CN102165125A - 多功能衬底隔音垫和系统 - Google Patents
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Abstract
一种放置于底层地板和带有浇筑式衬底的成品地板之间的隔音垫,所述隔音垫包括:与底层地板相接触的缠结纤维的底层;和附着于所述底层上的防水非织造聚合物织物顶层,其中所述衬底浇筑于所述顶层之上。
Description
相关申请
本申请基于美国临时专利申请No.61/100,529并根据美国法典第35条第119(e)款要求优先权。
技术领域
本发明涉及地板系统,其设计为用于降低声音传播,尤其涉及一种改进的非织造垫(nonwoven mat),其提高了隔音性同时避免了在一些常规的浇筑式衬底安装中可能出现水分滞留。
背景技术
常规地板系统包括由浇筑式混凝土或胶合板制成的底层地板。已经在底层地板和成品地板(通常是陶瓷砖、乙烯基板或硬木板)之间使用声音垫(sound mat)和衬底的各种组合,以降低声音传播。
已知声音额定(sound rated)或浮式地板系统用于对地板下方的房间进行隔音,该地板上会出现撞击,例如行人踏步、体育活动、玩具掉落或移动家具时造成的刮擦。通常可以通过使用厚地毯来减少撞击性噪音的生成,但在使用塑料、油毡、瓷砖、硬木板、木制层压板和包括装饰性混凝土成品的其他类型坚硬表面的情况下,声音额定地板是所期望的且也是多家庭住宅的隔音规范所需要的。可以通过弹性支持或从声学角度分离和/或减震衬底地板而脱离地板下部结构,减少撞击性噪音向下方区域传播。整个地板系统促成了噪音向下方区域传播。如果将接收撞击的地板表面与下部结构隔离,就将大大减少冲击性噪音的传输。阻尼材料也可减少传输的噪音。同样,如果下方的天花板与下部结构是隔离开的,那么撞击声音向下方区域的传播就会受到限制。
通常声音额定地板由美国试验与材料协会(ASTM)的用于对声音传输等级(STC)评级的标准E90和关于撞击隔离等级(IIC)的E492来评估。IIC级别越大,将要传递至下方区域的撞击噪音越小。STC级别越大,将要传递至下方区域的空气传声越小。国际建筑规范(IBC)规定:多个家庭建筑物的单元之间的地板/天花板的安装必须具有不小于50的IIC级别和不小于50的STC级别。即使IIC级别为50符合许多建筑规范,经验表明在豪华公寓应用(application)中,IIC小于55的地板-天花板系统是不能被接受的,因为一些撞击噪音还是可以听见,且认为那种程度是令人厌烦的。
常规的地板系统会采用设在成品地板和底层地板之间的浇筑式衬底,通常用于给成品地板提供一个平坦的整体基底。合适的浇筑式衬底为LEVELROCK地板衬底,其由伊利诺伊州芝加哥市的United States Gypsum(USG)公司出售。LEVELROCK衬底为巴黎熟石膏、波特兰水泥和结晶二氧化硅的混合物。该衬底为地板系统的一部分,该地板系统还可包括提供隔音性的织物、聚合物或两者的组合,或者橡胶类的垫子。几个排水垫和声音垫的生产厂家生产可用于地板/天花板组件(assemblies)的隔音(IIC和STC)的缠结垫(entangled mat)。这些垫通常夹在底层地板和浇筑式地板衬底之间,且通常包含带有某种背衬(backing)的各种石油化工原料的基质,该各种石油化工原料例如是尼龙、聚丙烯或聚乙烯。该背衬的功能是提供一个衬底被浇筑于其上的平台。
令人担忧的是,这些背衬可能使水渗漏到洞内而带来不良后果。一个可能的问题是安装前浇筑式衬底浆料(slurry)中过量的水提供的水分会促使霉和霉菌的生长;其次该水分会对一些材料如尼龙有影响且会被聚合物吸收而使其大小改变。当发生这种大小变化时,结果是在接缝处经常发生凸起(lipping),随后导致该衬底本身内部出现开裂问题。
由于目前市售的垫子上的背衬趋于薄,因此对声音垫的声音衰减性能很少有或没有贡献。该声音垫的IIC和STC性能通过分隔效应(decoupling effect)来实现。
发明内容
