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 
       [0001]    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 
       [0002]    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 
       [0003]    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. 
         [0004]    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. 
         [0005]    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 
       [0006]    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. 
         [0007]    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. 
         [0008]    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. 
         [0009]    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 
         [0010]    The present invention will become more fully understood from the detailed description and the accompanying drawings, wherein: 
           [0011]      FIG. 1  illustrates an exemplary tongue and groove flooring member having an engagement protrusion according to the disclosure. 
           [0012]      FIG. 2  illustrates an exemplary tongue and groove flooring member having an engagement recess corresponding to the flooring member of  FIG. 1  according to the disclosure. 
           [0013]      FIG. 3  illustrates an exemplary tongue and groove flooring member having an engagement protrusion and an engagement recess according to the disclosure. 
           [0014]      FIG. 4  illustrates an exemplary tongue and groove flooring member having an engagement protrusion and an engagement recess corresponding to the flooring member of  FIG. 3  according to the disclosure. 
           [0015]      FIG. 5  illustrates an exemplary tongue and groove flooring member having an engagement protrusion and an engagement recess according to the disclosure. 
           [0016]      FIG. 6  illustrates an exemplary tongue and groove flooring member having an engagement protrusion and an engagement recess corresponding to the flooring member of  FIG. 5  according to the disclosure. 
       
    
    
       [0017]    Wherever possible, the same reference numbers will be used throughout the drawings to represent the same parts. 
       DETAILED DESCRIPTION 
       [0018]    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. 
         [0019]    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. 
         [0020]    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. 
         [0021]    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. 
         [0022]    Referring to  FIG. 1 , a sound-reducing tongue and groove member  100  includes a treatment region  102  extending from an outer surface  104 , such as a walking surface, a covered outer surface, an uncovered outer surface, a finished outer surface, and/or an unfinished outer surface of the member  100 . Additionally or alternatively, in one embodiment, the treatment region  102  extends from a lower surface  105  of the member  100 , is positioned on an engagement protrusion  103 , is positioned in an engagement recess  202  (see  FIG. 2 ), or combinations thereof. 
         [0023]    The member  100  further includes a sound-reducing blend  108  positioned on one or more locations  107  within the treatment region  102 . The positioning of the sound-reducing blend  108  provides sound mitigation, which may reduce or eliminate noise generated from walking on the outer surface  104 , which may reduce or eliminate noise generated from expansion and contraction of the member  100 , which may reduce or eliminate noise generated from other forces applied to the member  100 , or combinations thereof. 
         [0024]    In one embodiment, the sound mitigation reduces or eliminates noise even when the member  100  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 the member  100  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. 
         [0025]    The member  100  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. 
         [0026]    The member  100  is any suitable product or portion of a product that is subject to the generation of noise through forces being applied to the outer surface  104  and/or through expansion and contraction of the member  100 . In one embodiment, the product is a wood flooring assembly including a plurality of the members  100  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. The member  100  is capable of being positioned within the product, outside or on the exterior of the product, and/or under other products and/or surfaces. The member  100  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. 
         [0027]    In an embodiment where the member  100  is a composite, the member  100  includes a substantially homogenous composition, such that interior portions of the member  100  and exterior portions of the member  100  include substantially the same composition. Exterior portions are capable of including coatings, surface treatments, or other suitable materials. In a further embodiment, the member  100  is devoid of embedded waxes and/or similar additives. 
         [0028]    The member  100  includes a predetermined geometry permitting engagement of a second member  100  that is identical in geometry to the member  100  or corresponds in geometry to the member  100 . For example, referring to  FIGS. 1 and 2 , in one assembly, each of the members  100  includes two contact surfaces  106  extending, for example, in a substantially horizontal direction substantially parallel to the outer surface  104 . In one embodiment, one or more of the contact surfaces  106  are devoid of the sound-reducing blend  108  and/or other waxes. The contact surfaces  106  extend from each of the treatment regions  102  and form the engagement protrusion  103  (see  FIG. 1 ), such as a tongue, or the engagement recess  202  (see  FIG. 2 ), such as a groove. Alternatively, only one of the contact surfaces  106  extends from the treatment region(s)  102 , three of the contact surfaces  106  extend from the treatment region(s)  102 , or more than three of the contact surfaces  106  extend from the treatment region(s)  102 . In embodiments with more than four contact surfaces  106 , all four of the contact surfaces  106 , fewer than four of the contact surfaces  106 , or more than four of the contact surfaces  106 , extend from the treatment region(s)  102 . 
