed with a protruding tongue 50, both of which may be coated with a lubricant.

As shown in FIG. 1 and FIG. 1B, the groove connector 52 extends along the back and side surfaces 16 and 22, and the tongue connector 50 extends along front surface 16 and the side surface 20, between upper and lower edges 51. Along one or both of the upper and lower edges 51, a mini-step “stop” formation 53 also extends along the front and side surfaces 16 and 20. The rise and run of the stop formation 53 is a fraction of the thickness of the tongue 42. In one embodiment, the fraction is between about 30% to 40%, preferably about 35%. The stop formation 53 provides a space gap 55 between the front, back and side surfaces 14, 16, 18, 20 and 22 of adjacent sub-flooring panels 10 to accommodate shrinkage and expansion of the sub-flooring panel due to temperature and humidity fluctuations which may otherwise cause the panels to abut and buckle against each other along their front, back and side surfaces and form an uneven floor surface.

FIG. 6 shows the tongue and groove connectors 50 and 52 in accordance with another embodiment, wherein three sub-flooring panels 10A, 10B and 10C are adjoined. The tongue connector 50A of panel 10A is engaged with and received in the groove connector 52B of adjacent panel 10B. Likewise, the tongue connector 50B of the panel 10B is engaged with and received in the groove connector 52C of adjacent panel 10C. As mentioned, the stop formations 53A and 53B of the tongue connectors 50A and 50B, respectively, provide the lateral gap 55 between the panels 10A and 10B and between the panels 10B and 10C. Notably, distal ends of tongue connectors 50A and 50B are beveled on their upper and lower edges 56A and 56B to facilitate insertion of the tongues connectors 50A and 50B, respectively, into the grooves connectors 52A and 52B, respectively. Likewise, the upper and lower outer edges 58A and 58B of the groove connectors 52A and 52B, respectively, are beveled. In that regard, the rise R of the stop formations 53 should be sufficiently large so that the stop formations 53 remain outside of the beveled edges 58A and 58B and the groove connectors 52A and 52B, respectively, so as to maintain the gaps 55 between the adjacent panels. Outer surfaces of the tongue and groove connectors 50A and 50B and 52A and 52B may be covered with a TC liner 37 that spans over the front, back and/or side surfaces 16, 18, 20 and/or 22.

For the sub-flooring panel assembly, the present invention includes sub-flooring panels of different configurations, each with two or more piping grooves 24 tracing predetermined patterns, for receiving different segment portions of an elongated, flexible piping 26. As shown in FIG. 7, sub-flooring panel 10A has a longitudinal rectangular configuration with two linear piping grooves 24 parallel with the longitudinal axis of the panel. As shown in FIG. 8, sub-flooring panel 10B has a generally square configuration, also with two linear piping grooves 24 parallel to a side of the panel. As shown in FIG. 9, sub-flooring panel 10C has a transverse rectangular configuration with four linear parallel piping grooves 24, all orthogonal to the longitudinal axis of the panel. As shown in FIG. 10, a sub-flooring panel 10D has a rectangular configuration with three piping grooves 24, two of which are nonlinear, and one of which is linear and parallel to the longitudinal axis of the panel. The two nonlinear grooves are each curved, for example, U-shaped, such that each leg 24U of the U-shaped grooves terminates at the same longitudinal edge of the panel. As shown in FIG. 11, a sub-flooring panel 10E has a rectangular configuration with three nonlinear piping grooves 24, one of which is curved as a U-shape, and two of which are curved as opposite halves of a U-shape. Both legs 24U of the U-shaped groove terminate at the same longitudinal edge, along with one leg each 24A of the half-U-shape groove, whereas the other legs 24B of the half-U-shape grooves terminates at opposite transverse edges.

Each of the foregoing sub-flooring panels has at least one piping groove 24 that can be covered by a respective protective cap member 36 (or portion thereof). The cap member 36 therefore has generally the same predetermined pattern (e.g., linear, curve, U-shape, etc.) as its piping groove 24.

In the embodiment of FIG. 5A, the sub-flooring panel assembly 100A comprises offset columns of the sub-flooring panels 10A and 10B that are bounded along two peripheries by the sub-flooring panels 10D (along the upper periphery) and sub-flooring panels 10E (along the lower periphery). In the alternate embodiment of FIG. 5B, a sub-flooring panel assembly 100B may comprises rows of the panels 10A, alternating with rows of the panels 10C, that are similarly bounded along two peripheries by the sub-flooring panels 10A and 10B.

By combining selected sub-flooring panels 10A-10E and any other sub-flooring panels, a variety of sub-flooring panel assemblies can be formed, each with a continuous groove G adapted to receive an elongated, flexible piping 26. It is understood that inlet/outlet sub-flooring panel 10I/O for the ingress/egress of a piping into a room or area can be “customized” by using a selected portion of any of the foregoing sub-floor panels 10A, 10B, 10C, 10D or 10E. Moreover, “customizing” a sub-flooring panel with additional inlet/outlet grooves may be performed by workers as needed or desired during installation. Thus, for a room or area of any size or shape, the temperature thereof can be affected or controlled by a sub-flooring panel system 100 of the present invention adapted to receive one or more piping(s) 26 that are laid in the grooves 24 of the sub-flooring panels 10. In both FIG. 5A and FIG. 5B, the overall resulting pattern traced by the connected grooves of the sub-flooring panel assembly has a serpentine portion GS and a linear portion GL, where the inlet and outlet grooves 24I and 24O are formed on one corner panel 10I/O, which can be formed by using, for example, about a quarter portion of the side (right of FIG. 10) of the panel 10D.