通过提供隔音及拒水性并具有承受贸易运输(trade traffic)的经久耐用表面,本发明的多功能衬底隔音垫克服或超越了常规垫子的缺点。当用作其上置有浇筑式衬底的基底时,来自该衬底浆料中的水分被阻止进入到底层地板或相关结构。实现这些目的的方法之一是提供一种组合垫,其具有缠结聚合物纤维的基底或下层(lower layer)以及吸音的上层(upper layer),该上层由不同于基底层材料的拒水非织造聚合物织物构成。该上层优选是2种不同材料的组合物—其中之一具有阻尼特性(dampening characteristic)和衬底浇筑于其上的上层,且该上层具有出众的防水和耐磨性。由于各层的不同,每层具有不连续的消音特性,其减少了在各层间传播并最终通过所述地板的声音能量。
更特别地,提供一种放置于底层地板和带有浇筑式衬底的成品地板之间的隔音垫。所述垫包括:与底层地板接触的缠结聚合物纤维的底层和附着于所述底层上且为防水非织造聚合物织物的顶层,所述衬底浇筑于所述顶层之上。
在优选实施方案中,提供一种放置于底层地板和成品地板之间的隔音衬底系统。该系统包括隔音垫,该隔音垫具有提供分隔声音并与底层地板相接触的空间限定支撑结构的底层;和附着于所述底层上且为防水、耐磨、非织造聚合物织物的顶层,该顶层还提供声音阻尼特性。所述隔音垫的顶层之上放置有浇筑式衬底。
附图说明
图1为本发明衬底系统的垂直剖面示意图;以及
图2为本发明衬底系统的优选实施方式的垂直剖面示意图。
具体实施方式
现在参见图1,其中示意性地示出了各层且各层不必然符合比例,本发明地板系统通常标示为10,并用于具有底层地板12的结构中,该底层地板以至少一层胶合板或定向刨花板(OSB)而示意性和典型地示出。该底层地板12也可以是浇筑式混凝土或混凝土板(concrete plank)。尽管仅公开了上述两种替代物,但是也可以考虑使用任何适合用于本发明地板系统10的常规底层地板材料。本领域人员公知的是,该底层地板12以通常由木头或钢铁制造且在一些结构中可以得到的框架构件(未示出)支撑,或由浇筑式混凝土面板(concrete deck)或混凝土板支撑。
本发明地板系统10包括浇筑式衬底,如LEVELROCK地板衬底,通常标示为14,其设置于底层地板12和成品地板16之间,该成品地板16通常为陶瓷砖、塑料板、硬木(包括层压木地板和工程木地板)或其他除地毯之外的硬质材料。注意,地毯和衬垫(pad)安装的声学特性是它们通常无需声音垫系统。然而,一些目前用于办公建筑物内的薄地毯块(carpet tile)的声学价值差,还需要带有衬底和声音垫的声音系统以用于该地板覆盖。例如砂浆、胶泥或化学粘合剂的粘合层18将成品地板16固定于衬底14上。对于木地板,这些材料可以浮于该衬底之上或根据各种工作因素和制造商推荐而进行粘着。
隔音垫(SRM)20位于底层地板12上且由聚合物材料制成。在该优选实施方案中,隔音垫20设置有用于支撑、具有空间限定结构的底层22,例如缠结纤维或视情况与底层地板12接触的整体式支撑小底脚。该底层22也称为分隔层,因其具有产生声音隔离空间的声学特性。此外,该底层22优选由例如尼龙,、聚丙烯或聚乙烯的材料制成。该底层22优选的厚度或高度范围为1/8-1英寸(0.635-2.54厘米)。此外,该底层22具有足够的密度以支撑地板系统10以及该地板上的承载物的重量,同时保留有也可作为隔音屏障的一个空气层。可以理解,底层22的厚度可以变化以适合场所并满足所期望的地板系统10的声学性能。
顶层24固定或附着于SRM 20的底层22上,其通过热融合、粘和、共挤压(co-extrusion)或类似制造技术附着于该底层上。用于该层24的期望材料是由威斯康辛州宁那(Neenah)市Kimberly-Clark公司生产的,且为“吸声剂”5.5oz./sq.yd.(142g/sq.m)的针刺结合MB织物(pinbonded Mb fibric)。该针刺结合织物被发现具有所期望的声学特性以及防水性能。该织物24的特性列举如下:
名称:5.5oz./sq.yd.(142g/sq.m)针刺结合MB织物
颜色:白色
基重:5.5oz./sq.yd.(142g/sq.m)
大小:0.10英寸(0.254厘米)
边缘基重:5.21oz./sq.yd.(147.7g/sq m)
平均卷厚度:0.06lbs.(.0271kg)
油容量:1350%
针刺结合内聚力测试:1827克力
颜色(白度)Rd 98
