EP1249561A2 - A multilayered floor covering, to be laid floatingly - Google Patents

Abstract

The floor covering which comprises wood parquet panels (1) consists of a first rigid, hard layer (2) and a second rigid mechanically resistant underlying support layer (3). The underlying layer has structural discontinuities (5) defining cavities which reduce the resonance of the covering.

Description

The invention relates to decorative wall coverings (in particular floors) to be laid floating, that is to say not secured to the slab or structure to be clad with the building that we want to equip.

• d'un "vrai parquet" dont la couche de surface est (essentiellement) en bois et se présente sous la forme d'une ou plusieurs lame(s) (également appelées planches, frises, lattes, ...),
• ou d'un "similiparquet" (appelé également "faux parquet" ou "laminé", c'est-à-dire un revêtement ayant l'aspect d'un parquet mais contenant beaucoup moins de bois qu'un "vrai parquet"), tant le parquet que le similiparquet étant à poser flottant.

In particular, the invention relates to a coating consisting of an element, or a set of elements:

• a "real parquet" whose surface layer is (essentially) wooden and is in the form of one or more plank (s) (also called boards, friezes, slats, ...),
• or a "similiparquet" (also called "false parquet" or "laminate", that is to say a coating having the appearance of a parquet but containing much less wood than a "real parquet") , both the parquet and the faux-parquet being floating.

• les poses flottantes,
• les poses collées.

In the field of these coatings, two installation techniques are preferred:

• floating poses,
• the poses glued.

As has been understood, the invention relates to the field of floating poses in which typically a underlay (felt, carpet, ...) or a foam sheet is interposed between the covering and the floor.

In the other technique, the covering is fixed (typically glued) on the ground on a slab (often a patched slab covered with a fluid coating forming a bonding bed).

Under these conditions, an object of the invention is to reduce the the sound of a decorative floor covering, to be laid floating.

The object is in particular to reduce the noise caused, in the room where the covering is located, by an impact on the covering (impacts of steps, for example).

One solution proposed by the invention consists in that the coating includes structural discontinuities creating cavities which reduce the sound of the coating and which do not open on its face upper, visible.

• une première couche rigide dure, présentant une face supérieure visible,
• et au moins une deuxième couche sous-jacente, mécaniquement résistante, rigide, de support de la première couche.

Typically, the coating includes:

• a first hard rigid layer, having a visible upper face,
• and at least one second underlying layer, mechanically resistant, rigid, for supporting the first layer.

In this case, we advise that the (some at least of) second layer (s) present (s) said structural discontinuities reducing the sound of the coating, the discontinuities being interrupted before reaching the visible upper face of the first layer (and particular, before reaching this first layer if it is thin, or in this first layer, if it is thick and preferably, then going also as close to the surface as possible, without weakening it).

Thus, we will disturb the waves emitted in the coating during impact, the "cavities" defined by the discontinuities consisting of pockets of air, or areas of change of medium (material / gas) in the horizontal circulation of sound waves.

The discontinuities will typically appear as openings creating a series of interfaces with air or with another medium if air gives way to such a medium, for example an elatomic material, these openings are interrupted however before reaching the upper face of the first layer (which can therefore be continuous).

• le revêtement consiste en une ou plusieurs planches ou panneaux réunis d'un parquet de bois, ou d'un simili parquet, à poser flottant,
• lesdites discontinuités s'étendent individuellement, pour certaines au moins d'entre elles, sur au moins l'essentiel de la hauteur de la deuxième couche.

A complementary object of the invention being to define conditions favorable to the realization of these "structural discontinuities", with an optimized result, it is advised that:

• the covering consists of one or more planks or panels joined together of a parquet of wood, or a simili parquet, to pose floating,
• said discontinuities extend individually, for at least some of them, over at least most of the height of the second layer.

In addition, the discontinuities will preferably be low thickness, with parallel and elongated faces in a direction substantially parallel to the visible upper face of the upper layer.

Thus, notches, preferably vertical, made for example at the saw in said "second layer", will easily create one of the discontinuities sought. Typically, the height thus provided will be between 3 mm and 30 mm (preferably 5 mm to 25 mm).