         [0029]    Referring to  FIGS. 3 and 4 , in one assembly, each of the members  100  includes two of the contact surfaces  106  extending, for example, in the substantially horizontal direction substantially parallel to the bottom surface  302 . On each of the members  100 , one of the contact surfaces  106  extends from the treatment region  102  and forms the engagement protrusion  103  and one of the contact surfaces  106  extends from the treatment region  102  and forms the engagement recess  202 . 
         [0030]    Referring to  FIGS. 5 and 6 , in one embodiment, each of the members  100  includes one of the contact surfaces  106  extending, for example, in the substantially horizontal direction substantially parallel to the outer surface  104 . Referring to  FIG. 5 , in one embodiment, the contact surface  106  is apart from the treatment region  102  and is between the engagement recess  202  and the engagement protrusion  103 . Referring to  FIG. 6 , in one embodiment, the contact surface  106  extends from the treatment region  102  and forms a portion of the engagement protrusion  103 . 
         [0031]    According to an embodiment of the sound-reducing fabrication process, the sound-reducing blend  108  is applied to the location(s)  107  within the treatment region  102  of the member  100 . In further embodiments, the treatment region  102  includes the sound-reducing blend  108  and extends in or only in the substantially vertical direction with respect to the outer surface  104  (see  FIGS. 1 ,  2 ,  5 , and  6 ), extends at or only at an inclined direction with respect to the outer surface  104  (see  FIGS. 3 and 4 ), or extends in or only in both the substantially vertical direction and the substantially horizontal direction with respect to the outer surface  104  (see  FIGS. 5 and 6 ). 
         [0032]    In general, although not intending to be bound by theory, noise generated by the member  100  is believed to be caused by vertical movement occurring between the members  100  forming the assembly, such as a floor. The vertical movement is based upon force applied from the outer surface  104 , 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 the members  100  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 the members  100  to frictionally rub, thereby generating the noise. The sound-reducing blend  108  lubricates and/or decreases the friction between the members  100 , thereby reducing or eliminating the generation of noise. 
         [0033]    The sound-reducing blend  108  provides sound mitigation when applied. In one embodiment, the sound-reducing blend  108  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-reducing blend  108  includes hydrogenated soybean oil and/or a hydrogenated metathesis dimer. In one embodiment, the sound-reducing blend  108  is substantially devoid of or completely devoid of oil. In one embodiment, the sound-reducing blend  108  includes a paraffin. In one embodiment, the sound-reducing blend  108  includes or is a biobased material. In one embodiment, the sound-reducing blend  108  is solid at room temperature. 
         [0034]    In one embodiment, the sound-reducing blend  108  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. 
         [0035]    In one embodiment, the sound-reducing blend  108  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 
       [0036]    A series of trials were conducted with various application positions and compositions. The trials involved having an individual walk on a surface of the member  100  in a consistent manner. Evaluating individuals rated noises generated from the member  100  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 the member  100 . 
         [0037]    In a control example, no treatment was applied to the member  100 . In this control, the noise rating was about 1.5 when the outer surface  104  of the member  100  was walked on. 
         [0038]    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 the outer surface  104  of the member  100  was walked on. 
         [0039]    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 the outer surface  104  of the member  100  was walked on. 
         [0040]    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 the outer surface  104  of the member  100  was walked on. 
         [0041]    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 the outer surface  104  of the member  100  was walked on. 
         [0042]    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 the outer surface  104  of the member  100  was walked on. 
         [0043]    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 the outer surface  104  of the member  100  was walked on. 
         [0044]    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 the outer surface  104  of the member  100  was walked on. 
         [0045]    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 the contact surface  106  oriented in a horizontal direction with respect to the outer surface  104  in the engagement recess  202  (see  FIGS. 3 and 4 ). In this example, the noise rating was at about 3.0 when the outer surface  104  of the member  100  was walked on. 
         [0046]    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 the treatment region  102  oriented in an inclined direction with respect to the outer surface  104  and bordering the engagement recess  202  (see  FIGS. 3 and 4 ). In this example, the noise rating was at about 1.5 when the outer surface  104  of the member  100  was walked on. 
         [0047]    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.