# US 2014/0196982 A1 · Sound attenuating laminate materials

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- Number: US 2014/0196982 A1
- Document ID: US20140196982A1
- Status: Published application
- Kind: A1
- Application number: 14/218,032
- Filed: 2014-03-18
- Published: 2014-07-17
- Earliest claimed: 2011-09-06
- Inventors: Robert N. Clausi; Salvatore Anthony Diloreto
- Web page: https://patentgrep.com/patent/US20140196982A1

## CPC

- E04B 1/84: Sound-absorbing elements
- B32B 21/02: {the layer being formed} of fibres, chips, or particles {, e.g. MDF, HDF, OSB, chipboard, particle board, hardboard}
- B32B 21/045: {of natural rubber or synthetic rubber}
- B32B 21/06: of paper or cardboard
- B32B 21/08: of synthetic resin
- B32B 21/14: comprising wood board or veneer
- B32B 25/06: of paper or cardboard
- B32B 25/12: comprising natural rubber
- B32B 25/14: comprising {synthetic rubber copolymers (B32B25/18 and B32B25/20 take precedence)}
- B32B 27/10: of paper or cardboard
- B32B 27/205: {the fillers creating voids or cavities, e.g. by stretching}
- B32B 27/302: {comprising aromatic vinyl (co)polymers, e.g. styrenic (co)polymers}
- B32B 27/304: {comprising vinyl halide (co)polymers, e.g. PVC, PVDC, PVF, PVDF}
- B32B 27/306: {comprising vinyl acetate or vinyl alcohol (co)polymers}
- B32B 27/308: {comprising acrylic (co)polymers}
- B32B 27/32: comprising polyolefins {(comprising vinyl (co)polymers or acrylic (co)polymers B32B27/30)}
- B32B 27/36: comprising polyesters
- B32B 27/40: comprising polyurethanes
- B32B 27/42: comprising condensation resins of aldehydes, e.g. with phenols, ureas or melamines
- B44C 5/04: Ornamental plaques, e.g. decorative panels, decorative veneers
- E04F 15/02: Flooring or floor layers composed of a number of similar elements (of webs E04F15/16)
- E04F 15/102: {of fibrous or chipped materials, e.g. bonded with synthetic resins}
- E04F 15/107: {composed of several layers, e.g. sandwich panels (layered products in general B32B; producing decorative panels or veneers B44C5/04)}
- E04F 15/206: {Layered panels for sound insulation}
- B32B 2255/08: on wood layer
- B32B 2255/12: on paper layer
- B32B 2255/26: Polymeric coating
- B32B 2260/028: Paper layer
- B32B 2260/046: Synthetic resin
- B32B 2264/02: Synthetic macromolecular particles
- B32B 2307/10: having particular acoustical properties
- B32B 2307/412: Transparent
- B32B 2307/536: Hardness
- B32B 2307/546: Flexural strength; Flexion stiffness
- B32B 2307/554: Wear resistance
- B32B 2307/75: Printability
- B32B 2471/00: Floor coverings (B32B2419/04 takes precedence)
- B32B 2479/00: Furniture
- B32B 2607/00: Walls, panels
- E04F 2290/042: with a facing or top layer for sound insulation
- E04F 2290/043: with a bottom layer for sound insulation
- Y10T 156/10: Methods of surface bonding and/or assembly therefor
- E04B: GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS (border constructions of opening in walls, floors or ceilings E06B1/00; {electromagnetic shielding H05K9/0001})
- B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B44C: PRODUCING DECORATIVE EFFECTS (processes for applying liquids or other fluent materials to surfaces, in general B05D; shaping of plastics or substances in a plastic state B29C; printing processes to produce transfer pictures B41M3/12; thermographic duplication or marking methods B41M5/00); MOSAICS; TARSIA WORK (imitation of mosaic or tarsia work patterns B44F11/04); PAPERHANGING {(labels G09F; multi-step processes for making paper labels or tags B31D1/02)}
- E04F: FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS (windows, doors E06B)
- Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION

## Abstract

Sound absorbing or attenuating laminate flooring materials are provided, which are directed to be used in the production of floor covering, floor panels, furniture panels, cabinets, counter-tops and wall panels. As well, the methods for producing such products are provided. hi particular, abrasion resistant panels, with a laminated structure, created by forming an assembly which consists of laminating a heat-activated resin impregnated paper wear layer, a decorative layer with printed graphics or a wood veneer decorative layer, a medium density (MDF) or high-density (HDF) natural fiber-based core and a resin impregnated paper balancing layer. To achieve sound absorbing and/or attenuating properties, any or all paper layers may be pre coated with an additional flexible elastomeric coating, film or material prior to assembly of the panel, or the natural fiber core panel may be coated with a flexible elastomeric coating, film or material prior to assembly with the papers. The flexible elastomeric coating, film or material acts to absorb, reduce, and/or ameliorate the sound transmissions inherent in laminated panels.

## Claims

### Claim at position 1

1-22. (canceled)

### Claim 23

A sound attenuating laminated panel comprising:
a core;
a layer positioned on at least one side of the core, wherein the layer comprises an elastomeric material in the form of a film or a coating; and
wherein said elastomeric material comprises at least one material selected from the group consisting of polyurethane, styrene acrylic copolymers, rubber based materials selected from NBR (nitrile butadiene), SBR (styrene butadiene), and CR (chloroprene), and natural or synthetic rubber based materials.

### Claim 24 (depends on 23)

The panel of claim 23, wherein the core is elastomeric.

### Claim 25 (depends on 23)

The panel of claim 23, wherein the material is a film.

### Claim 26 (depends on 25)

The panel of claim 25, wherein the film comprises at least one of a printed layer and a wear layer containing wear particles.

### Claim 27 (depends on 25)

The panel of claim 25, wherein the film comprises a decorative print thereon.

### Claim 28 (depends on 23)

The panel of claim 23, wherein the layer consists of at least one material selected from the group consisting of polyurethane, styrene acrylic copolymers, rubber based materials selected from NBR (nitrile butadiene), SBR (styrene butadiene), and CR (chloroprene), and natural or synthetic rubber based materials.

### Claim 29 (depends on 23)

The panel of claim 23, wherein the panel comprises a decoration printed thereon.

### Claim 30 (depends on 23)

The panel of claim 23, wherein the core is one selected from the group consisting of fiberboard and particleboard.

### Claim 31

A process for the production of a sound attenuating laminated panel comprising:
providing a core;
applying a layer of an elastomeric material in the form of a film or a coating to the core to form a laminated assembly, wherein said elastomeric material comprises at least one material selected from the group consisting of polyurethane, styrene acrylic copolymers, rubber based materials selected from NBR (nitrile butadiene), SBR (styrene butadiene), and CR (chloroprene), and natural or synthetic rubber based materials; and
compressing the laminated assembly under heat.

### Claim 32 (depends on 31)

The panel of claim 31, wherein the core is elastomeric.

### Claim 33 (depends on 31)

The panel of claim 31, wherein the material is a film.

### Claim 34 (depends on 33)

The panel of claim 33, wherein the film comprises at least one of a printed layer and a wear layer containing wear particles.

### Claim 35 (depends on 33)

The panel of claim 33, wherein the film comprises a decorative print thereon.

### Claim 36 (depends on 31)

The panel of claim 31, wherein the layer consists of at least one material selected from the group consisting of polyurethane, styrene acrylic copolymers, rubber based materials selected from NBR (nitrile butadiene), SBR (styrene butadiene), and CR (chloroprene), and natural or synthetic rubber based materials.

### Claim 37 (depends on 31)

The panel of claim 31, wherein the panel comprises a decoration printed thereon.

### Claim 38 (depends on 31)

The panel of claim 31, wherein the core is one selected from the group consisting of fiberboard and particleboard.