EP2662508B1 - Mehrschichtige schalldämpfende Fußbodenfliese und Herstellungsverfahren - Google Patents

Mehrschichtige schalldämpfende Fußbodenfliese und Herstellungsverfahren Download PDF

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Publication number
EP2662508B1
EP2662508B1 EP13165658.9A EP13165658A EP2662508B1 EP 2662508 B1 EP2662508 B1 EP 2662508B1 EP 13165658 A EP13165658 A EP 13165658A EP 2662508 B1 EP2662508 B1 EP 2662508B1
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EP
European Patent Office
Prior art keywords
sub
layers
vinyl
floor
layer
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Active
Application number
EP13165658.9A
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English (en)
French (fr)
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EP2662508A2 (de
EP2662508A3 (de
Inventor
Michael Freedman
Dale Tucker
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Michael Freedman & Associates Inc
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Michael Freedman & Associates Inc
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Priority claimed from US13/468,103 external-priority patent/US8640824B2/en
Application filed by Michael Freedman & Associates Inc filed Critical Michael Freedman & Associates Inc
Publication of EP2662508A2 publication Critical patent/EP2662508A2/de
Publication of EP2662508A3 publication Critical patent/EP2662508A3/de
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Publication of EP2662508B1 publication Critical patent/EP2662508B1/de
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    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F15/00—Flooring
    • E04F15/02—Flooring or floor layers composed of a number of similar elements
    • E04F15/10—Flooring or floor layers composed of a number of similar elements of other materials, e.g. fibrous or chipped materials, organic plastics, magnesite tiles, hardboard, or with a top layer of other materials
    • E04F15/107—Flooring or floor layers composed of a number of similar elements of other materials, e.g. fibrous or chipped materials, organic plastics, magnesite tiles, hardboard, or with a top layer of other materials composed of several layers, e.g. sandwich panels
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F15/00—Flooring
    • E04F15/02—Flooring or floor layers composed of a number of similar elements
    • E04F15/10—Flooring or floor layers composed of a number of similar elements of other materials, e.g. fibrous or chipped materials, organic plastics, magnesite tiles, hardboard, or with a top layer of other materials
    • E04F15/105—Flooring or floor layers composed of a number of similar elements of other materials, e.g. fibrous or chipped materials, organic plastics, magnesite tiles, hardboard, or with a top layer of other materials of organic plastics with or without reinforcements or filling materials
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F15/00—Flooring
    • E04F15/18—Separately-laid insulating layers; Other additional insulating measures; Floating floors
    • E04F15/20—Separately-laid insulating layers; Other additional insulating measures; Floating floors for sound insulation
    • E04F15/206—Layered panels for sound insulation
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F2290/00—Specially adapted covering, lining or flooring elements not otherwise provided for
    • E04F2290/04—Specially adapted covering, lining or flooring elements not otherwise provided for for insulation or surface protection, e.g. against noise, impact or fire
    • E04F2290/041—Specially adapted covering, lining or flooring elements not otherwise provided for for insulation or surface protection, e.g. against noise, impact or fire against noise
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F2290/00—Specially adapted covering, lining or flooring elements not otherwise provided for
    • E04F2290/04—Specially adapted covering, lining or flooring elements not otherwise provided for for insulation or surface protection, e.g. against noise, impact or fire
    • E04F2290/041—Specially adapted covering, lining or flooring elements not otherwise provided for for insulation or surface protection, e.g. against noise, impact or fire against noise
    • E04F2290/043—Specially adapted covering, lining or flooring elements not otherwise provided for for insulation or surface protection, e.g. against noise, impact or fire against noise with a bottom layer for sound insulation

