Multi-layer acoustical flooring tile and method of manufacture

Abstract

An acoustical vinyl tile having an integral acoustical layer is disclosed. The vinyl tile includes a vinyl portion and an acoustical portion. The acoustical portion comprises a plurality of individual layers, the combination of which is customized to the particular sub-floor structure to which the tile will be adhered or overlain. The individual layers of the acoustical portion can include any of a variety of combinations of rubber, cork, polyurethane foam, and the like. The resulting tile meets one or more of ASTM E 2179, ASTM E 989, ASTM E 492, and ASTM E1007 IIC sound requirements. A method of designing the disclosed tile to suit a particular flooring application is also disclosed. Other embodiments are described and claimed.

What is claimed is: 
     
         1 . A vinyl tile, comprising:
 a vinyl portion; and   an acoustical portion disposed adjacent the vinyl portion, the acoustical portion comprising a plurality of individual sub-layers;   wherein first and second sub-layers of the plurality of individual sub-layers comprise material compositions that are different from each other.   
     
     
         2 . The vinyl tile of  claim 1 , wherein the first and second sub-layers have thicknesses that are different from each other. 
     
     
         3 . The vinyl tile of  claim 1 , wherein the first and second sub-layers have thicknesses that are the same. 
     
     
         4 . The vinyl tile of  claim 1 , wherein the first sub-layer comprises rubber and the second sub-layer comprises a mixture of rubber and cork. 
     
     
         5 . The vinyl tile of  claim 1 , wherein the first sub-layer comprises a mixture of rubber and cork and the second sub-layer comprises rubber. 
     
     
         6 . The vinyl tile of  claim 1 , wherein the plurality of individual sub-layers comprise three individual sub-layers. 
     
     
         7 . The vinyl tile of  claim 7 , wherein the three individual sub-layers each comprises a material composition that is different from the other individual sub-layers. 
     
     
         8 . The vinyl tile of  claim 1 , wherein the plurality of individual sub-layers comprise greater than three individual sub-layers. 
     
     
         9 . The vinyl tile of  claim 1 , wherein the plurality of individual sub-layers comprise materials selected from the list consisting of rubber, a mixture of cork and rubber, a mixture of rubber and polyurethane foam (PU), a mixture of PU foam and cork, and combinations thereof. 
     
     
         10 . A method of designing a vinyl tile to suit a particular flooring application, comprising:
 determining a type of a sub-floor system that includes a floor/ceiling assembly to which a vinyl tile will be applied;   selecting an acoustical portion of said vinyl tile to include “n” sub-layers, where “n” is a number greater than  1  and is based on the type of said sub-floor;   selecting a material composition for each of said “n” sub-layers, where the material composition for each of said “n” sub-layers is based on the type of said sub-floor system that includes the floor/ceiling assembly and the number “n” of sub-layers.   
     
     
         11 . The method of  claim 10 , further comprising selecting a thickness for each of said “n” sub-layers, where the thickness for each of said “n” sub-layers is based on the type of said sub-floor system that includes the floor/ceiling assembly, the number “n” of sub-layers, and the material composition of each of said “n” sub-layers. 
     
     
         12 . The method of  claim 11 , further comprising bonding the “n” individual sub-layers together to form said acoustical portion. 
     
     
         13 . The method of  claim 12 , further comprising bonding the acoustical portion to a vinyl tile portion of said vinyl tile. 
     
     
         14 . The method of  claim 13 , further comprising applying the vinyl tile to the sub-floor system that includes the floor/ceiling assembly. 
     
     
         15 . A vinyl tile, comprising:
 a vinyl portion; and   an acoustical portion comprising a plurality of individual sub-layers;   wherein first and second sub-layers of the plurality individual sub-layers comprise material compositions that are different from each other.   
     
     
         16 . The vinyl tile of  claim 15 , wherein the first and second sub-layers have thicknesses that are different from each other. 
     
     
         17 . The vinyl tile of  claim 15 , wherein the first and second sub-layers have thicknesses that are the same. 
     
     
         18 . The vinyl tile of  claim 15 , wherein the first sub-layer comprises rubber and the second sub-layer comprises a mixture of rubber and cork. 
     
     
         19 . The vinyl tile of  claim 15 , wherein the first sub-layer comprises a mixture of rubber and cork and the second sub-layer comprises rubber. 
     
     
         20 . The vinyl tile of  claim 15 , wherein the plurality of individual sub-layers comprise three individual sub-layers. 
     
     
         21 . The vinyl tile of  claim 20 , wherein the three individual sub-layers each comprises a material composition that is different from the other individual sub-layers. 
     
     
         22 . The vinyl tile of  claim 15 , wherein the plurality of individual sub-layers comprise greater than three individual sub-layers. 
     
     
         23 . The vinyl tile of  claim 15 , wherein the plurality of individual sub-layers comprise materials selected from the list consisting of rubber, a mixture of cork and rubber, a mixture of rubber and polyurethane foam (PU), a mixture of PU foam and cork, and combinations thereof.