CH718816B1 - Kit for obtaining a layer of building soil. - Google Patents

Abstract

The subject of the invention is a kit for obtaining a layer of building floor, comprising: – a component A which is a powder mixture comprising a hydraulic binder and aggregates, including rubber powder, and – a component B which is an aqueous dispersion comprising a dispersed organic phase comprising a polymer chosen from acrylates and styrene-acrylates or a mixture of two or more of these polymers, and optionally tackifiers and/or plasticizers, the glass transition temperature of the phase consisting of said polymer or mixture of polymers and any tackifiers and/or plasticizers being less than or equal to -5°C.

Description

[0001] The invention relates to the field of building floors, in particular for residential, commercial, industrial or tertiary use.

[0002] These are most often interior floors (located inside the building), but they can also be exterior floors (part of the building but located outside it, such as the floors of balconies or terraces).

[0003] The layers of floors, in particular interiors, are layers generally deposited above a floor substrate, such as a slab or a screed, and under a floor finishing covering (for example tiles, a parquet floor, a carpet, etc.). The floor layers can have several alternative or cumulative functions: they can be used in particular to fill a thickness, to fix the finishing floor covering (for example gluing tiles), to ensure waterproofing, or even to dampen the noise of the floor. 'impact. The soil layers must also meet strong requirements in terms of mechanical resistance (in particular in terms of resistance to compression, bending, wear or impact), so as to resist the stresses exerted by people, furniture etc...

[0004] The ground layers are frequently based on cementitious materials which, due to their rigid and dense nature, are known to transmit impact noise, in any case when they are applied to admissible thicknesses in the range of construction of buildings.

[0005] An aim of the invention is to propose a mortar-based floor layer comprising a hydraulic binder having in themselves, therefore without requiring the addition of an acoustic underlay, acoustic properties, in particular in terms of impact sound insulation.

[0006] For this purpose, the subject of the invention is a kit for obtaining a layer of building floor, comprising: – a component A which is a powder mixture comprising a hydraulic binder and aggregates, including rubber powder, and – a component B which is an aqueous dispersion comprising a dispersed organic phase comprising a polymer chosen from acrylates and styrene-acrylates or a mixture of two or more of these polymers, and optionally tackifiers and/or plasticizers, the glass transition temperature of the phase consisting of said polymer or mixture of polymers and any tackifiers and/or plasticizers being less than or equal to -5°C.

Another object of the invention is a process for obtaining a layer of building floor, in which components A and B of the kit are mixed to form a paste, then said paste is applied to an element of said ground, in particular on a slab, a screed or a floor surface to be restored.

[0008] Another object of the invention is also a layer of building floor made of hardened mortar comprising at least one hydraulic binder and aggregates, said hardened mortar having, at a temperature of 20°C and for at least one frequency included between 100 and 1000 Hz, a dynamic shear modulus G' of at most 70 MPa and a loss factor tanδ of at least 0.30. The soil layer is obtained by the process of the invention.

[0009] The hardened mortar preferably comprises at least one polymer, in particular chosen from acrylates and styrene-acrylates.

The hardened mortar floor layer is preferably obtained from the kit of the invention and/or by the method of the invention. Thus, the following details concerning the composition of the kit preferably also apply to the layer of soil according to the invention, in the sense that the ingredients of one or other of the components of the kit will be found in the layer of soil. .

[0011] In the present text, the contents indicated are always weight contents. A content of a constituent in a given component or product is expressed in relation to the weight, respectively, of this component or this product.

Component A

[0012] Component A is a powdery mixture, in particular of the dry mortar type ready to mix.

[0013] The hydraulic binder of component A or of the soil layer is preferably chosen from Portland cements, aluminous cements, sulphoaluminous cements, hydrated lime, crushed granulated blast furnace slag, fly ash and mixtures. two or more of these binders. Portland cements cover type CEM I and CEM II cements as defined by standard EN 197-1. A CEM I cement comprises at least 95% clinker while a CEM II cement comprises at least 65% clinker and at most 35% blast furnace slag, silica fume, pozzolan, fly ash, calcined shale and/or limestone.

[0014] The aggregates of component A or of the soil layer are preferably chosen from siliceous and/or carbonated aggregates, in particular silica sands, crushed limestones and dolomites. The aggregates may also include lightweight aggregates chosen from perlite, vermiculite, expanded glass beads, expanded polystyrene beads, cenospheres, expanded silicates, aerogels and mixtures thereof.