Definitions

  • the present disclosure relates to vinyl flooring systems in general, and more particularly to an improved vinyl tile having enhanced acoustical properties coupled with improved long term stability.
  • Vinyl flooring has been a popular floor covering material for many years. Vinyl flooring is typically available in either tile or sheet form for both commercial and residential use. As finished flooring material, vinyl tile has been used extensively in commercial, institutional and public building applications, such as, for example, malls, schools, healthcare facilities, convention and exposition centers, civic buildings, private office buildings, sports facilities, and so forth. Vinyl flooring is durable, easy to maintain and is often more moisture-resistant than many alternative flooring materials. Vinyl flooring can also have limited acoustical properties, in that the material offers some rebound or resilience upon compression (i.e., when walked on).
  • Vinyl tiles can be composed of colored vinyl formed into generally planar solid sheets by heat and pressure, and cut into squares or other shapes. Manufacturers have created vinyl tiles that very closely resemble wood, stone, terrazzo, and concrete. Tiles are typically applied to a smooth, leveled bare floor or sub-floor usually using a suitable adhesive.
  • acoustical base layer such as rubber or cork.
  • the acoustical layer can serve one or more of a variety of different functions in a given installation.
  • the function of this underlayment material is to provide a cushioning effect to the floor system.
  • the function of the underlayment material is to compensate for imperfections in the surface of the sub-floor, which can be concrete, plywood, or a number of other different materials that are commonly used and known.
  • Another function of the underlayment which is particularly pertinent to the present invention, is to reduce the transmission of sound through the floor to a room below, such as in the case of a multi-floor building. This is particularly significant where the maximum allowable level of sound transmission is controlled by local building codes, which is increasingly common.
  • a single acoustical base layer is adhered to the sub-floor, and the vinyl tiles are installed over the acoustical base layer, again using an adhesive.
  • the base layer and vinyl tiles are standard elements that are used without regard for the particular sub-floor structure upon which the sub-floor is laid.
  • US2010319282 A1 discloses a vinyl floor panel for a flooring system prepared from a blend of a polymer and cork granules.
  • the floor panel includes top and bottom surfaces with a first layer between both surfaces.
  • DE202004014160U1 discloses a flooring element including a wear layer including a foamed PVC core arranged between two vinyl panels.
  • WO2012/045343A1 discloses a floor covering, comprising loosely laid floor panels having an upper cover layer, a plaster layer arranged below the cover layer, and an insulating layer.
  • an improved vinyl tile system whose structure can be customized to provide a desired acoustical dampening for any of a variety of different flooring structures.
  • the improved vinyl tile system includes sound dampening properties that meet applicable acoustical limitations associated with multi-family dwellings.
  • the improved vinyl tile also provides a desired resilience, and is easy to manufacture and install.
  • the disclosed system and method include an improved vinyl tile having enhanced stability, resilience and acoustical properties.
  • the disclosed vinyl tile incorporates an acoustical layer made up of a plurality of individual sub-layers.
  • the composition and arrangement of the sub-layers can be adjusted to provide desired sound dampening properties that are customized to a particular flooring structure.
  • a vinyl tile includes a vinyl portion and an acoustical portion comprising a plurality of individual acoustical sub-layers.
  • the plurality of individual acoustical sub-layers includes first and second sub-layers, the first sub-layer being bonded to the vinyl portion, the second sub-layer being bonded to the first sub-layer.
  • the first and second sub-layers of the plurality of individual sub-layers comprise material compositions that are different from each other.
  • the plurality of individual sub-layers comprises materials selected from the list consisting of rubber, a combination of cork and rubber, a combination of rubber and polyurethane foam (PU), and a combination of PU foam and cork.
  • a method for designing a flooring system to suit a particular flooring application.
  • the method includes: determining a type of a sub-floor system that includes the floor/ceiling assembly to which a vinyl tile which comprises a vinyl portion will be applied; selecting an acoustical portion of said vinyl tile to include "n" sub-layers, where "n” is a number greater than 1 and is based on the type of said sub-floor; and selecting a material composition for each of said "n” sub-layers, where the material composition for each of said "n” sub-layers is based on the type of said sub-floor system and the number "n” of sub-layers.
