US20160076259A1 - Sound reducing tongue and groove member sound reducing fabrication process and sound reducing blend - Google Patents

Abstract

Described herein is a flooring member comprising: a panel body and a sound-deadening composition applied to a vertical portion of at least one of a first or a second profiled edge of the panel body, the sound-deadening composition including: a first wax having a melting point between about 53° C. and about 56° C. and a second wax having a melting point between about 67° C. and about 71° C.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS
• This application is a continuation of U.S. patent application Ser. No. 13/191,539 filed on Jul. 27, 2011. The disclosure(s) of the above application(s) is (are) incorporated herein by reference.
FIELD OF THE INVENTION
• The present invention relates to tongue and groove products, blends for tongue and groove products, and processes of fabricating tongue and groove products. More specifically, the present invention relates to sound reduction of such products and processes.
BACKGROUND
• Tongue and groove products, such as tongue and groove flooring, are used in various facilities where quick assembly is desired and/or where lateral stability is desired. These products include features for engaging individual members that form an assembly of the products. The features can include male parts or tongues and/or female parts or grooves. Tongue and groove products engage each other along such features.
• Known tongue and groove products suffer from a drawback that they can be noisy when walked upon. When tongue and groove floors are walked on, force is applied downward and/or in a lateral direction. Such forces distribute in numerous directions due to the mating features of the tongue and groove flooring. Such complex mating features result in these forces generating noises. Such noises are especially loud and frequent when installed at inconsistent temperatures and/or at temperatures of less than 60° F. Known products with waxes positioned on horizontal surfaces in regions that generate noises have failed to reduce such noises. To the contrary, known waxes have been positioned in regions that generate noises and/or have compositions that fail to reduce noises.
• A tongue and groove member or assembly, a fabrication process, and a blend that do not suffer from one or more of the above drawbacks would be desirable in the art.
BRIEF SUMMARY
• The present invention is directed to a flooring member comprising: a panel body comprising: a lower surface; an upper surface opposite the lower surface; a first profiled edge extending between the upper and lower surfaces, the first profiled edge comprising a tongue and at least one vertical portion; a second profiled edge extending between the upper and lower surfaces, the second profiled edge opposite the first profiled edge, the second profiled edge comprising a groove and at least one vertical portion; and a sound-deadening composition applied to the vertical portion of at least one of the first or second profiled edges, the sound-deadening composition comprising: a first wax having a melting point between about 53° C. and about 56° C.; and a second wax having a melting point between about 67° C. and about 71° C.
• Other embodiments of the present invention are directed to a flooring member comprising: a panel body comprising: a lower surface; an upper surface opposite the lower surface; a first profiled edge extending between the upper and lower surfaces, the first profiled edge comprising a tongue and at least one vertical portion; a second profiled edge extending between the upper and lower surfaces, the second profiled edge opposite the first profiled edge, the second profiled edge comprising a groove and at least one vertical portion; and a sound-deadening composition applied to the vertical portion of at least one of the first or second profiled edges, the sound-deadening composition comprising: a first wax having a melting point between about 82° C. and about 85° C.; and a second wax having a melting point between about 67° C. and about 71° C.
• Other embodiments of the present invention are directed to a flooring member comprising: a panel body comprising: a lower surface; an upper surface opposite the lower surface; a first profiled edge extending between the upper and lower surfaces, the first profiled edge comprising a tongue and at least one vertical portion; a second profiled edge extending between the upper and lower surfaces, the second profiled edge opposite the first profiled edge, the second profiled edge comprising a groove and at least one vertical portion; and a sound-deadening composition applied to the vertical portion of at least one of the first or second profiled edges, the sound-deadening composition comprising: a first wax having a first needle penetration of about 10 dmm; a second wax having a second needle penetration of about 20 dmm.
