Sound attenuating laminate materials

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 method for producing such products are provided. In 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.

1 . A sound attenuating laminated panel, having a laminate structure comprising a plurality of layers, wherein one or more layers comprising said laminate structure, has been treated with an elastomeric coating, film or material, so as to form a treated layer, in order to reduce the noise generated by said panel. 
     
     
         2 . A sound attenuating laminated panel as claimed in  claim 1 , wherein said laminated panel is a floor covering, and in particular, a floor panel. 
     
     
         3 . A sound attenuating laminated panel as claimed in  claim 1 , wherein said laminated panel comprises a decorative layer, a core layer, a backing layer, and optionally, a wear layer. 
     
     
         4 . A sound attenuating laminated panel as claimed in  claim 1 , wherein said treated layer has been formed by pre-impregnating a selected layer, with said elastomeric coating, film or material prior to production of said laminated panel. 
     
     
         5 . A sound attenuating laminated panel as claimed in  claim 1 , wherein said elastomeric coating, film or material is a liquid, solid or film. 
     
     
         6 . A sound attenuating laminated panel as claimed in  claim 1  wherein said elastomeric coating, film or material comprises a natural or synthetic resin with elastomeric properties, applied to the paper layers and/or the wood core. 
     
     
         7 . A sound attenuating laminated panel as claimed in  claim 5 , wherein said elastomeric coating, film or material is a one component or multi-component, thermoset, thermoplastic (TPE), solution polymer or water-based or solvent-based dispersion and latexes. 
     
     
         8 . A sound attenuating laminated panel as claimed in  claim 7 , wherein said elastomeric coating, film or material is based on polyethylene (PE) of all grades (including LLDPE, LDPE, MDPE, HDPE); Polyurethane; Polypropylene; Ethylene vinyl acetate;
 Ethylene vinyl alcohol; Polyester; Polyolefin (TPO); modified Melamine-based thermoset resins; ESI—ethylene styrene interpolymer or any of the styrene acrylic copolymers; rubber based materials, NBR (nitrile Butadiene), SBR (styrene butadiene), CR (chloroprene), silicone, fluorocarbon, acrylamide, epichlorohydrin, carboxylated, natural and syntheric latexes.   
     
     
         9 . A sound attenuating laminated panel as claimed in  claim 1 , wherein said elastomeric coating has a thickness from  1  micron to  3  mm. 
     
     
         10 . A sound attenuating laminated panel as claimed in  claim 1 , wherein elastomeric coating is used in the form of a water-based dispersion or a water-based or solvent based solution polymer. 
     
     
         11 - 22 . (canceled)