  • the acoustical portion includes at least first and second sub-layers.
  • the first and second sub-layers comprise material compositions that are different from each other.
  • the first and second sub-layers comprise materials selected from the list consisting of rubber, a combination of cork and rubber, a combination of rubber and polyurethane foam (PU), and a combination of PU foam and cork.
  • the disclosed vinyl tile comprises a vinyl layer with an integrated sound reducing underlayment permanently attached thereto.
  • the resulting floor/ceiling assembly including the tile meets one or more of ASTM E 2179, ASTM E 989, ASTM E 492, and ASTM E1007 IIC sound requirements.
  • the disclosed vinyl tile includes a customizable sound reducing underlayment (referred to as an "acoustical layer" or "acoustical portion") that is selected for the particular sub-floor system that includes the floor/ceiling assembly design with this which the tile will be used.
  • the disclosed tile thus provides a desired level of sound dampening that is not achievable with prior standard tiles.
  • the acoustical layer includes a plurality of sub-layers that can be formulated from different materials, and provided in different thicknesses, to provide superior sound dampening characteristics based on the associated sub-floor system that includes the floor/ceiling assembly design.
  • the disclosed vinyl tile includes recycled content.
  • the disclosed vinyl tile includes an antifungal compound to inhibit the growth of fungus.
  • an exemplary vinyl tile 1 includes an upper vinyl portion 2 and a lower acoustical portion 4.
  • the vinyl tile 1 is shown as having a rectangular plank shape, it will be appreciated that tiles according to the disclosure can be manufactured in any of a variety of desired geometric and non-geometric shapes.
  • Non-limiting examples of such shapes include rectangular planks with a width of 4-inches (101,3 mm) and a length of 36-inches (914,4 mm), rectangular planks with a width of 6-inches (152,4 mm) and a length of 36-inches (914,4 mm), and 18-inch (457,2 mm) by 18-inch (457,2 mm) square shapes.
  • the vinyl portion 2 may include a surface wear layer 6 to enhance the wear life of the vinyl portion.
  • the surface wear layer 6 may have a thickness of about 0.005-inches (5 mils or 0,127 mm) to about 40 mils (1,016 mm). In one embodiment, the surface wear layer may be about 8 mils (0,2032 mm).
  • the surface wear layer 6 may comprise polyvinyl chloride (PVC). In one non-limiting exemplary embodiment, the surface wear layer 6 includes at least 90% PVC.
  • the vinyl portion 2 may comprise a polyvinylchloride (PVC) material.
  • the acoustical portion 4 may comprise a plurality of layers including a variety of different sound dampening materials, as will be described in greater detail later. The vinyl portion 2 may be bonded to the acoustical portion 4 using a suitable adhesive 8.
  • FIG. 2 shows a cross-section of the vinyl tile 1.
  • This exemplary embodiment includes a vinyl portion 2 (with surface wear layer 6) and an acoustical portion 4 that includes first and second sub-layers 4a, 4b.
  • the vinyl portion 2 is bonded to the first sub-layer 4a by adhesive layer 8, while the first and second sub-layers 4a, 4b are bonded together by adhesive layer 10.
  • the layers may be bonded to each other without adhesive, such as by heat bonding or the like.
  • the acoustical portion 4 (including its sub-layers) can be permanently bonded to the vinyl portion 2 using an adhesive layer 8 material that is highly compatible both with the vinyl portion 2 and the first sub-layer 4a.
  • the material making up the first sub-layer 4a may be highly compatible with the vinyl portion 2 to reduce the chances for de-lamination and/or degradation of the vinyl portion from the acoustical portion during extended use.
  • the same may be true of the compatibility of the adhesive layer 10 and the first and second sub-layers 4a, b to ensure long term durability of the resulting tile 1.
  • the vinyl portion 2 has a thickness of about 2 millimeters (mm), while the acoustical portion 4 has a combined thickness of about 4 mm.
  • the sub-layers 4a, 4b are shown as having thicknesses of 2 mm each. It will be understood that these thicknesses are merely exemplary, and that different individual layer thicknesses can be used to suit a particular application, as will be explained.
  • the actual composition of layers within the tile 1 be variable so as to be customizable to the particular flooring application. That is to say that different sub-floor structures can require different combinations of acoustical portion sub-layer gauges, thicknesses and materials in order to achieve specific construction demands of a particular building. It will be appreciated that modern construction methods include the manufacture of buildings having concrete sub-flooring (six-inch (152,4mm) concrete, light concrete, etc.), and a wide variety of different truss-based sub-floor systems (metal trusses, wooden trusses, and combinations thereof).