• Further areas of applicability of the present invention will become apparent from the detailed description provided hereinafter. It should be understood that the detailed description and specific examples, while indicating the preferred embodiment of the invention, are intended for purposes of illustration only and are not intended to limit the scope of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
• The present invention will become more fully understood from the detailed description and the accompanying drawings, wherein:
• FIG. 1 illustrates an exemplary tongue and groove flooring member having an engagement protrusion according to the disclosure.
• FIG. 2 illustrates an exemplary tongue and groove flooring member having an engagement recess corresponding to the flooring member ofFIG. 1 according to the disclosure.
• FIG. 3 illustrates an exemplary tongue and groove flooring member having an engagement protrusion and an engagement recess according to the disclosure.
• FIG. 4 illustrates an exemplary tongue and groove flooring member having an engagement protrusion and an engagement recess corresponding to the flooring member ofFIG. 3 according to the disclosure.
• FIG. 5 illustrates an exemplary tongue and groove flooring member having an engagement protrusion and an engagement recess according to the disclosure.
• FIG. 6 illustrates an exemplary tongue and groove flooring member having an engagement protrusion and an engagement recess corresponding to the flooring member ofFIG. 5 according to the disclosure.
• Wherever possible, the same reference numbers will be used throughout the drawings to represent the same parts.
DETAILED DESCRIPTION
• The following description of the preferred embodiment(s) is merely exemplary in nature and is in no way intended to limit the invention, its application, or uses.
• As used throughout, ranges are used as shorthand for describing each and every value that is within the range. Any value within the range can be selected as the terminus of the range. In addition, all references cited herein are hereby incorporated by referenced in their entireties. In the event of a conflict in a definition in the present disclosure and that of a cited reference, the present disclosure controls.
• Unless otherwise specified, all percentages and amounts expressed herein and elsewhere in the specification should be understood to refer to percentages by weight. The amounts given are based on the active weight of the material.
• Provided is a sound-reducing tongue and groove member or assembly, a sound-reducing fabrication process, and a sound-reducing blend. Embodiments of the present disclosure reduce or eliminate noises generated from walking on a walking surface, include a desirable hardness, include desirable lubricity, include a desired lack of tackiness, include desirable wear resistance, include desirable resistance to flaking, and combinations thereof.
• Referring toFIG. 1, a sound-reducing tongue andgroove member100 includes atreatment region102 extending from anouter surface104, such as a walking surface, a covered outer surface, an uncovered outer surface, a finished outer surface, and/or an unfinished outer surface of themember100. Additionally or alternatively, in one embodiment, thetreatment region102 extends from alower surface105 of themember100, is positioned on anengagement protrusion103, is positioned in an engagement recess202 (seeFIG. 2), or combinations thereof.
• Themember100 further includes a sound-reducingblend108 positioned on one ormore locations107 within thetreatment region102. The positioning of the sound-reducingblend108 provides sound mitigation, which may reduce or eliminate noise generated from walking on theouter surface104, which may reduce or eliminate noise generated from expansion and contraction of themember100, which may reduce or eliminate noise generated from other forces applied to themember100, or combinations thereof.