Manufacture of ISD Sub-Flooring Panel

With reference to FIG. 1 and FIG. 2, the sub-flooring panel body 11 is formed with an appropriate shape and size having a desired length, width and thickness. The panel 10 with the piping groove 24 (with depths D1, D2 and widths W1 and W2), the tongue and groove connectors 50 and 52 are formed, e.g., by milling, drilling, CNC routing, press-molding, etc. The coating of ISD adhesive 44 or the like may be applied to the TC liners 32 before their affixation to the panel body 11, or it may be applied on portions of the upper surface 12 and/or the rises 42 and runs 41 of the body 11. The overlying liner 32 with perforation(s) 61 is positioned and fixed (e.g., laminated) on the upper surface 12 such that the TC liner 32 straddles the groove 24 and the perforations are generally longitudinally aligned with the groove 24. In one embodiment, the TC liner 32 remains intact as a single sheet through installation of the sub-flooring panel with other adjoined sub-flooring panels to form a sub-flooring assembly that spans an area, until the piping 26 is installed in the grooves 24 of the adjoined sub-flooring panels. Where it is desired that the TC liner(s) 30 and/or 32 line the groove 24 prior to installation of the piping 26, the TC liners may be stamped into the groove 24 manually or by machine.

ISD Underlayment Assemblies

As shown in FIGS. 12A-12C, the present invention also includes an underlayment assembly 200 as part of a flooring system 300 that includes the sub-flooring panel assembly 100 and the underlayment assembly 200 installed between a slab 63 and a top finishing flooring or laminate 90. The underlayment assembly 200 includes one or more underlayment layers which are positioned between the sub-flooring panel assembly 100 and a slab 63, e.g., a concrete slab. The underlayment layers serve various functions, including impact deadening, impact sound deadening and/or sound deadening (collectively “ISD”). A suitable underlayment layer includes a layer of fiberboard 62, including natural fiberboard, as shown in FIG. 12A. The layer of fiberboard 62 may be used in place of other underlayment layer 60 (FIG. 12B) or in addition to the underlayment layer 60 (FIG. 12C). The underlayment layer 60 may include a layer of loose natural wood chips, fiber chips, or any combinations thereof.

FIG. 12D illustrates one embodiment of an underlayment fiberboard layer 62 including a plurality of ISD fiberboards 62A-62I arranged side-by-side to span the room or area. Each fiberboard may be about 0.5 inches thick and its upper and lower surfaces may have ISD 77 pads or laminates affixed thereto with ISD adhesive 242 or the like. Side surfaces may be coated with a water-proofing or water-resistant sealant.

In accordance with another embodiment of a sub-flooring system 300, the underlayment assembly 200 has a plurality of base stabilizing supports 210 and one or more underlayment layers. As shown in FIG. 13A, a sub-flooring system 300 includes the sub-flooring panel assembly 100 and the underlayment assembly 200 that are installed between a slab 63 and a top finishing flooring or laminate 90. The underlayment assembly 200 is situated between the sub-flooring panel assembly 100 and the slab 63. The slab 63 has a horizontal portion 63H and at least one vertical side portion 63V. The horizontal portion 63H provides a planar surface 63P on which the underlayment assembly 200 is assembled and supported. The vertical side portions 63V contain and support the assembly 200 on its sides.

The supports 210 are conveniently portable, repositionable and advantageously adjustable in height to serve multiple purposes and functions, including (1) leveling and stabilizing the sub-flooring panel assembly 100, especially where the slab 63 is not horizontally level, and (2) height-setting of the sub-flooring panel 100 (and hence of the finishing flooring or laminate 90). The supports also significantly increase the ISD properties of the underlayment assembly 200 by providing a stable and noncompressible layer that can both bear the weight load of the structures above while allowing the layer to be filled with a loose, volume-filling (“LVF”) substance 228 with ISD properties, for example, natural fiber chips, such as wood chips and/or annually renewal fiber chips such as kenaf chips, cotton, peanut shells, rice husks, coconut husks and the like, and synthetic fibers such as fiberglass and the like, or any combinations of any or all of the foregoing. By allowing the LVF substance 228 to stay loose and fluffy, their ISD properties are maximized.

As shown in the embodiment of FIG. 14 and FIG. 15, a stabilizing support 210 has a hollow tubular (or annular) member 212 and a piston 214. The tubular member 212 is positioned on the slab 63 with its upper and lower openings 215 and 217 generally vertically aligned. The tubular member 212 may sit on an oversized ISD pad 219 that is affixed to the planar surface 63H of the slab 63 by ISD adhesive or the like (not shown). The tubular member 212 has a predefined cross-sectional pattern X and a height H. An interior volume V spans between the lower and upper openings 215 and 217.

An ISD inner liner 221 is provided with a surrounding side portion 221S and a base portion 221B, where the side portion 221S lines an inner side surface 222 of the tubular member 212 and the base portion 221B seals the lower opening 217 of the tubular member 212. The ISD liner 221 is affixed to the inner side surface 222 of the tubular member 212 and an upper surface of the ISD pad 219 by ISD adhesive 242 or the like. The upper opening 215 allows communication between outside the tubular member 212 and the interior volume V, which is partially filled or occupied by a noncompressible, volume-filling particulate (“VFP”) substance 218. As shown in FIG. 15, at least a lower portion of the piston 214 is inserted into the interior volume V through the upper opening 215 and the piston rests on the VFP substance 218 such that an upper surface 214U (see FIG. 13A) of the piston 14 is higher than an upper rim 212R of the tubular member 12. The lower end of the tubular member 212 may be sealed by the liner 221B, or it may be formed with a solid bottom portion 223 (see FIG. 14B). Alternatively, the bottom portion may have a grid or vane formations 220 (FIG. 14A) to minimize shifting of the VFP substance 218 in the tubular member 212. Where the tubular member 212 has a grid or vane formations 220, the depth h′ of the VFP substance 218 should be greater than the height of the grid or vane formations 220 so that the surface level of the VFP substance 218 is above the formations 220.

As their names suggest, the ISD pad 219 and ISD liner 221 are made of any suitable material with ISD properties, for example, rubber and/or expanded polypropylene (EPP) which is an exceptionally eco-friendly, flexible and versatile plastic foam designed for lightweight, energy management and cushioning applications. The tubular member 212 is made of any suitable material that is rigid and lightweight but can bear weight and compression loads, for example, PVC, other plastics, metal, concrete, or any combinations thereof. It is understood that the cross sectional pattern X of the tubular member is not limited to a circle, but may in fact be a variety of shapes, for example, the circular and polygonal shapes shown in FIG. 16.

