Soundproof flooring system

Abstract

A soundproof flooring system for overlying a sub floor includes a resilient soundproof membrane laying down on the sub floor. Elongated supports disposed generally parallel and spaced relationship relative to each other lay down on the membrane in alternate fashion with elongated spacers. Each support includes an elongated channel with a core slip encased therein. The plywood slip has a rib with an outer surface protruding out from the channel to support and secure the finish floor thereto. Each spacer slightly protrudes out upwardly from the rib outer surfaces of the plywood slips to support the finish floor thereon. The wood planks of the finish floor are transversely secured to the plywood slips using a bonding agent with staples or cleats.

Description

FIELD OF THE INVENTION

[0001] The present invention relates to a floor system and more particularly to a soundproof floor system for use in different constructions where soundproofing is required between floors.

BACKGROUND OF THE INVENTION

[0002] It is well known that there is a practical need for an effective soundproofing flooring system used in different constructions. Especially in high-end condo apartments installation of a hardwood flooring system is very limited, as there had always been a problem of obtaining a proper sound barrier between the wood flooring and the sub flooring to insulate noise and prevent it from passing through to the apartment below.

[0003] Carpets are used to be the only safe soundproof floor material. In fact, carpets cause certain allergies including asthma, skin disease from the dust and microbes accumulated in them with time, which cannot be freed by cleaning even using efficient methods.

[0004] In some cases cork was referred to use as a sound insulator. Since cork does not have uniform density throughout its surface and is bonded to the sub floor to be stable to receive wood floor, the object to obtain proper soundproofing is lost. The requirement to provide a peaceful and quiet living in the apartment below is not met since the bonding agent becomes a sound carrier.

[0005] Demand of wood flooring in different private and public places increased highly, because of health consideration and also for its natural beauty and warmth. Proper soundproofing is a must to honor the privacy of the neighborhood and it became a need to develop an efficient sub floor system to receive the wood floor there above.

OBJECTS OF THE INVENTION

[0006] It is therefore a general object of the present invention to provide an improved soundproof flooring system.

[0007] An advantage of the present invention is that the soundproof flooring system obviates the above mentioned disadvantages.

[0008] Another advantage of the present invention is that the soundproof flooring system ensures a proper sound barrier between the wood finish floor and the sub flooring to noise insulate adjacent higher/lower apartments from each other.

[0009] A further advantage of the present invention is that the soundproof flooring system requires minimum space in height for maximum soundproofing efficiency.

[0010] Still another advantage of the present invention is that the soundproof flooring system can be installed over radiant heated sub floors.

[0011] Still a further advantage of the present invention is that the soundproof flooring system has a width practical application.

[0012] Yet another advantage of the present invention is that the soundproof flooring system is of a floating type and easy to install.

[0013] Yet a further advantage of the present invention is that the soundproof flooring system ensures a uniform support of the finish floor all over its surface.

[0014] Still an advantage of the present invention is that the soundproof flooring system is water resistant since most of its components are water repellant materials.

[0015] Other objects and advantages of the present invention will become apparent from a careful reading of the detailed description provided herein, within appropriate reference to the accompanying drawings.

SUMMARY OF THE INVENTION

[0016] According to an aspect of the present invention, there is provided a soundproof flooring system for overlying a sub floor and for attachably supporting a finish floor thereon, said system comprises:

[0017] a resilient soundproof membrane for laying down on said sub floor;

[0018] elongated supports laying down on said membrane and disposed in a generally parallel and spaced relationship relative to each other, each of said supports including an elongated channel and a core slip, said channel tightly receiving said core slip therein, said channel defining opposite longitudinal retaining flanges and a longitudinal opening therebetween, said retaining flanges defining a flange outer surface, said core slip defining a rib extending through said longitudinal opening and protruding outwardly from said channel for securing said finish floor thereto, said rib defining a rib outer surface being in spaced relationship relative to and generally parallel to said flange outer surface for supporting said finish floor thereon; and

[0019] generally elongated spacers laying down on said membrane, each of said spacers being located between two adjacent of said elongated supports and protruding outwardly from said rib outer surfaces so as to ensure compression of said membrane by said spacers and said finish floor under the weight of the latter.

[0020] Preferably, each of said spacers substantially longitudinally abuts both of said supports adjacent thereto.

[0021] Typically, the membrane has a thickness of about between an eighth and a quarter of an inch, and is an open cell type rubber cushion material. Preferably, the membrane is made out of a material being heat resistant up to at least 325 degrees Fahrenheit.