• In one embodiment, the sound mitigation reduces or eliminates noise even when themember100 is installed at inconsistent temperatures and/or at a predetermined temperature or temperature range, for example, at about 70° F., at about 60° F., at about 50° F., between about 50° F. and about 70° F., between about 50° F. and about 60° F., between about 60° F. and about 70° R, less than about 70° F., less than about 60° F., less than about 50° F., less than about 40° F., less than about 35° F., or any combination or sub-combination thereof. In a further embodiment, the sound mitigation reduces or eliminates noise even when themember100 is used in conditions at a higher temperature, for example, at about 60° F., at about 70° F., at about 80° F., at about 90° F., at about 100° F., between about 60° F. and about 100° F., between about 70° F. and about 90° F., between about 70° F. and about 80° F., greater than about 60° F., greater than about 70° F., greater than about 80° F., or any combination or sub-combination thereof.
• Themember100 is any suitable material, including, but not limited to, wood, wood composite, vinyl, polymeric material, stone, ceramics, metal, or a combination thereof. Suitable woods include, but are not limited to, birch, poplar, oak, pine, maple, hardwoods, softwoods, treated wood species, untreated wood species, and combinations thereof. Suitable wood composites include, but are not limited to, medium density fiberboard, high density fiberboard, low density fiberboard, filled polymer composites, wood plastic composites, veneers over different woods or over non-wood or partially wood materials, and recycled or blended materials having cellulosic components. Suitable vinyl compositions include, but are not limited to, polyvinylchloride, luxury vinyl tile, vinyl compositions of vinyl composition tile, and vinyl compositions of vinyl asbestos tile. Suitable polymeric materials include, but are not limited to, poly plastic asphalt tile. Suitable stone materials include, but are not limited to, granite, marble, concrete, and cement. Suitable ceramic materials include, but are not limited to, fired-ceramics. Suitable metal materials include, but are not limited to, steel, aluminum, iron, copper, alloys, and superalloys.
• Themember100 is any suitable product or portion of a product that is subject to the generation of noise through forces being applied to theouter surface104 and/or through expansion and contraction of themember100. In one embodiment, the product is a wood flooring assembly including a plurality of themembers100 engaged to each other. In general, suitable tongue and groove products include, but are not limited to, flooring, sub-flooring, structural floors, exposed floors, cabinets, drawers, ceilings, walls, cubicles, walkways, pavers, roads, bridges, decks, patios, homes, mobile homes, recreational vehicles, boats, airplanes, automobiles, trims, molding, transitions trips, and trucks and truck trailers. Themember100 is capable of being positioned within the product, outside or on the exterior of the product, and/or under other products and/or surfaces. Themember100 has a predetermined thickness or thickness range, for example, between about 0.25 inches and about 1 inch, between about 0.30 inches and about 0.65 inches, between about 0.30 inches and about 0.50 inches, between about 0.35 inches and about 0.40 inches, above about 0.1 inches, between about 0.1 inches and about 0.2 inches, between about 0.1 inches and about 1 inch, or any combination or sub-combination thereof.
• In an embodiment where themember100 is a composite, themember100 includes a substantially homogenous composition, such that interior portions of themember100 and exterior portions of themember100 include substantially the same composition. Exterior portions are capable of including coatings, surface treatments, or other suitable materials. In a further embodiment, themember100 is devoid of embedded waxes and/or similar additives.
• Themember100 includes a predetermined geometry permitting engagement of asecond member100 that is identical in geometry to themember100 or corresponds in geometry to themember100. For example, referring toFIGS. 1 and 2, in one assembly, each of themembers100 includes twocontact surfaces106 extending, for example, in a substantially horizontal direction substantially parallel to theouter surface104. In one embodiment, one or more of the contact surfaces106 are devoid of the sound-reducingblend108 and/or other waxes. The contact surfaces106 extend from each of thetreatment regions102 and form the engagement protrusion103 (seeFIG. 1), such as a tongue, or the engagement recess202 (seeFIG. 2), such as a groove. Alternatively, only one of the contact surfaces106 extends from the treatment region(s)102, three of the contact surfaces106 extend from the treatment region(s)102, or more than three of the contact surfaces106 extend from the treatment region(s)102. In embodiments with more than fourcontact surfaces106, all four of the contact surfaces106, fewer than four of the contact surfaces106, or more than four of the contact surfaces106, extend from the treatment region(s)102.