The volume-filling particulate (“VFP”) substance 218 is pourable, spreadable and noncompressible. For example, the VFP substance 218 may be sand with sand particles having a diameter ranging from about 0.0625 mm (or 1/16 mm) to 2 mm. For example, the VFP substance may be silt with silt particles having a diameter ranging from about 0.0625 mm down to 0.004 mm. It is understood that the VFP substance may include sand, silt, or any combinations thereof. It is also understood that sand, silt, or any combinations thereof, may be combined with finer gravel particles having a diameter of about 6.3 mm or less to form other suitable VFP substances.

In the illustrated embodiment of FIG. 14 and FIG. 15, the piston 214 also has a cross-section pattern X, although it is understood that the piston 214 may have any cross-section pattern (see, e.g., FIG. 16) that allows the piston to fit within the tubular member 212. In that regard, the girth/diameter of the piston 214 is lesser than the effective inner circumference/diameter of the tubular member 212 (with or without the ISD liner 221), so that it can fit within the tubular member 212.

In the illustrated embodiment, the piston 214 includes a generally solid body 214B and it may include an upper ISD piston pad 230 and/or a lower ISD piston pad 232. The piston body 214B is constructed of any suitable material that is generally noncompressible with ISD properties and can bear significant weight and pressure loads, for example, oriented strand board (OSB), medium density fiberboard (MDF), particle board (PB), wood, plastic, concrete, or any combinations thereof. The upper and lower ISD pads 230 and 232 are affixed to upper and lower surfaces of the piston body 214B by ISD adhesive 242 or the like. As their names suggest, the upper and lower ISD pads 230 and 232 are also constructed of a material with ISD properties. The upper and lower pads have a girth/width slightly greater than that of the piston body so that a peripheral lip 234 is formed around the piston body 214B which prevents direct lateral contact between the piston body and the tubular member 212, as the present invention recognizes that direct contact between “nonISD” components may undesirably amplify impact and/or sound waves.

In the illustrated embodiment, the effective height h of the piston 214 (the piston body 214B with or without the upper and/or lower ISD pads 230 and 232) is also lesser than the height H of the tubular member 212, although it is understood that the height h need not be so lesser, provided the combined height of the piston body h and the height (or depth) h′ of the VFP substance 218 is sufficient so that the upper surface of the piston body 214U supported on the VFP substance 218 is higher than the upper rim 212U of the tubular member 212 (see FIG. 13A and FIG. 13B). This combined height ensures that the structure(s) on the supports 210 are not resting on the tubular member 212 but on the piston 214 to bear entire weight load. In an embodiment, the height H of the tubular member 212 and the height h of the piston 214 each ranges between about 0.5 inch and 3.0 inches, preferably between about 0.75 inches and 3.0 inches, the diameter/girth of the tubular member 212 ranges between about 6 inches and 16 inches, preferably between about 6 inches and 14 inches, more preferably about 12 inches, and the diameter/girth of the piston ranges between about 5.5 inches and 15.5 inches, preferably between about 5.5 inches and 13.5 inches, more preferably about 11.5 inches.

It is understood that one or more of the foregoing ISD pads and/or ISD liner may not be used, or that additional ISD pads or ISD liners may be used, as needed or appropriate, depending on a number of factors, including the structure of the slab 63, and the quantity and nature of underlayment layers, and/or the finishing floor 90.

Where the interior volume of the tubular member 212 (with or without the inner liner 221) is V, the portion occupied by the VFP substance 218 ranges between about 20% to 80% of V, preferably between about 30% to 70%, and more preferably about 50%. In addition to, or in lieu of the foregoing volume ratios, where the height of the tubular member 212 is H, the height h of the piston 214 ranges between about 50% to 100% of H, preferably between about 60%-80% of H, and more preferably about 75% of H. These ratios ensure that the piston 214 remains in the tubular member 212 and can properly support the structures above the supports 210. It is understood that these ratios can vary depending on the how horizontally level the slab 63 is. For example, where the slab 63 (whose left portion is shown in FIG. 13A and whose right portion is shown in FIG. 13B) is tilted with the right portion being lower than the left portion, the depth h′ of the VFP substance 218 is greater in the support 210B of FIG. 13B than in the support 210A so as to offset the tilt so that any board or component resting on both supports 210A and 210B is horizontally level and balanced. It is understood that the amount of VFP substance 18 in either supports 210A or 210B can be adjusted as desired or needed to correct any tilt in the slab, or, for that matter, to introduce a tilt where the slab is horizontally level. It is also understood that the relative height difference or adjustment between the supports 210A and 210B may be accomplished through adding or removing ISD pads and/or liners, changing by adding or reducing volume of the VFP, using taller or shorter cylinder and/or using taller or shorter pistons with different heights. Any combination of these methods may also be used.

The piston 214 is configured with at least one longitudinal channel 236 extending through at least the upper ISD pad 230 and the piston body 214B. In the illustrated embodiment, the channel 236 extends also through the lower ISD pad 232. The channel serves multiple purposes and function, including use as a handhold which facilitates the insertion, placement and removal of the piston 214 from the tubular member 212. The channel 236 also advantageously allows impact and sound waves from the sub-flooring panel 10 and the finished flooring 90 above to pass through the piston 214 and be trapped and absorbed by the VFP substance 218. To that end, the piston 214 may have more than one longitudinal channel 236.