[0015] In order to improve the acoustic properties, component A comprises rubber powder, in particular in a weight content of at least 5% by weight, in particular between 7 and 20%, relative to the weight of the component. A. This powder is part of the aggregates. The soil layer therefore preferably comprises rubber powder, in particular in a content of at least 1% by weight, in particular between 2 and 10% by weight, relative to the weight of the soil layer. The rubber powder preferably has a particle size distribution by volume such that the D50 is between 80 and 160 µm, in particular between 100 and 150 µm. The D90 is preferably less than 250 µm, in particular less than 180 µm.

[0016] The total content of hydraulic binder in component A is preferably between 5 and 30% by weight. The total content of aggregates in component A is preferably between 50 and 90% by weight. These contents are indicated in relation to the weight of component A.

[0017] The total content of hydraulic binder in the hardened mortar of the soil layer is preferably between 2 and 20%, in particular between 3 and 15% by weight. The total content of aggregates in the hardened mortar of the soil layer is preferably between 15 and 60%, in particular between 20 and 50% by weight. These contents are indicated in relation to the weight of the soil layer.

Component B

[0018] By acrylate polymer is meant in particular a polymer obtained from monomers chosen from acrylic acid, acrylate salts and/or acrylate esters. The acrylate esters are preferably esters of C1-C10 alcohols.

[0019] By styrene-acrylate polymer is meant in particular a copolymer of styrene (or styrene derivatives, such as for example methylstyrene) and acrylate monomers as defined above.

[0020] These polymers have proven to be advantageous in particular due to good compatibility with hydraulic binders such as cements, which have a high basicity, and good resistance to exothermic hydration reactions of these hydraulic binders. Acrylate polymers are preferred because they provide better acoustic properties.

The hardened mortar of the ground layer therefore preferably comprises such a polymer. The total content of acrylate and styrene-acrylate polymer in the hardened mortar of the ground layer is preferably between 9 and 50% by weight, in particular between 15 and 35% by weight.

The acrylate or styrene-acrylate polymers in the aqueous dispersion are preferably in the form of particles whose size is preferably between 0.1 and 100 µm, in particular between 0.15 and 50 µm, or even between 0 ,2 and 2 µm. By size we mean the number average equivalent diameter, for example determined by laser diffraction spectroscopy.

The aqueous dispersion (component B) is preferably an emulsion in which the organic phase is stabilized by an emulsifying agent, in particular a surfactant. The surfactant may be non-ionic (for example based on polyethylene oxide - PEO - or polypropylene oxide - PPO, including their triblock copolymer derivatives of the PEO-PPO-PEO type), anionic (for example salts of sulfates or sulfonates such as sodium lauryl sulfate) or even cationic (for example quaternary ammonium salts such as dodecyltrimethylammonium or hexadecyltrimethylammonium bromide).

The total content of acrylate and styrene-acrylate polymer in component B is preferably between 25 and 75% by weight, in particular between 35 and 65% by weight, or even between 45 and 60% by weight. Too high a concentration leads to too viscous dispersion, while high dilutions lead to reduced acoustic performance.

Various acrylate or styrene-acrylate polymers can be used in the present invention. We can in particular cite dispersions sold under the reference Acronal® by the company BASF, or under the reference Encor® by the company Arkema, or even under the reference Revacryl® by the company Synthomer.

[0026] Component B and/or component A, and therefore the hardened mortar, preferably comprises tackifiers and/or plasticizers, in order to adjust the vibration damping as well as the position of the damping peak on the frequency of interest.

These compounds can be in liquid form, and therefore present in component B, which constitutes a preferred embodiment. They can alternatively be in powder form, obtained for example by atomization, and in this case be added to component A.

The or each tackifier is preferably chosen from natural tackifying resins (for example rosins, rosin derivatives, such as hydrogenated rosins, terpenes) and synthetic tackifying resins (for example aliphatic, aromatic and hydrogenated resins). from oil). Preferably, the tackifier used is a rosin and/or a terpene, in particular in the form of dispersion and/or powder. We can in particular cite the products Dermulsene® (A7510, RE1513, TR602, etc.), Dertoline®, Staybelite®, Foral®, Dertophene® marketed by the company DRT.

The plasticizer makes it possible to shift the glass transition temperature (Tg) of the material constituting the ground layer towards lower temperatures, in other words towards higher frequencies. Preferably, the plasticizer used is a derivative of triethylene glycol. It may be, for example, triethylene glycol bis (2-ethylbutyrate) known under the trade name 3GH, or triethylene glycol bis (2-ethylhexanoate) known under the name 3G8.