• Referring toFIGS. 3 and 4, in one assembly, each of themembers100 includes two of the contact surfaces106 extending, for example, in the substantially horizontal direction substantially parallel to thebottom surface302. On each of themembers100, one of the contact surfaces106 extends from thetreatment region102 and forms theengagement protrusion103 and one of the contact surfaces106 extends from thetreatment region102 and forms theengagement recess202.
• Referring toFIGS. 5 and 6, in one embodiment, each of themembers100 includes one of the contact surfaces106 extending, for example, in the substantially horizontal direction substantially parallel to theouter surface104. Referring toFIG. 5, in one embodiment, thecontact surface106 is apart from thetreatment region102 and is between theengagement recess202 and theengagement protrusion103. Referring toFIG. 6, in one embodiment, thecontact surface106 extends from thetreatment region102 and forms a portion of theengagement protrusion103.
• According to an embodiment of the sound-reducing fabrication process, the sound-reducingblend108 is applied to the location(s)107 within thetreatment region102 of themember100. In further embodiments, thetreatment region102 includes the sound-reducingblend108 and extends in or only in the substantially vertical direction with respect to the outer surface104 (seeFIGS. 1,2,5, and6), extends at or only at an inclined direction with respect to the outer surface104 (seeFIGS. 3 and 4), or extends in or only in both the substantially vertical direction and the substantially horizontal direction with respect to the outer surface104 (seeFIGS. 5 and 6).
• In general, although not intending to be bound by theory, noise generated by themember100 is believed to be caused by vertical movement occurring between themembers100 forming the assembly, such as a floor. The vertical movement is based upon force applied from theouter surface104, for example, by an individual walking on the floor. The force from walking is in a diagonal direction (in relation to gravity) and can be broken into a force vector having a horizontal component and a vertical component. The tongue-and-groove features permit slight movement between themembers100 while maintaining a generally stable assembly. The horizontal component of the force vector pushes and pulls the members causing such slight movements. The vertical component of the force vector causes themembers100 to frictionally rub, thereby generating the noise. The sound-reducingblend108 lubricates and/or decreases the friction between themembers100, thereby reducing or eliminating the generation of noise.
• The sound-reducingblend108 provides sound mitigation when applied. In one embodiment, the sound-reducingblend108 includes a soft wax (not shown) and a hard wax (not shown), for example, homogenously mixed, in solution, in suspension, or combinations thereof. For example, in one embodiment, the wax is a plant wax, an animal wax, a synthetic wax, a derivative thereof, or a combination thereof. In a further embodiment, the wax is an epicuticular wax, a candelilla wax, a retamo wax, a sugarcane wax, a carnauba wax, an ouricury wax, a hydrogenated and deodorized soybean oil or plant oils, a lanolin wax, a beeswax, a lignite wax, a paraffin wax, a polyethylene wax, a polypropylene wax, polytetrafluoroethylene wax, a derivative thereof, or a combination thereof. In one embodiment, the sound-reducingblend108 includes hydrogenated soybean oil and/or a hydrogenated metathesis dimer. In one embodiment, the sound-reducingblend108 is substantially devoid of or completely devoid of oil. In one embodiment, the sound-reducingblend108 includes a paraffin. In one embodiment, the sound-reducingblend108 includes or is a biobased material. In one embodiment, the sound-reducingblend108 is solid at room temperature.
• In one embodiment, the sound-reducingblend108 includes, by weight, between about 50%, about 70%, or 100% of a soft and oily wax having a melting point of about 53° C. to 56° C. and a needle penetration of about 35 to about 45 dmm at 25° C.
• In one embodiment, the sound-reducingblend108 includes, by weight, between about 30%, about 50%, or 100% of a hard and slick-to-touch wax having a melting point of about 67° C. to 71° C. and a needle penetration of about 10.0 to about 20.0 dmm at 25° C.
Examples