A plurality of the supports 10 are placed on the slab in selected positions relative to the sub-flooring panel assembly above it, as illustrated in FIG. 5A and FIG. 5B. Where a plurality of sub-flooring panels 10 are arranged to provide a sub-flooring panel assembly, each sub-flooring panel is supported from below by at least one support 210. In the illustrated embodiment of FIG. 5A, each sub-flooring panel 10A, 10B, 10D and 10E is supported by balance board 238, and/or fiberboard 240 and at least four supports 210. Depending on the configuration of the sub-flooring panel, a given sub-flooring panel may be supported by balance board 238, and/or fiberboard 240 and/or four, five, six or seven supports. For example, the generally square sub-flooring panel 10B is supported by at least four supports 210B, with each under and near a respective corner of the sub-flooring panel 10B. A fifth support 210B′ may be placed under a noncorner edge region under or near corners of adjacent sub-flooring panels. Each of rectangular sub-flooring panels 10A, 10D and 10E is supported by at least four supports. For example, an interior rectangular panel 10Ai is supported by four supports 210A, one under each corner, and at least fifth and sixth supports are placed below those panels' noncorner edge regions, under or near corners of adjacent sub-flooring panels. For peripheral panels 10Ap, a support 210B is under each corner, at least a fifth support 210A′ is placed under a noncorner edge and at least a sixth support 21 OA″ is placed under or near corners of adjacent panels. For peripheral rectangular sub-flooring panels 10D and 10E along a periphery of the sub-flooring panel assembly, a support 210D or 210E is under each corner, at least fifth supports 210D′ and 210E′ are placed under a noncorner edge, and at least sixth and seventh supports 210D″ and 210E″ are placed under or near corners of adjacent sub-flooring panels. Accordingly, in the illustrated embodiment of FIG. 5A, any given support 210 may partially support and be under one sub-flooring panel 10 (see support 210X), two adjoined corners of two adjacent sub-flooring panels (see support 210Y), or two adjoined corners of two adjacent sub-flooring panels along with an adjoined length edge of a third adjacent sub-flooring panel (see support 210Z). Thus, any given support 210 partially supports up to three sub-flooring panels 10 and any sub-flooring panel 10 is supported by no less than four supports 210. In the illustrated embodiment of FIG. 5B, any given support 210 may partially support and be under one sub-flooring panel (see support 210X), two adjoined corners of two adjacent sub-flooring panels (see support 210Y), two adjoined corners of two adjacent sub-flooring panels along with an adjoined length edge of a third adjacent sub-flooring panel (see support 210Z), or four adjoined corners of four adjacent sub-flooring panels (see support 210W).

In the illustrated embodiment of FIG. 13A, the layers of the underlayment assembly 200 include at least a bottom layer of loose volume filler (“LVF”) substance 228 generally coextensive with the supports 210, a generally rigid board 238 that is balanced on and directly supported from below by the supports 210, and a fiberboard 240H above the generally rigid “balance” board 238. The underlayment layers may also include a plurality of vertical side fiberboards 240V that line the vertical side portions of the slab 63. The LVF substance 228 is generally vertically and horizontally coextensive with the supports 210 in that the LVF substance occupies generally the same layer L1 of the underlayment assembly 200 occupied by the supports 210, filling in the space horizontally around the between the supports 210 and vertically between the slab 63 and the balance board 238. The balance board 238 is made of any suitable noncompressible material that can bear the weight and pressure load from the structures above it, including, for example, oriented strand board (OSB), medium density fiberboard (MDF), particle board (PB), wood, plastic, concrete, or any combinations thereof. The horizontal and vertical fiberboards 240H and 240V are made of any suitable material, including, for example, natural fiberboard, of new and/or recovered fibers, preferably organically produced. Between the sub-flooring panel assembly 10 and the balance boards 238, each fiberboard 240H has an ISD pad 277 on its upper and lower surface which may be applied as a laminate with the use of a coating or layer of ISD adhesive 242 or the like. Another coating or layer of ISD adhesive 242 or the like affixes the upper ISD pads 277 and the sub-flooring panel assembly 100, and another coating of layer of ISD adhesive 242 or the like affixes the lower ISD pads 277 and the balance boards 238. As mentioned above, the present invention recognizes that ISD properties are improved where there is minimal direct contact between “nonISD” materials that have little or no ISD properties. In the illustrated embodiment, ISD materials separate the finishing flooring 90 and the slab 63, including separation of the supports 210 and the slab 63 by the ISD base pad 219, and separation of the supports 210 and the balance board 238 by the ISD upper pad 230. A coating of water-proof sealant may be applied to the outer surfaces of the balance board 238 and/or the fiberboards 240H and 240V as needed or desired.

In another embodiment as illustrated in FIG. 17, the underlayment layers of the underlayment assembly 200 include a “loose” cement or mortar layer 246 between the finishing flooring 90 and the sub-flooring panel assembly 100. As shown, the groove 24 is shallower with only the bottom portion 25B of the trough 25 receiving the piping 26, wherein an upper portion of the piping extends above the upper surface 12 of the sub-flooring panel assembly 100. Accordingly, as mortar is poured onto the sub-flooring panel assembly 100, the mortar layer 246 is formed with a recess on its lower surface which encases the piping. It is understood that TC liners may be provided over and/or under the piping 26 and on the upper surface 12 of the sub-flooring panels as needed or desired prior to the mortar being poured.

Installation and Assembly

For a room or an area to be covered by the sub-flooring panel assembly, a slab 63 is provided, on which one or more layers of ISD underlayment are installed. In the embodiments of FIG. 12A, FIG. 12B, FIG. 12C and FIG. 12D, a fiberboard 62 and/or an underlayment layer 60 may be placed on the slab 63, followed by the installation of a plurality of sub-flooring panels 10 joined together to form a sub-flooring panel assembly 100. The panels 10 are laid so that the piping grooves 24 of adjacent panels are aligned and the piping grooves form a continuous overall groove pattern G that spans the room or area and is adapted to receive at least one continuous elongated piping 26 (see FIG. 5A and FIG. 5B). Any inlet groove 24I and outlet groove 24O continuous with the pattern G are formed in a selected sub-flooring panel of the sub-flooring assembly 100 to provide ingress and egress of the piping 26 in and out of the room or area.

Each panel 10 may already have an overlying TC liner 32 (with perforations 61) affixed or laminated to the upper surface 12 (see FIG. 1A) prior to installation or being joined with other panels 10. Alternatively, larger sheets of TC liners 32 may be applied to yet unlined panel bodies 11, for example, covering rows or columns of the sub-flooring panels 10. Any other underlying or overlying TC liners 30 and 35 may be wrapped onto the piping 26. For example, a TC liner may be formed as an elongated sleeve that is slipped onto the piping 26. The piping 26 is then laid out onto the assembly 100 tracing the pattern G (as visually indicated by the perforations 61 above the grooves 24) and pushed downwardly to tear through the perforations and drop into the groove 24. Inspections and adjustments are made to ensure the piping 26 has dropped completely into the trough 25 of the groove 24 and is in contact directly with the TC liner 32 or indirectly via TC liners 30 and 35 where the liners are overlapping or at least in contact with each other.

