Corrugated decking flooring system

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.

2. The sound insulation layer for a corrugated decking flooring system of claim 1 , wherein the corrugated decking comprises steel.

3. 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).

4. The sound insulation layer for a corrugated decking flooring system of claim 1 , wherein the corrugated deck is supported by a joist.

5. The sound insulation layer for a corrugated decking flooring system of claim 4 , wherein the joist comprises steel.

6. The sound insulation layer for a corrugated decking flooring system of claim 1 , wherein the voluminous core comprises a plurality of fused entangled filaments.

7. The sound insulation layer for a corrugated decking flooring system of claim 1 , wherein the voluminous core comprises a polymer.

8. The sound insulation layer for a corrugated decking flooring system of claim 1 , wherein the voluminous core comprises nylon.

9. 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.

10. 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.

11. 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.

12. The sound insulation layer for a corrugated decking flooring system of claim 1 , wherein the backing layer comprises a nonwoven fabric.

13. The sound insulation layer for a corrugated decking flooring system of claim 12 , wherein the nonwoven fabric comprises polyester.

14. 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.

15. The sound insulation layer for a corrugated decking flooring system of claim 14 , wherein the underlayment layer comprises gypsum.

16. 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.

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.

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.