[0030] When it is present, the total weight content of tackifier in component B is preferably between 0.5 and 40%, in particular between 2 and 20%, or even between 3 and 15%, relative to the weight of dry matter. The total weight content of tackifier in the hardened mortar of the soil layer is then preferably between 0.2 and 25%, in particular between 5 and 15%, or even between 8 and 10%.

[0031] When it is present, the total weight content of plasticizer in component B is preferably between 0.5 and 20%, in particular between 1 and 10%, or even between 2 and 8%, relative to the weight of dry matter. The total weight content of plasticizer in the hardened mortar of the soil layer is then preferably between 0.2 and 15%, in particular between 0.5 and 8%, or even between 1 and 6%.

The phase for which the glass transition temperature is measured is the phase, in component B, consisting of the acrylate or styrene-acrylate polymer or the mixture of such polymers and, when such compounds are present in component B, tackifiers and/or plasticizers.

[0033] In certain embodiments, component B is an aqueous dispersion of a single acrylate or styrene-acrylate polymer, without addition of tackifier or plasticizer. In this case the glass transition temperature to be considered corresponds to the glass transition temperature of said polymer.

[0034] In other embodiments, component B is an aqueous dispersion comprising at least two polymers chosen from acrylates and styrene-acrylates, without addition of tackifier or plasticizer. In this case the glass transition temperature to be considered corresponds to the glass transition temperature of the mixture of these polymers.

When component B comprises tackifiers and/or plasticizers, the glass transition temperature to be considered corresponds to the glass transition temperature of the mixture consisting of the acrylate or styrene-acrylate polymer(s) and the tackifiers and/or plasticizers.

The glass transition temperature of the phase to be considered, that is to say of the phase consisting of said polymer or mixture of acrylate or styrene-acrylate polymers and any tackifiers and/or plasticizers, is preferably lower or equal to -10°C, and even to - 20°C, or even to -30°C or -40°C. It is preferably greater than or equal to -100°C. Such a glass transition temperature has proven to be advantageous for obtaining good absorption of impact noise by giving a viscoelastic character to the hardened mortar.

The glass transition temperature of the phase to be considered is determined by differential scanning calorimetry (DSC) between -100°C and 120°C with a heating rate of 20°C per minute. The determination is made from the curve obtained using the tangent method, taking the point of intersection with the curve of the bisector of the tangents to the curve. The measurement is carried out on the phase to be considered, obtained after drying of the aqueous dispersion.

[0038] In the kit according to the invention, the respective mass proportions of component A and component B (A:B) preferably vary from 30:70 to 70:30, in particular from 40:60 to 60:40, or even from 45:55 to 55:45.

Component A and/or component B may also comprise at least one additive chosen from setting retarders, setting accelerators, rheology agents (in particular thickeners or thixotropics), dispersing agents, leveling agents, water retaining agents, anti-caking agents, plasticizers or superplasticizers.

[0040] Preferably the hardened mortar has, at a temperature of 20°C and for at least one frequency between 100 and 1000 Hz, and advantageously for any frequency between 100 and 1000, at least one of the following characteristics: – a dynamic shear modulus G' of at most 70 MPa, in particular at most 60 MPa, and even at most 50 MPa, in particular at most 40 MPa, or even at most 30 MPa, – a loss factor tanδ of at least 0.30, in particular at least 0.33, or even at least 0.35.

[0041] In known manner, the dynamic shear modulus G' corresponds to the real part of the complex shear modulus. It is also called “shear conservation modulus”. The loss factor tanδ (also called damping factor) is equal to the ratio between G'' and G', the quantity G'', called "shear loss modulus", corresponding to the imaginary part of the complex shear modulus .

The kit according to the invention generally consists of component A and component B; it is then a two-component kit.

The two components of the kit are normally physically separated in order to avoid any premature reaction between them. The kit may for example comprise two distinct containers each containing one of the components A or B. The kit may also comprise a container comprising two distinct compartments each containing one of the components A or B. The kit may for example be sold in the form of a bucket containing two plastic bags, each containing one of the components. The two bags can then be emptied into the bucket in order to mix in the latter. Component B generally contains the quantity of water necessary for mixing, but it is obviously possible to add water if necessary.