Such thickness and elongation characteristics eliminate the solution of using an expanded or cellular structure to create these "air pockets" of change of environment disturbing the waves emitted upon impact.

This creates disruptive air knives that are easy to produce, by particular by different mechanical means well controlled by coating manufacturers, or by spacing between two blocks of adjacent material constituting the coating.

This is also how another characteristic of the invention advise to create discontinuities, namely that the second layer includes a succession of mechanically resistant battens or battens arranged side by side, at least two battens or battens adjacent among them being separated by a so-called discontinuity which then presents as an intermediate space between these two battens or adjacent battens.

This typically applies to "real parquet".

In the particular case of a laminate, we will rather choose to create cutouts (at least) in the underlying wood / resin layer that extends typically immediately below the decorative sheet of paper or wood veneer that can be seen from above, under the top layer of transparent resin.

In the first case which uses battens or battens, crossing the wood grain in the first layer (direction of elongation of the boards parquet) and the lengthening direction of the discontinuities, we limit the risks mechanical distortion.

However, it may prove mechanically useful that the second layer be lined, immediately below it, with a layer of counterbalance for the mechanical strength of the coating, the counterbalance then closing the discontinuities at their end lower.

A reconciliation of these discontinuities makes it possible to climb into the frequency range of sound waves propagating following an impact (this also applies to a false parquet).

To absorb the highest sound frequencies produced, and to reduce noise transmission in the vicinity, we recommend in addition to the covering comprising a third layer of material acoustically absorbent extending under the second layer (s) where discontinuities are formed.

Advantageously, this third layer will have a thickness between approximately 0.4 mm and 15 mm and will consist of either a cellular or expanded, flexible and / or viscoelastic material, either in a complex comprising a first cellular underlay and a second denser and more viscoplastic underlay than the first underlay.

Note that the term "flexible" applied to the constitution of the alveolar or expanded layer is to be considered as opposed to a foam rigid, such as polyurethane or polystyrene.

Moreover, to strengthen the sound absorption of coating, discontinuities (or more exactly the cavities than these will have been created) can be, at least for some, filled at least in part by an acoustically absorbent material different from the material of constitution of the second layer.

Another aspect of the invention relates to the manner of creating the discontinuities.

A first solution relates in particular to "real parquet floors" (wood) in which typically a second layer containing wood extends under the top layer of wood.

• pour constituer la deuxième couche, de disposer côte à côte, sensiblement parallèlement, entre eux, une succession de liteaux ou tasseaux en maintenant un espace d'écartement entre certains au moins d'entre eux, ces espaces d'écartement définissant certaines au moins des discontinuités,
• puis, ultérieurement, de lier entre elles la première et la deuxième couches.

In particular in this case, we advise:

• to constitute the second layer, to have side by side, substantially parallel, between them, a succession of battens or battens while maintaining a spacing space between at least some of them, these spacing spaces defining at least some of the discontinuities
• then, later, to link the first and second layers together.

A second solution may be suitable for "real parquet" than laminates, or even other synthetic coatings.

In this case, we advise, after having carried out the first and the second layer and to have connected at least these two layers, of mechanically cutting the discontinuities in the second layer, from the underside thereof opposite the visible upper face of the first layer.

These two solutions have the advantages of being simple to implement, economically profitable and effective in terms of effects products vis-à-vis the sound of the coating.

• la figure 1 est une vue partielle en perspective et en coupe d'un élément de vrai parquet à poser flottant, comprenant ici quatre lattes jointives,
• la figure 2 est une vue en coupe d'une alternative de réalisation du parquet de la figure 1,
• la figure 3 est une autre alternative de réalisation de ce parquet,
• la figure 4 est une vue de détail IV de la figure 1,
• la figure 5 est une vue à plus petite échelle d'un ensemble de lattes de parquet conformes à l'invention,
• et la figure 6 est une autre réalisation montrant, en coupe, un faux parquet (ou laminé).

An even more detailed description of the invention is presented below, with reference to the drawings in which:

• FIG. 1 is a partial perspective view in section of a real floating parquet element, here comprising four contiguous slats,
• FIG. 2 is a sectional view of an alternative embodiment of the parquet of FIG. 1,
• FIG. 3 is another alternative embodiment of this parquet,
• FIG. 4 is a detail view IV of FIG. 1,
• FIG. 5 is a view on a smaller scale of a set of parquet slats according to the invention,
• and Figure 6 is another embodiment showing, in section, a false parquet (or laminate).

