# US 7,861,488 B2 · Corrugated decking flooring system > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 7,861,488 B2 - Document ID: US7861488B2 - Status: Granted - Kind: B2 - Application number: 12/126,537 - Filed: 2008-05-23 - Published: 2008-11-27 - Granted: 2011-01-04 - Earliest claimed: 2007-05-23 - Assignees: Maxxon Corporation; Colbond B.V. - Inventors: Patrick Henry Giles; Clarence Curtis McCorsley, III - Web page: https://patentgrep.com/patent/US7861488B2 ## CPC - E04F 15/20: for sound insulation - E04B 5/02: Load-carrying floor structures formed substantially of prefabricated units (E04B5/43 - E04B5/48 take precedence) - E04B 5/40: with metal form-slabs - E04F 15/06: of metal, whether or not in combination with other material (gratings as building elements E04C2/42 {; of elements with a metal upper layer; E04F15/02405 takes precedence; metal treads E04F11/112}) - E04F 15/203: {Separately-laid layers for sound insulation} - Y10T 156/10: Methods of surface bonding and/or assembly therefor - E04F: FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS (windows, doors E06B) - 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}) - Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION ## Abstract The invention includes a corrugated decking flooring system. The corrugated decking flooring system can include a corrugated deck having at least two flutes and a trough between the flutes. A sound insulation layer generally conformal with both the flutes and the troughs of the corrugated deck can be provided. An underlayment layer can be provided over the sound insulation layer. ## Claims ### Claim 1 A sound insulation layer for a corrugated decking flooring system, comprising: a backing layer; and a voluminous core attached to the backing layer, the voluminous core including alternating flute resting portions and trough resting portions, the flute resting portion adapted to rest on a flute of a corrugated deck and the trough resting portion adapted to rest in a trough of the corrugated deck, the flute resting portion having a thickness such that the backing layer rests at a position above a high point of the flute when the sound insulation layer is positioned on the corrugated deck, wherein the flute resting portion includes a plurality of relatively small recesses formed of fused entangled filaments and the trough resting portion includes a plurality of relatively large recesses formed of fused entangled filaments, the relatively small recesses and relatively large recesses each having plateau bottoms residing in a same plane. ### Claim 2 (depends on 1) The sound insulation layer for a corrugated decking flooring system of claim 1, wherein the corrugated decking comprises steel. ### Claim 3 (depends on 1) The sound insulation layer for a corrugated decking flooring system of claim 1, wherein the flutes are spaced about 2.5 inches (about 6.35 cm) from center to center and have a depth of about 9/16 inch (about 1.43 cm). ### Claim 4 (depends on 1) The sound insulation layer for a corrugated decking flooring system of claim 1, wherein the corrugated deck is supported by a joist. ### Claim 5 (depends on 4) The sound insulation layer for a corrugated decking flooring system of claim 4, wherein the joist comprises steel. ### Claim 6 (depends on 1) The sound insulation layer for a corrugated decking flooring system of claim 1, wherein the voluminous core comprises a plurality of fused entangled filaments. ### Claim 7 (depends on 1) The sound insulation layer for a corrugated decking flooring system of claim 1, wherein the voluminous core comprises a polymer. ### Claim 8 (depends on 1) The sound insulation layer for a corrugated decking flooring system of claim 1, wherein the voluminous core comprises nylon. ### Claim 9 (depends on 1) The sound insulation layer for a corrugated decking flooring system of claim 1, wherein the flute resting portion includes a plurality of fused entangled filaments having a first average diameter and the trough resting portion includes a plurality of fused entangled filaments having a second average diameter, the second average diameter being greater than the first average diameter. ### Claim 10 (depends on 1) The sound insulation layer for a corrugated decking flooring system of claim 1, wherein the flute resting portion includes a plurality of fused entangled filaments having a generally corrugated shape, the corrugations proceeding in a first direction, and the trough resting portion having a longitudinal axis, the longitudinal axis being generally normal to the first direction. ### Claim 11 (depends on 1) The sound insulation layer for a corrugated decking flooring system of claim 1, wherein one or more of the plurality of relatively large recesses of the trough resting portion are separated by relatively small recesses. ### Claim 12 (depends on 1) The sound insulation layer for a corrugated decking flooring system of claim 1, wherein the backing layer comprises a nonwoven fabric. ### Claim 13 (depends on 12) The sound insulation layer for a corrugated decking flooring system of claim 12, wherein the nonwoven fabric comprises polyester. ### Claim 14 (depends on 1) The sound insulation layer for a corrugated decking flooring system of claim 1, wherein the sound insulation layer comprises a voluminous core attached to a backing layer, the backing layer suitable for being in apposition to an underlayment layer. ### Claim 15 (depends on 14) The sound insulation layer for a corrugated decking flooring system of claim 14, wherein the underlayment layer comprises gypsum. ### Claim 16 (depends on 14) The sound insulation layer for a corrugated decking flooring system of claim 14, wherein the underlayment layer has a thickness of at least about 1 inch. ### Claim 17 A method of making a sound insulation layer for a corrugated decking flooring system, the method comprising: providing a backing layer; and attaching a voluminous core to the backing layer, the voluminous core including alternating flute resting portions and trough resting portions, the flute resting portion adapted to rest on a flute of a corrugated deck, and the trough resting portion adapted to rest in a trough of the corrugated deck, the flute resting portion having a thickness such that the backing layer rests at a position above a high point of the flute when the sound insulation layer is positioned on the corrugated deck, wherein the flute resting portion includes a plurality of relatively small recesses formed of fused entangled filaments and the trough resting portion includes a plurality of relatively large recesses formed of fused entangled filaments, the relatively small recesses and relatively large recesses each having plateau bottoms residing in a same plane. ### Claim 18 A method of installing a sound insulation layer for a corrugated decking flooring system, the method comprising: placing the sound insulation layer in apposition to a corrugated deck, the sound insulation layer having a backing layer and a voluminous core attached to the backing layer, the voluminous core including alternating flute resting portions and trough resting portions, wherein the flute resting portion is placed on a flute of the corrugated deck and the trough resting portion is placed in a trough of the corrugated deck, the flute resting portion having a thickness such that the backing layer rests at a position above a high point of the flute, wherein the flute resting portion includes a plurality of relatively small recesses formed of fused entangled filaments and the trough resting portion includes a plurality of relatively large recesses formed of fused entangled filaments, the relatively small recesses and relatively large recesses each having plateau bottoms residing in a same plane.