  • a single building may include multiple different sub-floor types, each of which can have a different acoustical "response.”
  • vinyl tiles 1 used with each of these different sub-flooring types may need to include a customized acoustical portion 4 in order to provide desired sound dampening in such buildings.
  • the acoustical portion 4 may include a plurality of sub-layers 4a - 4n of sound dampening material.
  • the illustrated embodiments include two sub-layers (4a, 4b) it will be appreciated that more than two sub-layers (i.e., up to "n" sub-layers) as desired to suit the application.
  • the illustrated embodiments show individual sub-layers 4a, 4b having respective thicknesses of 2 mm, that other thicknesses may also be used.
  • the individual materials used to form the sub-layers 4a-4n may be formulated to minimize sound impact transmissions at specific frequencies.
  • the thicknesses of the sub-layers 4a-4n may be selected to work in combination with the individual sub-layer material types to minimize sound impact transmissions at specific frequencies.
  • a non-limiting exemplary listing of of appropriate sub-layer materials include the following:
  • the above, and other, materials can be provided in a variety of different densities, multiple thicknesses, and may include one or more fiber components.
  • Each of the sub-layers 4a-4n may have a thickness in the range of about 0.5mm to about 5.5mm.
  • the thickness of the assembled layers i.e., total thickness of the acoustical portion 4) may be between about 2.5mm to about 6mm.
  • the number of sub-layers can be as few as two, but is not limited to several as the requirements are met for a particular need.
  • the layers are bonded together with specific adhesives in various ways depending on the composition of the layers.
  • a non-limiting exemplary listing of such adhesives includes cyanoacrylate, latex, acrylic, epoxy and the like.
  • incorporating polyurethane into one or more of the sub-layers 4a-4n can enhance compatibility between the acoustical portion 4 and the vinyl portion 2.
  • the acoustical portion comprises about 10-40% crumb rubber, about 60-90% polyurethane foam, and a resin binder.
  • the crumb rubber component is obtained from recycled tires or sneaker rubber.
  • the polyurethane foam may be an appropriate open cell or closed cell foam, while the resin binder may be a polyurethane binder.
  • FIG. 3 shows the tile 1 of FIG. 2 applied over a wood truss sub-floor assembly 12.
  • a wood truss sub-floor assembly 12 might be made of a variety of different burling materials, including plywood sheathing 14, wood beams 16, metal fastening plates 18, gypsum board 20 (where the sub-floor forms part of an adjoining ceiling, as in the illustrated embodiment), resilient channels 22, etc.
  • wood trusses tend to deflect and require backings that take such flexure into account.
  • the acoustical portion 4 includes a first sub-layer 4a comprising a rubber material, and a second sub-layer 4b comprising a combination of rubber and cork.
  • Each of the sub-layers 4a, 4b of this embodiment are about 2 mm thick, and are adhered together using any of a variety of appropriate adhesives, as previously described.
  • FIG. 4 shows an exemplary alternative floor tile 24 that includes a vinyl portion 26, and an acoustical portion 28 adhered thereto using an adhesive layer 30.
  • the acoustical portion 4 again includes first and second sub-layers 4a, 4b.
  • the first sub-layer 4a comprises a cork and rubber combination
  • the second sub-layer 4b comprises a rubber layer.
  • this alternative tile may be appropriate for use with a concrete sub-floor 32. Since concrete is more homogenous and rigid than the previously described wooden truss floor assembly 12, it can transmit more sound at some frequencies than others.
  • step 100 the design of a particular sub-floor system that includes the floor/ceiling assembly to which the vinyl tile 1 will be applied is determined.
  • step 110 an acoustical portion is designed to include "n" individual sub-layers where "n” is a number greater than 1. The number "n” of individual sub-layers is selected based on the design of the sub-floor.
  • each the "n" sub-layers are selected to comprise a particular material.
  • each of the "n" sub-layers are selected to have a particular thickness, where the thickness of each sub-layer is selected based on the design of the sub-floor, the number "n" of sub-layers and the material of each of the sub-layers.
  • the "n" individual sub-layers are bonded together.
  • the bonded sub-layers are bonded to a vinyl tile portion.
  • the vinyl tile is applied to the sub-floor.