In Figures 1 to 4, it is assumed that it is an element 1 of "real wood" floating parquet comprising a first upper layer 2 rigid, hard, and a second support layer, 3, which supports layer 2, immediately under it.

Layer 2, commonly called "wear layer", can be covered with a film 20 of wax, oil or varnish (Figure 2), to further improve its appearance and / or for its protection. We will consider despite all that the layer 2 has a solid or continuous upper face 2a, and visible (since this face will in practice be detectable through the layer of wax or varnish).

Layer 2 can be wooden or at least contains wood (other hard materials, in particular synthetic materials such as a resin, are however possible in the case of "false parquet"), likewise for the layer 3.

Layer 2 illustrated is a continuously full layer, i.e. without internal vacuum (it is not cellular or alveolar), similarly for its upper face 2a and its lower face 2b.

If the layer 2 contains wood, the immediately underlying layer 3 can then be constituted by a succession of battens, battens, 30, arranged parallel to each other, with a spacing d between two adjacent battens. Not all battens are necessarily pushed aside two by two.

The spacing d between the battens concerned is less than the width ℓ of these battens, which width (as, moreover, the spacing d ) is preferably constant in the direction of the height of the layer.

Each spacing, maintained over the entire length of the battens, creates an air space over the entire height h of the layer 3 (cf. FIGS. 1 and 3).

The direction 5a of elongation of the emerging discontinuities 5 thus created is, in FIG. 5, both perpendicular to the direction of elongation of the wooden panels forming the layer 2, and parallel to the visible upper surface 2a of this layer. However, the discontinuities 5 could extend in other directions, in particular several crossed directions to then define a sort of grid. They are preferably distributed homogeneously. Their individual volume is at least equal to 10 mm ³ and, preferably, greater than 100 mm ³ , approximately.

Since the air spaces created by the discontinuities 5 extend here over the entire height h , they then open onto the respectively upper, 3a, and lower, 3b, faces of this layer and are therefore closed at their upper end by the continuous underside 2b of layer 2 (face not visible).

In the example in Figure 1, immediately below the layer support 3, extends another layer 7 of acoustically absorbent material : elastomeric material (elastomer) or absorbent foam in particular. For the mechanical strength of the assembly, the foam should preferably be reinforced rigid fibers. We can also imagine a polyester nonwoven veil or glass lined with an expanded layer or in a viscoelastic material (Elastomer).

In Figure 4, we see the rigid, hard support layer, 3, with just below, a first sublayer of cellular material (such as cork), or expanded, 7a, and a second denser and more sub-layer 7b viscoplastic than the first (for example, cork with a loaded polyolefin).

Whether multilayer or monolayer, layer 7 closes the lower end of the discontinuities 5, in FIG. 1.

Typically, the thickness of layer 7 is between 0.5 mm and 20 mm.

In FIG. 2, an intermediate layer 9 of counterbalance, for the mechanical stabilization of the assembly, is interposed between the layers 3 and 7. The thickness of layer 9 is typically between 0.5 mm and 8 mm. It is then this layer 9 which closes the lower end discontinuities 5. It can be made of wood or another material likely to mechanically stabilize buckling and other deformations of set 1.

Advantageously, this layer will appear in the manner of a continuous solid plate (rigid wooden plate, in particular).

The spacings d corresponding to the width of the air knives 5, can be between 0.05 mm and 30 mm, their length L , between 2 cm and 3 m (or more) depending on the direction of the air knives created and corresponding widths and lengths of the slats. Their height may be between 2 mm and 25 mm. In practice, the average spacing d will preferably be between ½ and 1 / 300th of the distance ℓ between two consecutive air spaces.

• d = 1,5 mm à 5 mm,
• h = 5 mm à 20 mm (correspondant ici à la hauteur des discontinuités),
• L = 30 mm à 500 mm (largeur de la latte ou de l'ensemble des lattes constituant l'ensemble 1 : 35 mm à 500 mm, dans l'hypothèse d'un "panneau"),
• ℓ = 10 mm à 60 mm.