Elongated linear and curved strips of cap members 36 are then placed so that each groove 24 along the entirety of the pattern G, whether or not a segment of the piping 26 is in the groove, is covered and the piping below protected, taking care to avoid tearing or otherwise damaging the TC liners. Finishing flooring or laminates 90 are then installed above the sub-flooring panel assembly 100.

In another embodiment where supports 210 are used, the supports 210 are placed in selected locations on the slab 63. A “map,” for example, the top plan views of FIG. 5A or FIG. 5B, may be provided showing the layout of the sub-flooring panels, including the “seams” or lateral gaps 55 between adjacent sub-flooring panels 10. The locations of panel corners (intersections of the seams or gaps) can be visually indicated and marked on the upper surface of the slab 63. A support 210 is placed at each “corner” location. Additional the supports 210 may be positioned, for example, in noncorner locations along the periphery of the room or area. As described above, a support 210 may be placed under a side edge of a sub-flooring panel or under at least two adjoined corners of two adjacent sub-flooring panels, where each corner covers generally a quadrant of the cross sectional area of the piston 214 of the support 210.

To assemble and install a support 210, adhesive 242 is applied to the upper surface 63P of the slab at the selected location. Where the ISD base pad 219 is used, it is placed on the adhesive and affixed to the selected location. Adhesive 242 is applied to the upper surface of the ISD base pad 219 and the tubular member 212 is affixed thereto. Where the ISD liners 221B and 221S are used, adhesive 242 is applied to the inner surface 222 of the tubular member 212. The liners 221B and 221S are placed inside the tubular member 212 to line the interior volume V. It is understood that the liners 221B and 221S can be affixed to the tubular member 212 prior to installation.

The piston 214 may be assembled prior to insertion into the tubular member 214. The upper and lower pads 230 and 232 are affixed to the piston body 214B by adhesive 242. The pads are arranged relative to the piston body 214B in a manner whereby the channel 236 is aligned and the lips are provided in the periphery of the upper and lower pads 230 and 232.

During or after placement of all the tubular members 212 on the slab 63, the VFP substance 218 is poured or otherwise placed each tubular member 212 (the VFP substance 218 should be of a depth to at least cover any vane formations or grid formation 220). The piston 214 in each tubular member 212 is positioned to rest on the VFP substance 218. A measurement or assessment is made as to the effective height of the upper surface of each piston 214 (with or without upper ISD pad 230). Adjustments are made as needed so that each piston 214 is at a desired height, for example, where the upper surface of all pistons are above the upper rims of their respective tubular member and the upper surfaces of all pistons are at the identical altitude relative to ground (or the identical height from ground). Height adjustments may be made by, for example, by changing (increasing or decreasing) the amount of VFP substance 218 in the tubular member 212, removing or adding ISD pads, and/or replacing with a taller or shorter piston 214. After the desired height(s) are obtained, the spaces around and between the supports 210 are filled with LVF substance 228.

For another underlayment layer, a plurality of balance boards 238 are laid on the supports 210. Where balance boards 238 and fiberboards 240H are about the same sizes and shapes as the sub-flooring panels 10 for forming the sub-flooring panel assembly 100, the balance boards 238 and/or the fiberboards 240H may be installed in the same layout pattern as the sub-flooring panels. As shown in FIG. 13B, support 210B is positioned below corner regions of the panels 210N and 210M, balance boards 238N and 238M and fiberboards 240N and 240M. However, where the balance boards 238 and/or fiberboards 240 have different sizes and/or shapes from the sub-flooring panels 10, any two or more of these layers may be arranged and laid in a different layout pattern than the panel assembly 100. For example, any two or more of these layers may be arranged in “criss-crossing” patterns, such that their respective seams or lateral gaps are not vertically aligned between any two adjacent layers. For example, the balance boards 238 may be laid with their longitudinal axis along a first direction and the fiberboards 240 may be laid above with their longitudinal axis along a second direction angularly offset (e.g., about 45-90 degrees) from the first direction. Moreover, additional supports 210 may be used to be positioned under corner regions of the balance boards, fiberboards and/or elsewhere as needed or desired. As shown in FIG. 14 and FIG. 15, placement of structures, for example, corners of the balance boards 238, on the supports 210 may be guided by visual indicators 247, such as quadrant markers, provided on the piston, for example, the upper surface of the upper ISD pad 230.

After each of the balance boards 238 is laid on the supports 210, each is fastened to the supports 210 below it, for example, by fasteners, such as screws, nails or the like, driven through the balance boards and into at least the upper ISD pad 230, the piston body 214B and perhaps into the LVF particulate substance 218. The fiberboards 240 may also be fastened to the supports 210 in the same manner, either separately or simultaneously with the balance boards 238. As shown in FIG. 13A and FIG. 13B, a layer of ISD adhesive 242 or the like may be applied to the upper surface of the balance boards 238 before the fiberboards 240 are installed above the balance boards 238, and also applied to the upper surface of the fiberboards 240.

Above the underlayment assembly 200, the sub-flooring panels 10 may be arranged, joined, and laid in any manner depending on a number factors, including the shape and size of the room or area to receive the sub-flooring system 300, and the layout pattern(s) of the fiberboards and the balance boards below it. For example, sub-flooring panels 10D and 10E are arranged and joined along two opposing peripheral edges of the room and area and sub-flooring panels 10A, 10B and/or 10C are arranged and joined for the interior of the room or area. The grooves 24 of adjacent sub-flooring panels are align and connected to form a continuous groove having a pattern G with a generally serpentine portion GS, a linear traversing portion GL, an inlet 24I and an outlet 24O, as shown in FIG. 5A and FIG. 5B.