[0022] Preferably, the spacers are made out of a water repellant material, such as a wax impregnated wood fiberboard type material.

[0023] Typically, the elongated channels are made out of a rigid metallic type material, preferably an eighteen gauge commercial grade steel.

[0024] Typically, the elongated supports are substantially spaced apart from each other by a center-to-center distance of about between six to eighteen inches.

[0025] Preferably, the core slips are made out of a plywood type material and the rib defines a longitudinal groove extending inwardly from said rib outer surface and running therealong to receive a bonding material therein for securing a finish floor to said system.

[0026] According to another aspect of the present invention, there is provided a combination of a soundproof flooring system as defined above with a finish floor laying down on said rib outer surfaces of said elongated supports, said finish floor being substantially transversely mounted relative to said supports; and

[0027] fastener fixedly securing said finish floor to said core slip ribs of said elongated supports.

[0028] Typically, the fastener is a longitudinal continuous strip of an adhesive deposited on said rib outer surface of said core slips to bond said finish floor thereto.

[0029] Alternatively, the fastener is staples fixedly securing said finish floor to said ribs of said core slips.

[0030] Preferably, the finish floor is tongue and groove end matched wood planks.

BRIEF DESCRIPTION OF THE DRAWINGS

[0031] In the annexed drawings, like reference characters indicate like elements throughout.

[0032] FIG. 1 is a perspective view of an embodiment of a soundproof flooring system in accordance with the present invention;

[0033] FIG. 2 is a partial longitudinal section view taken along line 2 of FIG. 1;

[0034] FIG. 3 is a cross-sectional view taken along line 3-3 of FIG. 2;

[0035] FIG. 4 is a cross-sectional view taken along line 4-4 of FIG. 3; and

[0036] FIG. 5 is a plan view showing a typical layout of the embodiment of FIG. 1.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

[0037] With reference to the annexed drawings the preferred embodiment of the present invention will be herein described for indicative purpose and by no means as of limitation.

[0038] With reference to FIGS. 1 and 2, there is illustrated an embodiment 10 of a soundproof flooring system according to the present invention overlying a sub floor S generally made out of concrete and for securing a finish floor 20 thereon in different building constructions B where soundproofing is required. The system 10 is very effective to insulate noise and prevent it from passing through to the apartment below (see FIG. 1).

[0039] As illustrated in FIG. 2, the system 10 preferably includes the finish floor 20, such as wood planks 21 or the like, a resilient membrane 30 which has a soundproofing property and is laid on the sub floor S. A plurality of generally elongated supports 40 are laid down on the membrane 30. Each support 40 includes an elongated channel 41 of a generally U-shaped cross-sectional configuration and a core slip 42, preferably made out of Birch™ plywood type material. The channel 41 tightly receives the core slip 42 therein so as to prevent the latter from sliding in any direction relative to the channel 41. The open channel 41 defines a longitudinal opening 44 therethrough between opposite longitudinal retaining flanges 43, used to retain the core slip 42 from being displaced relative to the opening 44 in the vertical direction. The retaining flanges 43 define a flange outer surface 45. The plywood slip 42 defines a generally central rib 46 extending through the opening 44 and protruding outwardly from the channel 41 to secure the planks 21 thereto. The rib 46 defines a rib outer surface 47 in spaced relationship relative to and generally parallel to the flange outer surface 45 to support the planks 21 thereon. The supports 40 are disposed in a generally parallel and spaced relationship relative to each other and at a regular interval L with the planks 21 being preferably transversely positioned relative thereto.

[0040] A plurality of generally elongated spacers 50 is also laid on the membrane 30 along and between the longitudinal supports 40, preferably filling the entire spaces between adjacent supports 40. The spacers 50 are preferably made out of a soundproofing and water repellant material such as a wax impregnated wood fiberboard with density of approximately fourteen (14) lb/ft3 that keeps six (6) to eight (8) percent humidity at the most, as per ASTM standard D-1037. The spacers 50 substantially support a large proportion (most) of the wood planks 21 resting thereon. In fact, the spacers 50 protrude outwardly from the rib outer surfaces 47 so as to ensure compression of the membrane 30 by the spacer 50 supporting the planks 21 and the weight of the latter.

[0041] The planks 21 of the finish floor 20 are preferably tongue and groove end matched type planks (see FIGS. 2 and 4), which are typically kiln-dried down to between six (6) and eight (8) percent of humidity.