Good efficiency was obtained with the following dimensions:

• d = 1.5 mm to 5 mm,
• h = 5 mm to 20 mm (corresponding here to the height of the discontinuities),
• L = 30 mm to 500 mm (width of the slat or of the set of slats constituting the set 1: 35 mm to 500 mm, in the hypothesis of a "panel"),
• ℓ = 10 mm to 60 mm.

In FIG. 3, the discontinuities 5 are filled with a material acoustically absorbent 50, such as expanded or cellular material (for example, cork).

Filling may be only partial.

Once the cleats 30 are made, we discard them two by two individually or in series, and, after having interposed them between the layer upper 2 (also called wear layer in a parquet) and the layer lower 7 or 9, the whole is fixed together, by pressure bonding, as known per se in the technique of manufacturing multilayer parquet.

Element 1 can consist of one or more slats (also called planks, friezes, panels, boards, panels, ...) of parquet.

Figure 5 shows the result obtained in the form of a group 10 slats (three slats) with periodically elongated discontinuities forming air gaps across their width.

In FIG. 6, it is a laminate 20 (also called "false parquet ") successively comprising, from top to bottom, an upper layer 21 in resin (typically melamine), a decorative layer sheet 23 (paper, wood veneer, ..., typically 0.2 mm to 0.6 mm thick) and a support and structuring layer 25, typically in particles or in wood fibers bonded by a synthetic resin (such as an HDF layer "High Density Fiber"; high density fiber).

All or part of the thickness of layer 25 is interspersed of a series of notches 27 "break waves" in the manner of discontinuities preceding.

The dimensions can moreover be comparable.

These notches (or slits) can be provided by a means of cutting such as a saw, once the product is finished, so after manufacturing the laminated panel 20, which is of course to be laid "floating".

The respective thicknesses of layers 21 and 25 are typically each between 0.1 mm and 5 mm (preferably between 0.1 mm and 0.5 mm).

An acoustically absorbent layer 29 corresponding to the layer 7 already presented can double layer 25 below and close thus the lower end of the notches 27.

a) un vrai parquet flottant comprenant :

• une couche supérieure rigide, dure et pleine 2, contenant du bois (typiquement comprenant une ou plusieurs lattes diposée(s) latéralement bord à bord), présentant une face supérieure d'aspect visible et continue, 2a, cette couche supérieure (typiquement d'une épaisseur comprise entre 1,5 mm et 10 mm) pouvant être recouverte d'une couche protectrice, telle que du vernis, de l'huile ou une cire, 20,
• une deuxième couche sous-jacente, 3, de support de la couche supérieure, située immédiatement sous elle, cette deuxième couche qui est en un matériau rigide contenant du bois (y compris des particules agglomérées) présentant une série de fentes débouchantes au moins d'un côté (qui s'étendent donc sur une partie au moins de la hauteur h de la couche 3), ces fentes étant allongées, de préférence parallèles entre elles et s'étendant dans une direction d'allongement sensiblement parallèle à la surface supérieure 2a de ladite couche supérieure 2, les fentes ayant en outre une épaisseur d comprise avantageusement entre 0,05 mm et 30 mm (de préférence, 1,5 mm à 5 mm), avec un espacement ℓ entre deux fentes consécutives, compris de préférence entre 1 cm et 30 cm,
• avantageusement, une couche pleine 9 de contrebalancement, dure, contenant du bois (y compris des particules agglomérées), et s'étendant alors immédiatement sous la seconde couche 3, pour la tenue mécanique du parquet dans son ensemble, et tout particulièrement de la couche supérieure 2 (épaisseur comprise entre 0,1 mm et 5 mm),
• et/ou une couche d'insonorisation en un matériau acoustiquement absorbant, situé soit directement sous la couche de contrebalancement 9, soit directement sous la seconde couche 3 (étant précisé que, hormis cette couche d'insonorisation, 7, qui peut être rapportée, les autres couches sont liées ensemble au moment de la fabrication du parquet, typiquement par collage sous pression) ;

b) un faux parquet (que l'on appelle donc également "laminé") comprenant :