因此,本发明的垫20包括分开的两层,其各自具有不同的隔声特性,而仅顶层24是防水的。合在一起,该两层22、24提供不连续的材料和阻尼特性,该阻尼特性为降低穿过该地板系统10的声音传播的重要因素。
现在参见图2,其中的替代地板系统通常标示为30,其中与系统10共有的组件被认同为相同的附图标记,且其中各层被示意性地示出且不必然符合比例,优选地,类似于垫20但具有顶层34或约1/8英寸(0.3175厘米)的垫32由耐磨、拒水的材料36的夹层制成,该材料位于上述非织造、熔喷聚丙烯织物24之上,该织物24是防水的。虽然将材料36示意性地描述为单独一层,但是该材料层36优选为由美国威斯康辛州宁那(Neenah)市Kimberly-Clark公司生产的SM-250。该SM-250主要为聚丙烯织物,其为由两层外部纺粘材料夹着熔喷中心制成的三层薄层。所有三层都被超声层压。该SM-250层36的目的是增强防水和耐用性,并通过不同材料的组合用于为分隔层或底层22上方的阻尼层提供增强的声学特性,且耐磨的表面可承受该声音垫对其暴露的贸易运输。在使用该声音垫32后且在铺设浇筑式底衬14之前经受这种贸易运输。
更具体地,优选的SM-250层36由Kimberly-Clark公司指定为Block-ItTM 200系列车罩布,其具有如下特性:
基重:2.5osy
厚度:0.026英寸(0.06604厘米)
抓力度:纵向36磅(16.308kg)
横向30磅(13.59kg)
抑制撕裂度:纵向14磅(6.34kg)
横向12磅(5.436kg)
Taber磨损:5(视觉分级)
Frazier孔隙度:33英尺3/英尺2/min(11m3/m2/min)
MVTR:4300g/m2/day
氢化头:48厘米(121.92厘米)
UV添加剂:按重量1.25%。
在上述数据中,抓力度测定材料的有效强度。将样本的两端夹住,以恒定的伸展速度拉样本,以得到在破裂点前的各结果。撕裂力度测定织物在恒定伸展速度下的抗撕裂扩展性。沿着梯形样本不平行的边将在一个边缘上切割的织物夹住并施加拉力,使得样本在与负载垂直方向撕裂扩展。
Taber磨损涉及在受控制的压力和磨损作用下受到反复旋转摩擦作用时,织物的抗磨损性。磨损结果通常表示织物的耐久性或耐磨性能。Frazier孔隙度测定在规定的表面压力差下,通过织物的空气流的速率和体积。在受控制的条件下,抽气扇通过织物的已知区域抽气。空气流动速率被调节至规定的压力差。结果以空气流表示(立方英尺/min)。空气流的速率和体积指示织物透气性。
测试织物时,Kimberly-Clark公司参考几个ASTM方法如下:
抓力度:ASTM D5034-95和D1117
抑制撕裂度:ASTM D5733-95
Taber磨损:ASTM D5035
Frazier孔隙度:ASTM D737-96
本申请使用的SM-250的组成为:具有80-100%的编号为9003-07-0的CAS/EINECS的聚丙烯、具有0.1-1%的编号为1333-86-4/215-609-9的CAS/EINECS的炭黑、具有0.1-0.5%的编号为13463-67-7/236-675-5的CAS/EINECS的二氧化钛以及1-5%的UV稳定剂。
在该优选的实施方案中,所述两种材料(SM-25036和针刺结合24)被层压在一起,优选通过粘合剂粘接为一体,但是,也可考虑其他附着技术。
因此,本发明的垫32(参见图2)包括分开的两层,每层都具有不同的隔音特性,仅顶层34是拒水的和耐用的。合在一起,这两层22、34提供材料的不连续性和阻尼特性,该阻尼特性是降低穿过地板系统30的声音传播的重要因素。此外,具有顶层34的声音阻尼特性的隔音垫32允许底层22的厚度较小,在0.125-0.375英寸(0.318-0.953厘米)的范围内,并允许所用的衬底14的厚度较小,在0.5-1英寸(1.27-2.54厘米)的范围内,结果使该声音系统30整个外观较薄同时明显减少噪音。
在测试垫32的防水性时,从4英尺(1.22米)的高度倒水在垫上。该测试旨在模仿施工现场浇筑潮湿地板衬底14的情况。结果发现水被完全排斥而没有渗透过垫32。因此,当衬底浆料14倾倒在垫32上时,本发明的垫32会阻止浆料中的水分渗透到底层地板12。合适的防水测试为ASTM D 1776氢化头测试(hydrohead test)。