[0042] The finish floor 20 preferably has a thickness varying approximately between seven sixteenth and three quarter of an inch ({fraction (7/16)}″ and ¾″). When planks 21 are considered, they should have a minimum standard width such as one and half inches (1 ½″) with a minimum length of eighteen inches (18″).

[0043] The planks 21, or any other type of finish floor, is preferably secured to the plywood slips 42 using a fastener 22 that includes first a continuous strip of adhesive 22a, preferably of polyurethane type which provides high bond quality to wood materials, across the width of the planks 21, and second a plurality of staples 22b, cleats, nails or the like for fixed and rigid attachment between the two. The rib 46 of each plywood slip 42 preferably defines a groove 48 extending inwardly from the rib outer surface 47 and running along the rib 46 to receive the strip of adhesive 22a therein, as shown in FIGS. 3 and 4. The staples 22b are preferably twenty (20) or eighteen (18) gauge staples and their length depends on the thickness of the planks 21.

[0044] The membrane 30 is made out of heat-resistant materials for up to at least three-hundred and twenty-five degrees Fahrenheit (325° F.) to allow for the system 10 to overlay a sub floor S which may include a radiant type heater, according to ASTM standard E-648 for class-I radiant panel and meeting Canadian/CGSB 4 155-M88 standard test for flammability. The membrane 30 has a thickness preferably varying between an eighth (⅛″) and a quarter (¼″) of an inch with a density of approximately twenty-two (22) lb/ft3 such that it meets all applicable building code regulations. The membrane 30 is preferably an open cell rubber type cushion that may be made from recycled tires and include polyethylene back.

[0045] The channel 41 has a preferred thickness of three eighth of an inch (⅜″) and width of one and a half inch (1½″). Preferably, for rigidity purposes and resistance to eventual perforations from the staples 22b, each channel 41 is made out of an eighteen (18) gauge steel, ASTM-A366 commercial grade.

[0046] The spacers 50 are preferably slightly thicker than the longitudinal supports 40 to ensure that the membrane 30, due to its resiliency, is compressed by the spacers 50 themselves pushed down by the weight of the finish floor 20 when the latter is secured to the supports 40, as shown by the arrows of FIG. 3. The spacers 50, and the supports 40 to a smaller extent, are essentially sandwiched between the membrane 30 and the planks 21, as illustrated by the arrows of FIG. 3.

[0047] The spacers 50, although relatively light relative to either the membrane 30, the supports 40 or the planks 21, preferably have a density of fourteen (14) lb/ft3 with a thickness of {fraction (7/16)}″ and a generally pre-cut length of forty-eight inches (48″).

[0048] As illustrated in FIG. 5, the longitudinal supports 40 are uniformly placed in parallel relationship to each other and to a short dimension of the sub floor S to be covered and spaced apart by a generally constant interval L. The interval L could be anywhere between approximately six (6) to eighteen (18) inches depending on the type of finish floor 20 and the type of room, but is preferably ten inches (10″) such that the pre-cut pieces of spacers 50 are eight and a half inch (8½″) wide.

[0049] It is preferable to start by placing a first support 40 along the approximate centerline C-C of the long dimension of the sub floor S of a room. The subsequent supports 40 are then alternately installed with the spacers 50 up to the full covering of the sub floor S, with quantity N of supports 40 on each side of the centerline C-C, illustrated by (N×L) on FIG. 5. Since it is preferred to finish the covering with a last support 40′ along the short wall of the room, the width of the last spacer 50′ closest to the wall could obviously be different from the others and sized accordingly, as shown by interval L′ in FIG. 5.

[0050] The system 10 not only shows efficiency to soundproofing, but also, because of its thin structure and simplicity to install, is very practical and suitable for residential condo type apartments and commercial applications such as office, dance, exercise or even gymnasium floors without significantly reducing the bare height available between floor and ceiling. And finally, the rate of soundproofing of the system 10 does meet the 55 to 67 IIC (Impact Insulation Class) requirements for a sound relationship with neighbors living below.

[0051] The finish floor 20 may also be a custom pattern flooring or different plank flooring with different wood-mosaic surfaces. Some examples of surfaces are shown in FIG. 1.

[0052] The system 10 is designed to meet the North American standards for soundproofing, especially to the applicable building code regulations. Because the system 10 is a floating type flooring system, it is very simply installed, compared to any other system available.