The mixing of components A and B generally takes place on site, for example manually or by means of a mixer in order to obtain a paste which will then be applied to the floor substrate to be covered, for example a screed.

[0045] The application can be carried out in a known manner using a brush, a roller or a brush, a spatula, a Flemish trowel, a trowel, a smoother or again by spraying.

[0046] The invention also relates to a floor comprising a layer of floor according to the invention, in particular in the form of an adhesive layer and/or a waterproofing layer and/or an underlayer, said layer being interposed between a floor substrate (such as for example a slab, a screed or a floor to be renovated) and a floor finishing covering.

[0047] The floor finishing covering is in particular of the tile or parquet type, or even in particularly rigid PVC slabs, that is to say hard coverings for which the damping of impact noise is particularly crucial.

[0048] The thickness of the soil layer is preferably between 1 and 30 mm, in particular between 5 and 20 mm, or even between 8 and 15 mm.

[0049] According to one embodiment, the floor only comprises, between the floor substrate (in particular a screed) and the floor finishing covering, the layer according to the invention. This layer therefore plays an adhesive role (for example tile adhesive) in addition to ensuring acoustic damping properties, and possibly other functionalities (watertightness, leveling, flatness, etc.). In this case the thickness of the layer is preferably between 5 and 15 mm.

[0050] According to another embodiment, the floor comprises, from the substrate (in particular a screed), a layer according to the invention, a layer of glue (for example tile glue or parquet glue), then the covering floor finishing. The layer is then an underlayer with acoustic properties, and possibly a waterproofing layer. In this case the thickness of the layer is preferably between 8 and 15 mm.

[0051] Finally, the subject of the invention is the use of a building floor layer as defined above to dampen the transmission of impact noise.

[0052] Acoustic gains of at least 4 dB, in particular at least 6 dB and even at least 8 dB or at least 10 dB are notably obtained, in terms of improvement in noise on impact. ΔLw within the meaning of standard ISO 10140-3:2010.

[0053] The invention is illustrated by the non-limiting examples which follow.

Layers of soil were obtained by mixing a component A and a component B, then depositing the paste obtained on a screed so as to form a layer 10 mm thick. The measurements on the hardened mortar were carried out after 28 days of hardening.

[0055] In all the tests, component A was a dry mortar marketed by the Applicant under the reference weber.xerm 844. Such a dry mortar comprises Portland cement as hydraulic binder as well as aggregates, including rubber powder in a weight content of 10% relative to the weight of dry mortar.

Component B was an aqueous dispersion comprising a dispersed organic phase. The organic phase consisted of a polymer, with in certain cases the addition of plasticizer and tackifier.

[0057] In all the tests, the weight ratio A:B was 50:50.

[0058] The nature of component B in the different examples was as follows: Example 1: dispersion comprising 65% by weight of an acrylate polymer having a glass transition temperature Tg of -55°C. Example 2: dispersion comprising 69% by weight of an acrylate polymer having a Tg of -40°C. Example 3: dispersion comprising 60% by weight of an acrylate polymer having a Tg of -38°C. Example 4: dispersion comprising 54% by weight of a styrene-acrylate polymer having a Tg of -30°C. Example 5: dispersion comprising 57% by weight of a styrene-acrylate polymer having a Tg of -8°C. Example 6: dispersion comprising 57% by weight of a styrene-acrylate polymer (having a Tg of -2°C) with addition for one part of polymer of 0.1 part of plasticizer and 0.3 part of tackifier. The Tg of the phase consisting of the polymer, the plasticizer and the tackifier was less than -5°C. Example 7: dispersion of Example 5 with addition for one part of polymer of 0.1 part of plasticizer and 0.3 part of tackifier. Comparative Example C1: dispersion comprising 48% by weight of a styrene-butadiene elastomer having a Tg of -16°C. Comparative Example C2: dispersion comprising 57% by weight of a styrene-butadiene elastomer having a Tg of +5°C. Comparative Example C3: dispersion of Example 6, but without tackifier or plasticizer.

The plasticizer was triethylene glycol bis(2-ethylbutyrate). The tackifier was a rosin sold under the name Dermulsene® A7510 by the company DRT.

[0060] Table 1 below presents the results obtained by indicating the shear modulus G' (in MPa) and the loss factor tanδ, for the frequencies of 100 and 1000 Hz, as well as the improvement in noise at the impact ΔLw.