在安装过程中,首先将垫20、32置于底层地板12上,使得下层22与底层地板接触。然后,再安装衬底14。在优选的实施方案中,该浇筑式衬底14为USG LEVELROCK地板衬底水泥(cement),其以包括组合物的各种配制提供,该组合物包括主成份巴黎熟石膏、波特兰水泥和其他添加剂。该衬底水泥14在施工现场用水和砂子按各种比例(根据所需的强度)混合并以各种厚度抽到该底层地板上。通常,声音垫损害该地板的耐用性,为了弥补这种损害,需要在上面使用更大厚度的衬底。但是,由于本发明声音垫(尤其是有利于SRM发明的阻尼特性的层)的厚度相对较薄,因此所使用的衬底厚度有可能较小。可考虑使用其他可浇筑式衬底。当设置该衬底14时,如本领域众所周知的一样,应用成品地板16。使用Robinson滚动重量测试对类似上述构造的地板系统进行测试,获得了满意的测试结果。
尽管本文描述了本发明多功能隔音衬底垫和系统的特定实施方式,但是本领域技术人员可以理解在不脱离本发明的范围下在其更广的方面和如所附权利要求书中所阐明的,可以对本发明做出修改和变型。
Claims (10)
1.一种放置于底层地板和带有浇筑式衬底的成品地板之间的隔音垫,包括:
底层,由空间限定支撑材料制成,且与该底层地板相接触;和
顶层,附着于所述底层上且为防水非织造聚合物织物,该衬底浇筑于所述顶层之上。
2.如权利要求1所述的隔音垫,其中所述顶层还包括置于所述非织造聚合物织物之上的防水及耐磨织物。
3.如权利要求2所述的隔音垫,其中所述防水及耐磨织物被层压至所述非织造聚合物织物。
4.如权利要求2所述的隔音垫,其中所述防水及耐磨织物是由Kimberly-Clark公司制造的SM-250聚丙烯。
5.如权利要求2所述的隔音垫,该隔音垫被配置为抗拒从约4英尺即1.22米的高度滴落到所述顶层上的水。
6.如权利要求2所述的隔音垫,其中所述顶层的两种所述织物都对所述垫提供声音阻尼特性。
7.如权利要求1所述的隔音垫,其中所述底层约为1/8-1英寸即0.635-2.54厘米。
8.如权利要求2所述的隔音垫,其中所述底层的厚度在0.125-0.375英寸即0.318-0.953厘米的范围内且所述衬底的厚度在0.5-1英寸即1.27-2.54厘米的范围内。
9.如权利要求2所述的隔音垫,其中所述顶层由层压为Kimberly-Clark公司制造的SM-250织物的针刺结合MB聚丙烯非织造织物即针刺结合熔喷聚丙烯非织造织物制成。
10.一种放置于底层地板和成品地板之间的隔音衬底系统,包括:
隔音垫,具有底层和顶层,该底层由空间限定支撑结构制成且与该底层地板相接触并分隔声音,该顶层附着于所述底层且为防水、非织造、耐磨、声音阻尼的聚合物织物;以及
浇筑式衬底,置于所述顶层之上,其中所述顶层和所述底层都提供隔音,但仅所述顶层拒水。
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CN106013720A (zh) * | 2016-05-12 | 2016-10-12 | 张波 | 一种化学合成纤维pvc地板及其制造方法 |
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US10370860B2 (en) | 2019-08-06 |
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AU2009296715A1 (en) | 2010-04-01 |
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BRPI0913750A2 (pt) | 2017-06-20 |
MX2011002873A (es) | 2011-07-28 |
WO2010036683A3 (en) | 2010-07-01 |
CA2738460C (en) | 2018-04-24 |
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CA2738460A1 (en) | 2010-04-01 |
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