The piping 26 may be laid in the manner as described above. The strips of cap members 36 may be placed in the grooves 24 in the manner described above. Likewise, the finishing flooring or laminate 90 may be installed on the sub-flooring panel assembly. Finishing flooring or laminate may include, for example, laminated engineered wood flooring, hardwood flooring, tile or linoleum flooring.

As mentioned above, the cap members are preferably installed in each groove whether or not it contains the piping or any other elements. The protective cap member protect the piping and provides a smooth and even surface ready for installation of finishing flooring above the sub-flooring panel assembly.

Alternate Underlayment Assemblies

In other embodiments of the present invention, an underlayment assembly 400 includes one or more generally rigid stabilizing panels 402, multiples of which as needed are positioned in a side-by-side configuration, generally in contact and abutting with adjacent panels 402, to form a layer of stabilizing panels between the slab 63 and sub-flooring panels 10. As shown in FIG. 18, the stabilizing panels 402 are positioned on a layer of VFP 418 placed on the slab 63, which VFP can be arranged to compensate for any unevenness and/or unlevelness in the slab 63 in providing a suitable surface for the panels 402.

With reference to FIG. 18 and FIG. 19, a stabilizing panel 402 has a generally solid body made of a suitable material, including wood, OSB, MDF, plywood, particleboard, pre-formed pressed board or concrete. The panel 402 includes at least a first main upper portion or layer 404, and at least a second main lower portion or layer of 430, and one or more pistons 406, each situated in a respective recess 408 formed in the main portion 404. In some embodiments, the main portion 404 has a rectangular configuration with a length L ranging between about 300 mm to 1,200 mm, and preferably about 600 mm, a width W ranging between about 300 mm to 1,200 mm, and preferably about 600 mm, and a thickness T ranging between about 10 mm to 45 mm, and preferably about 29 mm. The main portion 404 has a plurality of recesses 408. Each recess may have a width or diameter ranging between 100 mm to 300 mm. In some embodiments, each stabilizing panel 402 has four recesses, and each recess has a width or a diameter of about 245 mm. The recesses 408 may extend the entire thickness of the upper panel as through-holes 408, and they may be arranged in any suitable configuration in the upper panel, including a grid pattern along with length and width axes, as shown in FIG. 19.

As better shown in FIG. 19, each recess 408 is lined circumferentially with a rigid tubular member 410 shaped and sized in conformity with its respective recess 408. The recesses 408 and tubular members 410 may have any suitable cross-sectional shape, including those shown in FIG. 16. In the illustrated embodiment, each of the recesses 408 and the tubular members 410 has a circular cross-section with corresponding diameters such that the tubular member has an interference fit within the recess 408. Each recess 408 is lined at its bottom with a respective lower ISD pad 412 that sits within and is circumscribed by the tubular member 410. Each recess 408 is at least partially filled with a layer of particulate substance 414. The particulate substance 414, and the tubular member 410 are covered by a respective upper ISD pad 416 which is shaped and sized to sit within and be circumscribed by the tubular member 410. The ISD pads 412 and 416 contain the particulate substance 414 within the recess 408.

On each upper ISD pad 416 and supported by the respective particulate substance 414 contained in the respective recess 408 is a respective piston 406. The piston 406 is shaped and sized to fit within the tubular member 410. The piston 406 has a generally solid body surrounding an inner cavity or channel 420 that is generally sealed at its lower end by the upper ISD pad 416 and at its upper end by a third ISD pad 422 that is positioned on the piston 406. The cavity 420 is therefore isolated within the piston 406 and provides an air pocket so as to provide sound, impact and/or thermal insulative properties in the piston 406. A coating or layer of ISD adhesive 424 may be applied to upper and lower surfaces of the piston 406 to affix the ISD pads 422 and 416 thereto.

In some embodiments, the stabilizing panel 402 includes a second or lower portion or layer 430 which is fastened or otherwise attached to the main portion 404, for example, by nails or screws 428 that extend through both portions. The lower portion 430 may be shaped and sized to match and correspond with the main portion 404 in the length and width dimensions, except the lower portion 430 may have a lesser thickness. The lower portion 430 also has a common plurality of recesses 432 which extend the entire thickness of the lower portion 430 to form through-holes 432, with each lower recess 432 being below or generally vertically aligned with the upper recesses 408 of the main portion 404, although the lower recesses 432 have a smaller cross-section than the cross-section of the upper recesses 408. The lower recess 432 forms an inner cavity that is sealed at its upper end by the ISD pad 412 and at its lower end by an ISD sheet 434 that extends between the slab and the lower layer and may be generally coextensive with the lower portion 430. The lower recess 432 therefore provides an air pocket providing sound, impact and/or thermal insulative properties to the lower portion 430 and hence the panel 402. The ISD sheet 434 may be affixed to the slab and/or the lower layer by a layer of ISD adhesive 436.

The stabilizing panel 402 and the piston 406 provide numerous advantages including many of those provided by the aforementioned stabilizing support 210 and piston 214, as described hereinabove. Moreover, suitable dimensions and configurations described hereinabove with regards to elements of the stabilizing support 210, including the tubular member 212, and the piston 214, are generally applicable to the stabilizing panel 402, tubular member 426, and the piston 406. It is understood that the volume or layer of particulate substance 414 within the recess 408 is of a quantity that allows a lower portion of the piston 406 to sit below an upper edge 426 of the tubular member 410 so that the tubular member 410 can contain the piston 406 and prevent the piston from sliding or otherwise moving outside of the tubular member 410. In turn, the tubular member 410 is contained and prevented from shifting by the recess 408 in the stabilizing panel 402. The body of the stabilizing panel thus supports the tubular member 410 which contains the particulate substance 414 which supports the pistons 406 which supports at least the sub-flooring panels 10 and any other components resting on the pistons 406. Without the body of the stabilizing panel, the tubular member 410 may break or crack under the weight or load imparted to the particulate substance 414 from above, causing the particulate substance 414 to leak. Such leakage can otherwise destabilize the piston 406 and thus the underlayment assembly, possibly leading to collapse of the underlayment assembly and the sub-flooring panels 10. Moreover, in the event of ground movement, such as an earthquake, the body of the stabilizing panel 402 can minimize lateral movement or shifting of the particular substance 414 and tubular members 426, and thus the pistons 406, particularly where the one or more stabilizing panels span the entirety of the room, abutting against the vertical wall isolator pads 510 and/or walls 64 of the room, as shown in FIG. 18.