• une couche supérieure rigide, dure et pleine, en résine, 21, présentant une face supérieure d'aspect, visible, continue, 21a, ainsi qu'une face inférieure 21b, également continue ;
• une feuille intermédiaire décorative 23 (papier, bois, ...) donnant au produit son aspect visible à travers la couche supérieure transparente 21,
• une seconde couche sous-jacente 25, rigide, de support de la couche supérieure 21 et située immédiatement sous la couche 23, cette deuxième couche en matériau rigide contenant du bois (particules ou fibres) lié par une résine synthétique et présentant une série de fentes (ou rainures) "brise-ondes", débouchantes au moins d'un côté (à leur extrémité supérieure et/ou inférieure), allongées, parallèles entre elles et s'étendant dans une direction d'allongement sensiblement parallèle à la face supérieure 21a de la couche supérieure, ces fentes ayant une largeur d et présentant entre elles un espacement ℓ identique au cas du "vrai parquet" (avec ℓ compris entre 1 cm et 30 cm, ℓ > d, et 0,05 mm ≤ d ≤ 30 mm et/ou d compris entre ½ et 1/300ème de l'écartement moyen d),
• et éventuellement, une couche supplémentaire d'insonorisation 29 qui peut être identique à la couche 7 présentée pour le "vrai parquet", c'est-à-dire contenant une matière expansée et/ou un matériau visco-élastique (élastomère), étant toutefois précisé que ladite couche d'insonorisation 29 est alors située immédiatement sous la couche de soutien et de structuration 25.

Finally, it will be understood from the above, that two types of products are particularly concerned with the invention:

a) a real floating parquet comprising:

• a rigid, hard and full upper layer 2, containing wood (typically comprising one or more slats disposed laterally edge to edge), having an upper face of visible and continuous appearance, 2a, this upper layer (typically of a thickness between 1.5 mm and 10 mm) which can be covered with a protective layer, such as varnish, oil or a wax, 20,
• a second underlying layer, 3, for supporting the upper layer, situated immediately below it, this second layer which is made of a rigid material containing wood (including agglomerated particles) having a series of at least through through slots one side (which therefore extend over at least part of the height h of the layer 3), these slots being elongated, preferably parallel to each other and extending in an elongation direction substantially parallel to the upper surface 2a of said upper layer 2, the slits further having a thickness d advantageously between 0.05 mm and 30 mm (preferably 1.5 mm to 5 mm), with a spacing ℓ between two consecutive slits, preferably between 1 cm and 30 cm,
• advantageously, a solid, counterbalancing layer 9, hard, containing wood (including agglomerated particles), and then extending immediately under the second layer 3, for the mechanical strength of the parquet as a whole, and particularly of the layer upper 2 (thickness between 0.1 mm and 5 mm),
• and / or a soundproofing layer made of an acoustically absorbent material, located either directly under the counterbalancing layer 9, or directly under the second layer 3 (it being specified that, apart from this soundproofing layer, 7, which can be added, the other layers are bonded together at the time of manufacture of the parquet, typically by pressure bonding);

b) a false parquet (which is therefore also called "laminate") comprising:

• a rigid, hard and full upper layer, made of resin, 21, having a visible upper face, continuous, 21a, as well as a lower face 21b, also continuous;
• a decorative intermediate sheet 23 (paper, wood, etc.) giving the product its visible appearance through the transparent upper layer 21,
• a second rigid underlying layer 25 supporting the upper layer 21 and located immediately under the layer 23, this second layer of rigid material containing wood (particles or fibers) bonded by a synthetic resin and having a series of slots (or grooves) "wavebreaker", emerging at least on one side (at their upper and / or lower end), elongated, mutually parallel and extending in an elongation direction substantially parallel to the upper face 21a of the upper layer, these slots having a width d and having between them a spacing ℓ identical to the case of "real parquet" (with ℓ between 1 cm and 30 cm, ℓ> d, and 0.05 mm ≤ d ≤ 30 mm and / or d between ½ and 1 / 300th of the average spacing d ),
• and optionally, an additional soundproofing layer 29 which may be identical to the layer 7 presented for "real parquet", that is to say containing an expanded material and / or a visco-elastic material (elastomer), being However, it should be noted that said soundproofing layer 29 is then located immediately under the support and structuring layer 25.