[0053] Although the present soundproof flooring system 10 has been described with a certain degree of particularity it is to be understood that the disclosure has been made by way of example only and that the present invention is not limited to the features of the embodiment described and illustrated herein, but includes all variations and modifications within the scope and spirit of the invention as hereinafter claimed.

Claims

1. A soundproof flooring system for overlying a sub floor and for attachably supporting a finish floor thereon, said system comprising:

a resilient soundproof membrane for laying down on said sub floor;

elongated supports laying down on said membrane and disposed in a generally parallel and spaced relationship relative to each other, each of said supports including an elongated channel and a core slip, said channel tightly receiving said core slip therein, said channel defining opposite longitudinal retaining flanges and a longitudinal opening therebetween, said retaining flanges defining a flange outer surface, said core slip defining a rib extending through said longitudinal opening and protruding outwardly from said channel for securing said finish floor thereto, said rib defining a rib outer surface being in spaced relationship relative to and generally parallel to said flange outer surface for supporting said finish floor thereon; and

generally elongated spacers laying down on said membrane, each of said spacers being located between two adjacent of said elongated supports and protruding outwardly from said rib outer surfaces so as to ensure compression of said membrane by said spacers and said finish floor under the weight of the latter.

2. The system of claim 1, wherein each of said spacers substantially longitudinally abuts both of said supports adjacent thereto.

3. The system of claim 1, wherein said membrane has a thickness of about between an eighth and a quarter of an inch.

4. The system of claim 3, wherein said membrane is an open cell type rubber cushion material.

5. The system of claim 1, wherein said spacers are made out of a water repellant material.

6. The system of claim 5, wherein said water repellant material is a wax impregnated wood fiberboard type material.

7. The system of claim 1, wherein said membrane is made out of a material being heat resistant up to at least 325 degrees Fahrenheit.

8. The system of claim 1, wherein said elongated channels are made out of a rigid metallic type material.

9. The system of claim 8, wherein said rigid metallic type material is an eighteen gauge commercial grade steel.

10. The system of claim 1, wherein said elongated supports are substantially spaced apart from each other by a center-to-center distance of about between six to eighteen inches.

11. The system of claim 1, wherein said core slips are made out of a plywood type material.

12. The system of claim 11, wherein said rib defines a longitudinal groove extending inwardly from said rib outer surface and running therealong to receive a bonding material therein for securing a finish floor to said system.

13. A soundproof flooring system for overlying a sub floor, said system comprising:

a resilient soundproof membrane for laying down on said sub floor;

elongated supports laying down on said membrane and disposed in a generally parallel and spaced relationship relative to each other, each of said supports including an elongated channel and a core slip, said channel tightly receiving said core slip therein, said channel defining opposite longitudinal retaining flanges and a longitudinal opening therebetween, said retaining flanges defining a flange outer surface, said core slip defining a rib extending through said longitudinal opening and protruding outwardly from said channel, said rib defining a rib outer surface being in spaced relationship relative to and generally parallel to said flange outer surface;

generally elongated spacers laying down on said membrane, each of said spacers being located between two adjacent of said elongated supports;

a finish floor laying down on said rib outer surfaces of said elongated supports, said finish floor being substantially transversely mounted relative to said supports, said spacers protruding outwardly from said rib outer surfaces so as to ensure compression of said membrane by said spacers and said finish floor under the weight of the latter; and

fastener fixedly securing said finish floor to said core slip ribs of said elongated supports.

14. The system of claim 13, wherein said fastener is a longitudinal continuous strip of an adhesive deposited on said rib outer surface of said core slips to bond said finish floor thereto.

15. The system, of claim 14, wherein said fastener is staples fixedly securing said finish floor to said ribs of said core slips.

16. The system of claim 13, wherein said finish floor is tongue and groove end matched wood planks.

17. The system of claim 13, wherein each of said spacers substantially longitudinally abuts both of said supports adjacent thereto.

18. The system of claim 13, wherein said membrane is made out of a material being heat resistant up to at least 325 degrees Fahrenheit.

19. The system of claim 13, wherein said membrane is an open cell type rubber cushion material, said spacers are made out of a water repellant material, said elongated channels are made out of a rigid metallic type material and said core slips are made out of a plywood type material.

20. The system of claim 19, wherein said elongated supports are substantially spaced apart from each other by a center-to-center distance of about between six to eighteen inches.