In some embodiments, the stabilizing panel 402 is about 300 mm to 600 mm×about 300 mm to 600 mm, and preferably about 600 mm×600 mm, the upper portion 404 has at thickness of about 19 mm, the lower portion 430 has a thickness of about 6.35 mm, the upper recess 408 has a circular cross-section, with a diameter of about 245 cm, and the lower recess 432 has a circular cross-section, with a diameter of about 110 cm. Furthermore, the piston 406 has an outer diameter of about 230 cm, an inner diameter of about 110 cm, and a height of about 19 cm. The tubular member 426 has an outer diameter generally equal to or no greater than 245 cm, an inner diameter of about 240 cm, a height of about 25 cm.

As shown in FIG. 18, the underlayment assembly 400 in some embodiments includes one or more generally rigid sound trapping panels 450, multiples of which as needed can be placed in a side-by-side configuration, generally in contact and abutting with adjacent panels 450, to form a layer of sound trapping panels between the stabilizing panels 402 and the sub-flooring panels 10. As illustrated in FIG. 20, each panel 450 has a generally solid body with a plurality of recesses 452 which may extend through the entire thickness to form through-holes 452 between an upper surface and a lower surface. As shown in FIG. 18, the through-holes 452 are sealed at their upper ends by an upper ISD sheet 454 and at their lower ends by a lower ISD sheet 456 so that the through-holes 452 form air pockets to provide sound, impact and/or thermal insulative properties to the panels 450. A coating or layer of ISD adhesive 458 is applied between an upper surface of the panels 450 and the upper ISD sheet 454, and a coating or layer of ISD adhesive 460 is applied between a lower surface of the panel and the lower ISD sheet 456 to affix these ISD sheets to the panel 450.

In the illustrated embodiment, each panel 450 has a plurality of larger through-holes 452 and a plurality of smaller through-holes 458, with four larger through-holes 452 arranged in quadrants around one smaller through-holes 458. In the illustrated embodiment, the larger and small through-holes have a circular cross-section. The larger through-holes 452 have a diameter of about 110 cm, and the smaller through-holes 458 have a diameter of about 60 cm.

The main portion 404, the piston 406 and/or the lower portion 430 of the stabilizing panels 402, and/or the sound trapping panels 450 may be constructed of any suitable material that is generally noncompressible with ISD properties and can bear significant weight and pressure loads, for example, oriented strand board (OSB), medium density fiberboard (MDF), particle board (PB), wood, plastic, concrete, or any combinations thereof. It is understood that the main portion 404 and the lower portion 430 of the stabilizing panel 402 may have a single body construction provided the larger recess 408 and the smaller recess 432 may be formed. Outer or exposed surfaces of the main portion 404, the piston 406, the lower portion 430 and the panels 450 may be coated with a water-proofing sealant, as needed or appropriate.

It is understood that the plurality of recesses in the stabilizing panel 402 and the sound trapping panels 450 may vary depending on a number of factors, including size of these panels.

In the illustrated embodiment, one or more sound trapping panels 450 are situated above the layer of stabilizing panels 402, as supported by at least one piston 406 at generally a common height so that multiple trapping panels form a layer of sound trapping panels. It is understood that the amount of particulate substance 414 in each recess 408 on which a respective piston 406 is supported may be adjusted and/or the particulate substance may be arranged as needed or appropriate to support the sound trapping panels in a desirable manner. Being supported on the pistons 406, the sound trapping panels 450 are separated from and raised above the upper surface of the stabilizing panels 402 to provide additional air gaps 515 within the underlayment assembly in further increasing its sound, impact and/or thermal insulative properties.

The underlayment assembly 400 may be arranged in any suitable configuration between the slab 63 and the sub-flooring panels 10. In some embodiments, the configuration includes general vertical alignment of the smaller through-holes 458, the piston 406 and the through-holes 432, as shown in FIG. 21, so that sound and/or impact waves may be better trapped and insulated within the underlayment assembly. For example, sound and/or impact waves entering the cavity 420 of the piston 406 and/or the lower recess 432 of the lower portion 430 can be better absorbed by the particulate substance 414 in the upper recess 408 each of the cavity 420 and the lower recess 432 abutting against (or is at least partially surrounded by) the particular substance 414. In the illustrated embodiment, each of the cavity 420 and the lower recess 432 is separated from the particulate substance 414 merely by an ISD pad or sheet.

In some embodiments, an underlayment assembly may include a second layer of sound trapping panels 500 between the first layer of sound trapping panels 450 and the sub-flooring panels 10. As shown in FIG. 22, the sound trapping panels 450 of the first layer and the sound trapping panels 500 of the second layer may arranged vertically offset from each other so that the through-holes (larger and/or smaller) of each layer are not directly vertically aligned so as to provide even greater sound, impact and/or thermal insulative properties to the underlayment assembly. ISD sheets 510 may be provided above and/or below each layer as appropriate, and ISD adhesive 512 may be applied between each ISD sheet and panel as appropriate.

It is understood that the ISD pads and sheets and the ISD adhesive may be provided and applied where appropriate or needed. Moreover, it is understood that any air pocket or air gap in the underlayment assembly may be left void or be partially or completely filled with particulate substance and/or loose volume filler substance.

Some embodiments of a method of installing the underlayment assembly 400 include placing the particulate substance 418 on the slab 63 and spreading it over the slab in a manner that can even out or otherwise compensate for any unevenness or unlevelness of the slab. One or more ISD sheets 434 are then placed above the particulate substance 418, followed by installation of one or more stabilizing panels 402. Where the stabilizing panels 502 have separate upper and lower portions 404 and 430, each is assembled prior to installation by affixing the upper and lower portions 404 and 430 together, for example, by nails 428. A coating of ISD adhesive 436 is applied to an upper surface of the ISD sheets 434 and the stabilizing panels 502 are placed on thereon.