Claims (18)

Decorative floating floor covering, comprising: a first rigid rigid first layer (2, 21), having a visible upper face, and at least one second underlying layer (3, 25) mechanically strong, rigid, for supporting the first layer, characterized in that the (at least some of) the second underlying layer (s) ) (3, 25) has (are) structural discontinuities (5, 27), defining cavities which reduce the sound of the coating. Covering according to claim 1, characterized in that it consists of one or more planks or panels (1, 20) of wooden parquet, or of a similiparquet, to be laid floating. Coating according to claim 1 or claim 2, characterized in that : the second layer where the structural discontinuities are formed (5, 27) has an upper face and a lower face, and at least some of the discontinuities (5, 27) open on at least one of these upper and lower faces. Coating according to any one of the preceding claims, characterized in that the said discontinuities (5, 27) extend individually, for at least some of them, over at least most of the height ( h ) of the second layer. Coating according to any one of the preceding claims, characterized in that the discontinuities (5, 27) are elongated in a direction substantially parallel to the visible upper face (2a) of the upper layer (2, 21). Covering according to any one of the preceding claims, characterized in that the second layer (3) comprises a succession of mechanically resistant battens or battens (30) arranged one next to the other, at least two battens or battens (30a, 30b) among this succession being arranged adjacent by being separated by a said discontinuity (5) which thus appears as an intermediate space between two adjacent battens or battens. Covering according to claim 6, characterized in that the first layer (2) is elongated in a first direction of elongation (2b), while the cleats or battens (30) are elongated in a second direction of elongation (30a) which crosses the first, the discontinuities (5) being elongated in this second direction of elongation (30a). Coating according to any one of Claims 1 to 5, characterized in that : said coating is a laminate, the first layer is a layer of melamine (21), the second layer (25) comprises particles or wood fibers linked by a synthetic resin, a decorative sheet (23) is interposed between the first and the second layer, and said discontinuities (27) appear as notches extending in the second layer, but not in the first layer. Coating according to any one of the preceding claims, characterized in that a third layer (7) of an acoustically absorbent material extends under the second layer (s). Coating according to claim 9, characterized in that the third layer (7) has a thickness of between approximately 0.5 mm and 20 mm and is made either of a cellular or expanded material, flexible and / or viscoelastic, or of a complex comprising a first sublayer of expanded material and a second denser and more viscoplastic sublayer than the first sublayer. Coating according to any one of the preceding claims, characterized in that the second layer (3) is doubled, immediately below it, by a counterbalancing layer (9) for the mechanical strength of the coating, the counterbalancing layer (9) closing the discontinuities (5) at their lower end. Coating according to any one of the preceding claims, characterized in that the discontinuities (5, 27) are, at least for some, filled at least in part by an acoustically absorbent material different from the material constituting the second layer. Coating consisting of one or more plank (s) (11) of a parquet essentially containing wood or a similar parquet, to be laid floating, the plank (s) having an upper face (2a, 21a), the covering being characterized in that it comprises structural discontinuities (5, 27) creating cavities which reduce the sound of the covering and which are not open on the upper face (2a, 21a). Coating according to claim 13, characterized in that the discontinuities (5, 27) are elongated in a direction substantially parallel to the upper face (2a) of the coating. Coating according to any one of the preceding claims, characterized in that the discontinuities (5, 27) individually have a volume of at least 10 mm ³ . Coating according to any one of the preceding claims, characterized in that at least some of the discontinuities (5, 27) individually have a volume of at least 100 mm ³ , approximately. Process for obtaining a decorative coating, according to any one of Claims 1 to 7, characterized in that : to constitute the second layer (3), there is side by side, substantially parallel to one another, a succession of battens or battens (30) while maintaining a space ( d ) for spacing between at least some of them, these spaces spacing defining at least some of the discontinuities (5), and subsequently the first and second layers (2, 3) are bonded together. Method for producing a decorative covering according to any one of Claims 1 to 12, characterized in that after having produced the first and second layers (2, 3; 21, 25) and having connected at least these two layers, the discontinuities (27) are mechanically cut in the second layer (3, 25), from the lower face (25a) thereof, opposite the upper face (21a) of the first layer.

Images