The shear modulus and the loss factor were determined by dynamic mechanical temperature analysis (DMTA). To do this, the hardened mortar sample is subjected to a sinusoidal stress for frequencies ranging from 1 to 100 HZ in a temperature range ranging from -40°C to 40°C with steps every 5°C. A master curve for the values of G' and tanδ between 0.1 and 10000 Hz can then be obtained by applying the Williams-Landel-Ferry (WLF) theory.

[0062] The acoustic performances of the hardened mortar, in this case the improvement in impact noise ΔLw (expressed in dB) were determined by the method described in standard ISO 10140-3:2010, but with samples 2.5 m<2>. The tests were carried out on a system comprising, on a screed, a layer of floor 10 mm thick covered with tiles.

[0063] [Fig. 1] shows the impact noise improvement curves (denoted ΔL) as a function of frequency (denoted f), in the range from 100 to 5000 Hz, for each of the examples.

[Table 1]

[0064] 100 Hz 1000 Hz 100 Hz 1000 Hz 1 19 30 0.33 0.43 8 2 14 18 0.28 0.35 9 3 12 15 0.25 0.33 7 4 50 100 0.35 0.35 4 5 35 50 0.31 0.28 5 6 44 60 0.53 0.25 12 7 12 18 0.35 0.47 11 C1 170 200 0.08 0.09 2 C2 200 170 0.07 0.08 2 C3 150 250 0.22 0.12 3

Claims (15)

1. Kit for obtaining a layer of building soil, comprising: – a component A which is a powder mixture comprising a hydraulic binder and aggregates, including rubber powder, and – a component B which is an aqueous dispersion comprising a dispersed organic phase comprising a polymer chosen from acrylates and styrene-acrylates or a mixture of two or more of these polymers, and optionally tackifiers and/or plasticizers, the temperature of glass transition of the phase consisting of said polymer or mixture of polymers and any tackifiers and/or plasticizers being less than or equal to -5°C. 2. Kit according to the preceding claim, in which the total content of hydraulic binder in component A is between 5 and 30% by weight and the total content of aggregates in component A is between 50 and 90% by weight. 3. Kit according to one of the preceding claims, in which component A comprises rubber powder in a weight content of at least 5% by weight, in particular between 7 and 20%, relative to the weight of component A . 4. Kit according to one of the preceding claims, in which the total content of acrylate and styrene-acrylate polymer in component B is between 25 and 75% by weight. 5. Kit according to one of the preceding claims, in which component B and/or component A comprises tackifiers and/or plasticizers. 6. Kit according to one of the preceding claims, such that the glass transition temperature of the phase consisting of said polymer or mixture of acrylate or styrene-acrylate polymers and any tackifiers and/or plasticizers is less than or equal to -10°C , particularly at -20°C. 7. Kit according to one of the preceding claims, in which the respective mass proportions of component A and component B (A:B) vary from 30:70 to 70:30, in particular from 40:60 to 60:40. 8. Kit according to one of the preceding claims, in which the acrylate or styrene-acrylate polymers in the aqueous dispersion are in the form of particles whose size is between 0.1 and 100 µm, in particular between 0.15 and 50 µm 9. Method for obtaining a layer of building floor, in which components A and B of the kit according to one of the preceding claims are mixed to form a paste, then said paste is applied to an element of said floor, in particular on a slab, screed or floor surface to be restored. 10. Building floor layer of hardened mortar, obtained by the process of the preceding claim, comprising at least one hydraulic binder and aggregates, said hardened mortar having, at a temperature of 20°C and for at least one frequency between 100 and 1000 Hz, a dynamic shear modulus G' of at most 70 MPa and a loss factor tanδ of at least 0.30. 11. Layer of soil according to the preceding claim, the thickness of which is between 1 and 30 mm, in particular between 5 and 20 mm. 12. Floor layer according to one of claims 10 and 11, comprising an acrylate or styrene-acrylate polymer, the total content of acrylate and styrene-acrylate polymer in the hardened mortar of the floor layer being between 9 and 50% by weight, in particular between 15 and 35% by weight. 13. Floor layer according to one of claims 10 to 12, comprising rubber powder in a content of at least 1% by weight, in particular between 2 and 10% by weight, relative to the weight of layer of ground. 14. Floor comprising a floor layer according to one of claims 10 to 13, said layer being interposed between a floor substrate, in particular a screed, a slab or a floor to be renovated, and a floor finishing covering, in particular of tile or parquet type. 15. Use of a building floor layer according to one of claims 10 to 13 to dampen the transmission of impact noise.