• A series of trials were conducted with various application positions and compositions. The trials involved having an individual walk on a surface of themember100 in a consistent manner. Evaluating individuals rated noises generated from themember100 to determine the intensity of the noise generated on a scale of 1 to 4 (4 being the highest amount). The same individuals were used for each trial and the ratings between the evaluators were averaged. The individuals had been trained to ignore sounds generated from the shoes or ambient sounds so that they could focus on sound generated by themember100.
• In a control example, no treatment was applied to themember100. In this control, the noise rating was about 1.5 when theouter surface104 of themember100 was walked on.
• In a first example, a treatment was applied to a predetermined location. The treatment was a blend including, by weight, about 50% of the soft and oily wax having a melting point of about 53° C. to 56° C. and a needle penetration of about 35 to about 45 dmm at 25° C. and about 50% of the hard and slick-to-touch wax having a melting point of about 67° C. to 71° C. and a needle penetration of about 10.0 to about 20.0 dmm at 25° C. in this example, the noise rating was between about 1.0 and about 1.5 when theouter surface104 of themember100 was walked on.
• In a second example, a treatment was applied to the predetermined location. The treatment was a blend including, by weight, about 70% of the soft and oily wax having a melting point of about 53° C. to 56° C. and a needle penetration of about 35 to about 45 dmm at 25° C. and about 30% of the hard and slick-to-touch wax having a melting point of about 67° C. to 71° C. and a needle penetration of about 10.0 to about 20.0 dmm at 25° C. In this example, the noise rating was about 1.0 when theouter surface104 of themember100 was walked on.
• In a third example, a treatment was applied to the predetermined location. The treatment was a blend including, by weight, about 50% of the hard and slick-to-touch wax having a melting point of about 67° C. to 71° C. and a needle penetration of about 10.0 to about 20.0 dmm at 25° C. and about 50% of a very hard and slick-to-touch wax having a melting point of about 82° C. to 85° C. and a needle penetration of about 2 dmm at 25° C. In this example, the noise rating was about 1.5 when theouter surface104 of themember100 was walked on.
• In a fourth example, a treatment was applied to the predetermined location. The treatment was the soft and oily wax having a melting point of about 53° C. to 56° C. and a needle penetration of about 35 to about 45 dmm at 25° C. In this example, the noise rating was about 1.0 when theouter surface104 of themember100 was walked on.
• In a fifth example, a treatment was applied to the predetermined location. The treatment was the hard and slick-to-touch wax having a melting point of about 67° C. to 71° C. and a needle penetration of about 10.0 to about 20.0 dmm at 25° C. in this example, the noise rating was about 1.0 when theouter surface104 of themember100 was walked on.
• In a sixth example, a treatment was applied to the predetermined location. The treatment was the very hard and slick-to-touch wax having a melting point of about 82° C. to 85° C. and a needle penetration of about 2 dmm at 25° C. In this example, the noise rating was about 2.0 when theouter surface104 of themember100 was walked on.
• In a seventh example, a treatment was applied to the predetermined location. The treatment was a soft and sticky wax having a melting point of about 74° C. to 78° C. and a needle penetration of about 25 to about 35 dmm at 25° C. In this example, the noise rating was between about 1.5 and about 3.0 when theouter surface104 of themember100 was walked on.
• In an eighth example, a treatment of the soft and sticky wax having a melting point of about 74° C. to 78° C. and a needle penetration of about 25 to about 35 dmm at 25° C. was applied to thecontact surface106 oriented in a horizontal direction with respect to theouter surface104 in the engagement recess202 (seeFIGS. 3 and 4). In this example, the noise rating was at about 3.0 when theouter surface104 of themember100 was walked on.
• In a ninth example, a treatment of the soft and sticky wax having a melting point of about 74° C. to 78° C. and a needle penetration of about 25 to about 35 dmm at 25° C. was applied to a location within thetreatment region102 oriented in an inclined direction with respect to theouter surface104 and bordering the engagement recess202 (seeFIGS. 3 and 4). In this example, the noise rating was at about 1.5 when theouter surface104 of themember100 was walked on.
• While the invention has been described with reference to a preferred embodiment, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out this invention, but that the invention will include all embodiments falling within the scope of the appended claims.