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  • Engineering & Computer Science (AREA)
  • Architecture (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Floor Finish (AREA)
  • Building Environments (AREA)

Claims (13)

  1. Eine Vinylfliese (1), die Folgendes beinhaltet:
    einen Vinylabschnitt (2); und
    einen Schalldämpfungsabschnitt (4), der eine Vielzahl einzelner schalldämpfender Unterschichten (4a-4n) beinhaltet, und wobei die einzelnen Unterschichten erste und zweite Unterschichten (4a, 4b) umfassen, wobei die erste Unterschicht (4a) mit dem Vinylabschnitt (2) verbunden ist, die zweite Unterschicht (4b) mit der ersten Unterschicht (4a) verbunden ist,
    wobei die ersten und zweiten Unterschichten (4a, 4b) der Vielzahl einzelner Unterschichten (4a-4n) Materialzusammensetzungen beinhalten, die voneinander verschieden sind, dadurch gekennzeichnet, dass die Vielzahl einzelner Unterschichten (4a-4n) Materialien beinhaltet, ausgewählt aus einer Liste bestehend aus Gummi, einer Kombination aus Kork und Gummi, einer Kombination aus Gummi und Polyurethanschaum (PU) und einer Kombination aus PU-Schaum und Kork.
  2. Vinylfliese (1) gemäß Anspruch 1, wobei die ersten und zweiten Unterschichten (4a, 4b) voneinander verschiedene Dicken aufweisen.
  3. Vinylfliese (1) gemäß Anspruch 1, wobei die ersten und zweiten Unterschichten (4a, 4b) gleiche Dicken aufweisen.
  4. Vinylfliese (1) gemäß einem der vorhergehenden Ansprüche, wobei die erste Unterschicht (4a) Gummi beinhaltet und die zweite Unterschicht (4b) eine Mischung aus Gummi und Kork beinhaltet.
  5. Vinylfliese (1) gemäß einem der Ansprüche 1 bis 3, wobei die erste Unterschicht (4a) eine Mischung aus Gummi und Kork beinhaltet und die zweite Unterschicht (4b) Gummi beinhaltet.
  6. Vinylfliese (1) gemäß einem der vorhergehenden Ansprüche, wobei die Vielzahl einzelner Unterschichten (4a-4n) drei einzelne Unterschichten beinhaltet.
  7. Vinylfliese (1) gemäß Anspruch 6, wobei die drei einzelnen Unterschichten (4a-4n) jede eine Materialzusammensetzung beinhaltet, die verschieden von den anderen einzelnen Unterschichten (4a-4n) ist.
  8. Vinylfliese (1) gemäß einem der vorhergehenden Ansprüche, wobei die Vielzahl einzelner Unterschichten (4a-4n) mehr als drei einzelne Unterschichten beinhaltet.
  9. Ein Verfahren zum Gestalten eines auf eine bestimmte Fußbodenbelagsanwendung abgestimmten Fußbodenbelagssystems, das Folgendes beinhaltet:
    Bestimmen eines Unterbodensystemtyps, der eine Fußboden/Deckenanordnung umfasst, an die eine Vinylfliese (1), die einen Vinylabschnitt (2) beinhaltet, angebracht wird;
    Auswählen eines Schalldämpfungsabschnitts (4) der Vinylfliese (1), um "n" Unterschichten (4a-4n) zu umfassen, wobei das Verfahren dadurch gekennzeichnet ist, dass: in dem Schritt des Auswählens eines Schalldämpfungsabschnitts eine Zahl "n" größer als 1 ist und sich nach dem Unterbodensystemtyp richtet; und dadurch, dass: das Verfahren den folgenden Schritt umfasst:
    Auswählen einer Materialzusammensetzung für jede der "n" Unterschichten (4a-4n), wobei die Materialzusammensetzung für jede der "n" Unterschichten (4a-4n) sich nach dem Unterbodensystemtyp, der die Fußboden/Deckenanordnung umfasst, und der Zahl "n" der Unterschichten (4a-4n) richtet, und
    wobei der Schalldämpfungsabschnitt (4) mindestens erste und zweite Unterschichten (4a, 4b) umfasst, wobei die ersten und zweiten Unterschichten (4a, 4b) Materialzusammensetzungen beinhalten, die voneinander verschieden sind, und wobei die ersten und zweiten Unterschichten (4a, 4b) Materialien beinhalten, ausgewählt aus der Liste bestehend aus Gummi, einer Kombination aus Kork und Gummi, einer Kombination aus Gummi und Polyurethanschaum (PU) und einer Kombination aus PU-Schaum und Kork.
  10. Verfahren gemäß Anspruch 9, das ferner das Auswählen einer Dicke für jede der "n" Unterschichten (4a-4n) beinhaltet, wobei die Dicke für jede der "n" Unterschichten (4a-4n) sich nach dem Unterbodensystemtyp, der die Fußboden/Deckenanordnung umfasst, der Zahl "n" der Unterschichten (4a-4n) und der Materialzusammensetzung jeder der "n" Unterschichten (4a-4n) richtet.
  11. Verfahren gemäß Anspruch 10, das ferner das Verbinden der "n" einzelnen Unterschichten (4a-4n) miteinander beinhaltet, um einen Schalldämpfungsabschnitt (4) zu bilden.
  12. Verfahren gemäß Anspruch 11, das ferner das Verbinden des Schalldämpfungsabschnitts (4) mit einem Vinylfliesenabschnitt (2) der Vinylfliese (1) beinhaltet.
  13. Verfahren gemäß Anspruch 12, das ferner das Anbringen der Vinylfliese (1) an dem Unterbodensystem, das die Fußboden/Deckenanordnung umfasst, beinhaltet.
EP13165658.9A 2012-05-10 2013-04-26 Mehrschichtige schalldämpfende Fußbodenfliese und Herstellungsverfahren Active EP2662508B1 (de)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US13/468,103 US8640824B2 (en) 2012-05-10 2012-05-10 Acoustical vinyl flooring and methods of manufacture
US201361808670P 2013-04-05 2013-04-05

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EP2662508A2 EP2662508A2 (de) 2013-11-13
EP2662508A3 EP2662508A3 (de) 2015-11-25
EP2662508B1 true EP2662508B1 (de) 2019-11-27

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* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB2517125A (en) * 2013-05-13 2015-02-18 Hardie James Technology Ltd An acoustic damping building material
EP3666993A1 (de) * 2014-06-03 2020-06-17 FLOOR4U PATENT Sp. z o.o. Mehrschichtiger bodenbelag

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DE202004014160U1 (de) * 2004-09-09 2004-11-18 Mohr, Wolfgang Bodenbelagelement
US8474208B2 (en) * 2009-06-22 2013-07-02 Novalis Holdings Limited Floor panel containing a polymer and cork
WO2012045343A1 (de) * 2010-10-06 2012-04-12 Knauf Gips Kg FUßBODENBELAG SOWIE FUßBODENPANEEL

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EP2662508A3 (de) 2015-11-25

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