A tubular member 410 is placed in a respective recess 408. An ISD pad 412 is placed in a respective recess 408, circumscribed by the respective tubular member 410, of one or more stabilizing panels 502, which creates an air pocket in the recess 432 that is sealed between the ISD pad 412 and the ISD sheet 434. Particulate substance 414 is placed in the recesses 408 (at least partially filling the recess 408), within the tubular member 410 and above the ISD pad 412. The particulate substance 414 is arranged to provide an even and level surface on which an ISD pad 416 is placed.

For a respective recess 408, a piston 406 is placed on the ISD pad 416 within the upper edge 426 of the tubular member 410 lining the recess 408. Care may be taken to arrange the height of the particulate substance 414 in adjacent recesses 408 so that the pistons 406 are supported in a desirable or appropriate manner, including at a desirable or appropriate height so that the pistons in turn can suitably support the components above. An ISD pad 422 is placed on an upper surface of the piston 406 which forms an air pocket in the inner channel 420 of the piston between the ISD pads 422 and 416. A coating of ISD adhesive 424 is applied to the upper and lower surfaces of the piston 406 to affix together the piston 406 and the ISD pads 422 and 416.

ISD sheets 454 and 456 may be affixed to upper and lower surfaces of one or more sound trapping panels 450 before the panels 450 are positioned above the pistons 406. The ISD sheets 454 and 456 seal the recesses 452 and 458 forming air pockets in the panels 450. Additional sound trapping panels 450 may be stacked on top of each other to form one or more layers of sound trapping panels as desired or appropriate above the pistons 406. The different layers may be staggered so the recesses 452 and 458 are staggered. Above the one or more layers of sound trapping panels 450 sub-flooring panels 10 may be installed, as described hereinabove.

One or more additional vertical pads 510, constructed of, for example, Low Density Fiberboard (LDF) pads, or felt pads, or any other ISD pads, may be situated vertically against vertical slab 64, as shown in FIG. 18.

In the illustrated embodiment, each stabilizing panel 402 has four pistons 406, and each sound trapping panel 450 is supported by eight pistons. The stabilizing panels 402 and the sound trapping panels 450 are sized and configured such that a sound trapping panel 450 is coextensive with two side-by-side stabilizing panels 402, with four pistons occupying a respective quadrant of the stabilizing panel 402 and supporting one half of the sound trapping panel 450, and a smaller recess 458 of the sound trapping panel 450 in vertical alignment with the piston 406 and the lower recess 432 of the stabilizing panel 402.

The preceding description has been presented with reference to presently preferred embodiments of the invention. Workers skilled in the art and technology to which this invention pertains will appreciate that alterations and changes in the described structure may be practiced without meaningfully departing from the principal, spirit and scope of this invention. In that regard, the drawings are not necessarily to scale. Any feature of any embodiment may be used in combination with any feature of any other embodiment, as needed or desired. It is understood that an electronic heating and/or cooling element may be used in lieu of or in addition to the piping. For example, an electronic heating wire or cord may be placed in the groove of the sub-flooring panel in lieu or in addition to the piping. Accordingly, the foregoing description should not be read as pertaining only to the precise structures described and illustrated in the accompanying drawings, but rather should be read consistent with and as support to the following claims which are to have their fullest and fair scope.

Claims

1. An underlayment assembly, comprising:

at least one stabilizing panel having an upper portion, a lower portion and at least one piston, the upper portion having at least one first recess adapted to contain particulate substance to support the at least one piston, the lower portion having at least one second recess adapted to form an air pocket.

2. The underlayment assembly of claim 1, wherein at least one second recess is generally in vertical alignment with the at least one first recess.

3. The underlayment assembly of claim 1, wherein at least one piston has an inner cavity adapted to form an air pocket.

4. The underlayment assembly of claim 3, wherein the at least one second recess is generally in vertical alignment with the at least one first recess and the inner cavity.

5. The underlayment assembly of claim 1, wherein at least the one stabilizing panel includes at least one tubular member configured to circumferentially line the at least one first recess and to circumferentially contain the particulate substance.

6. The underlayment assembly of claim 1, wherein the at least one first recess includes a first ISD pad below the particulate substance and a second ISD pad above the particulate substance.

7. The underlayment assembly of claim 6, wherein the at least one piston is positioned on the second ISD pad.

8. The underlayment assembly of claim 1, further comprising at least one sound trapping panel having at least one recess adapted to form at least one air pocket.

9. The underlayment assembly of claim 8, wherein at least one sound trapping panel is positioned on the at least one piston.

10. The underlayment assembly of claim 8, further comprising at least a second sound trapping panel arranged side-by-side with the at least first sound trapping panel.

11. The underlayment assembly of claim 8, further comprising at least a second sound trapping panel stacked on the at least first sound trapping panel.

12. The underlayment assembly of claim 11, wherein the at least second sound trapping panel is stacked vertically offset from the at least first sound trapping panel.

13. A sub-flooring system, comprising:

the underlayment assembly of claim 1; and

one or more sub-flooring panels above the underlayment assembly, at least one sub-flooring panel having a recess, and an elongated heating element positioned in the recess.

14. The sub-flooring system of claim 13, wherein the underlayment assembly further comprises at least one sound trapping panel having at least one recess adapted to form at least one air pocket.

15. A method of installing an underlayment assembly, comprising:

providing a support surface;

providing a first amount of particulate substance on the support surface;

positioning at least one stabilizing panel on the first amount of particulate substance, the at least one stabilizing panel having an upper portion, a lower portion and at least one piston, the upper portion having at least one first recess;

providing a second amount of particulate substance in the at least one first recess; and

positioning the at least one piston above the second amount of particulate substance.

16. The method of claim 15, farther comprising placing a tubular member in the at least one first recess before providing a second amount of particulate substance in the at least one first recess.

17. The method of claim 15, wherein the lower portion has at least one second recess.

18. The method of claim 15, further comprising providing at least one sound trapping panel on the at least one stabilizing panel.

19. The method of claim 15, further comprising positioning an ISD sheet on the first amount of particulate substance before positioning the at least one stabilizing panel.

20. The method of claim 17, further comprising vertically aligning the at least one first recess and the at least one second recess.