Claims (20)

What is claimed is:

1. A flooring member comprising:

a panel body comprising:

a lower surface;

an upper surface opposite the lower surface;

a first profiled edge extending between the upper and lower surfaces, the first profiled edge comprising a tongue and at least one vertical portion;

a second profiled edge extending between the upper and lower surfaces, the second profiled edge opposite the first profiled edge, the second profiled edge comprising a groove and at least one vertical portion; and

a sound-deadening composition applied to the vertical portion of at least one of the first or second profiled edges, the sound-deadening composition comprising:

a first wax having a melting point between about 53° C. and about 56° C.; and

a second wax having a melting point between about 67° C. and about 71° C.

2. The flooring member ofclaim 1 wherein the vertical portion of each of the first and second profiled edges is substantially perpendicular to the upper surface.

3. The flooring member ofclaim 2 wherein the vertical portion of the first profiled edge is located between the tongue and the upper surface and the vertical portion of the second profiled edge is located between the groove and the upper surface.

4. The flooring member ofclaim 3 wherein the sound-deadening composition is applied to both of the vertical portion of the first profiled edge and the vertical portion of the second profiled edge.

5. The flooring member ofclaim 1 wherein the vertical portion of the first profiled edge is located between the tongue and the upper surface and the vertical portion of the second profiled edge is located between the groove and the upper surface.

6. The flooring member ofclaim 1, wherein the sound-deadening composition is a solution, a mixture, a suspension, or a combination thereof.

7. The flooring member ofclaim 1, wherein the sound-deadening composition is solid at room temperature.

8. The flooring member ofclaim 1, wherein the first wax is present in an amount ranging from about 50 wt. % to about 70 wt. % based on the total weight of the sound-deadening composition.

9. The flooring member ofclaim 1, wherein the second wax is present in an amount ranging from about 30 wt. % to about 50 wt. % based on the total weight of the sound-deadening composition.

10. The flooring member ofclaim 1, wherein the first wax has a needle penetration of between about 35 dmm and about 45 dmm at 25° C.

11. The flooring member ofclaim 1, wherein the second wax has a needle penetration of between about 10 dmm and about 20 dmm at 25° C.

12. A flooring member comprising:

a panel body comprising:

a lower surface;

an upper surface opposite the lower surface;

a first profiled edge extending between the upper and lower surfaces, the first profiled edge comprising a tongue and at least one vertical portion;

a second profiled edge extending between the upper and lower surfaces, the second profiled edge opposite the first profiled edge, the second profiled edge comprising a groove and at least one vertical portion; and

a sound-deadening composition applied to the vertical portion of at least one of the first or second profiled edges, the sound-deadening composition comprising:

a first wax having a melting point between about 82° C. and about 85° C.; and

a second wax having a melting point between about 67° C. and about 71° C.

13. The flooring member ofclaim 12 wherein the vertical portion of each of the first and second profiled edges is substantially perpendicular to the upper surface.

14. The flooring member ofclaim 13 wherein the vertical portion of the first profiled edge is located between the tongue and the upper surface and the vertical portion of the second profiled edge is located between the groove and the upper surface.

15. The flooring member ofclaim 14 wherein the sound-deadening composition is applied to both of the vertical portion of the first profiled edge and the vertical portion of the second profiled edge.

16. The flooring member ofclaim 12 wherein the vertical portion of the first profiled edge is located between the tongue and the upper surface and the vertical portion of the second profiled edge is located between the groove and the upper surface.

17. The flooring member ofclaim 16, wherein the first wax is at a concentration, by weight, of about 50 percent and the second wax is at a concentration, by weight, of about 50 percent.

18. The flooring member ofclaim 16, further comprising a contact surface extending from the treatment region, the contact surface being substantially devoid of the sound-reducing blend.

19. The flooring member ofclaim 16, wherein the first wax has a needle penetration of about 2 dmm at 25° C.

20. A flooring member comprising:

a panel body comprising:

a lower surface;

an upper surface opposite the lower surface;

a first profiled edge extending between the upper and lower surfaces, the first profiled edge comprising a tongue and at least one vertical portion;

a second profiled edge extending between the upper and lower surfaces, the second profiled edge opposite the first profiled edge, the second profiled edge comprising a groove and at least one vertical portion; and

a sound-deadening composition applied to the vertical portion of at least one of the first or second profiled edges, the sound-deadening composition comprising:

a first wax having a first needle penetration of about 10 dmm;

a second wax having a second needle penetration of about 20 dmm.

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