FR2942829A1 - Sound-proofing material comprises an under-layer for floor coating, an upper rigid layer and a lower rigid layer, and a flexible intermediate layer disposed between the upper and lower layers, where the layers are made of non-woven cards - Google Patents

Abstract

The sound-proofing material (1) comprises an under-layer for floor coating, an upper rigid layer (40 wt.%) (2), a lower rigid layer (20 wt.%) (4), and a flexible intermediate layer (3) disposed between the upper and lower layers, where the layers are made of non-woven and needled cards and assembled by adhesion, ultrasonic welding or needle punching. The upper and lower rigid layers comprises 90-95 wt.% of core-coat type fused fibers, which are thermally interconnected for assuring rigidity of the layers, and 20-50 wt.% of hollow fibers having a helicoidal crimp. The sound-proofing material (1) comprises an under-layer for floor coating, an upper rigid layer (40 wt.%) (2), a lower rigid layer (20 wt.%) (4), and a flexible intermediate layer (3) disposed between the upper and lower layers, where the layers are made of non-woven and needled cards and assembled by adhesion, ultrasonic welding or needle punching. The upper and lower rigid layers comprises 90-95 wt.% of core-coat type fused fibers, which are thermally interconnected for assuring rigidity of the layers, 20-50 wt.% of hollow fibers having a helicoidal crimp, and greater than 30 wt.% of treated fibers having hydrophobic size. The upper layer is intended to be oriented towards the floor coating. The intermediate layer has 90-95 wt.% of hollow fibers having a helicoidal crimp, and comprises needled fused fibers along its thickness from top and lower layers, where the fibers are thermally connected for ensuring the interlocking between the layers. The material has a thickness of 6-12 mm, and a weight of 1500 g/m 2>. The lower layer, and upper layer comprise non-fusible fibers (20-50% wt.%) with a small titration [dtex] of 15 times the hollow fibers having the helical crimp used in the intermediate layer. Independent claims are included for: (1) a process for fabricating a sound-proof material e.g. an under-layer for floor coating; and (2) a sound-proof coating.

Description

SOUNDING MATERIAL

The present invention is in the technical field of soundproofing materials, especially as an underlay for flooring, in particular for tiling. It is known to have under the floor coverings a sound-absorbing sub-layer, in order to meet the standards in force in the field of the building. The demands of the users for the improvement of the sound insulation of their places of life are growing. The proposed soundproofing materials are effective but expensive, heavy, bulky to store and complex to ask. These soundproofing materials have the particular function of reducing airborne noise, caused by music broadcasts, radio or television receivers, and other household appliances, and impact noise, caused by the steps (heel, etc.). ), or shocks on the coating to be soundproofed. Soundproofing materials must meet soundproofing levels in the building, ranging from 18 dB to 19 dB. Sound insulation materials comprising a nonwoven web bonded to a layer of bitumen are known in the form of rigid plates. Such materials are described in FR 2,651,010. These plates are therefore proposed in limited dimensions, for example of the order of 50 cm × 50 cm, and have a high surface area, of the order of 11 kg / m 2, which complicates the storage, transportation and maintenance of the surface. pose.

An underlayer is also known, in the form of a fibrous mat, marketed in rigid rigid plates under the trademark CERMIPHONE by the company CERMIX. This sub-layer has the advantage over the sound insulation material described in document FR 2,651,010 to have a low surface density of the order of 1500 g / m 2 but has a lower acoustic efficiency of the order of 17 dB (according to standard NF EN ISO 140-8).

The soundproofing materials must meet the tests described in the NF P61-203 standard as well as the following tests: - Weight, thickness and dynamic stiffness according to NF EN ISO 29052: 1. - Variation of thickness db-dc between 50 kPa and 2 kPa according to standard NF EN 12431. This test is performed on a compression testing machine. The load variation on the sample and the duration of the compression steps are determined by the standard. - Measurement of the reduction of the weighted impact noise level OLw (NF EN ISO 140: 8) and the air noise Rw (C; Ctr) (NF EN ISO 140-3). The goal is to obtain an impact sound insulation OLw greater than or equal to 18 dB. - Determination of compression creep according to standard NF 1606. The test is carried out on 3 test pieces held for 122 days under a load of 5 kPa or 10 kPa. The dynamic stiffness is determined under a load of 4 Kg on the specimens subjected to the creep test before and after the test. - Resistance to nail tearing according to standard NF EN 12310-1. - Puncture resistance NF EN 12430.

The present invention relates to a soundproofing material at least meeting the sound insulation standards in force in the building described above, having a low surface weight and easy to install. The soundproofing material according to the invention comprises rigid upper and lower layers and a flexible intermediate layer disposed between and secured to said upper and lower layers, said upper, lower and intermediate layers being formed from carded and needled nonwovens. The soundproofing material is rigid since it can undergo a certain bending without deforming but can not be rolled up on itself so as to be stored in the form of rolls. The soundproofing material is thus in the form of a plate. This rigidity is advantageous for facilitating the installation of the floor covering since the thickness of the soundproofing material is even even under the weight applied by the floor covering, in particular by the tiles. Preferably, the upper and lower layers have relatively smooth outer surfaces, i.e. with few free fibers projecting therefrom, which facilitates the application of a glue mortar while providing good gripping surface because the upper and lower layers are based carded and needled nonwovens. Preferably, the upper and lower layers are substantially identical so that it is not necessary to distinguish them in order to identify the layer to be oriented towards the concrete and the layer to be oriented towards the outer decorative coating. The upper and lower layers being rigid, the acoustic waves are reflected between the upper and lower layers and are thus captured in the intermediate layer. The structure of the soundproofing material thus makes it possible to slow down the propagation of the acoustic waves and to absorb them. In addition, the rigidity of the upper and lower layers facilitates the cutting of the soundproofing material, for example by means of a cutter, which facilitates the installation.

The upper, lower and intermediate layers comprise a mixture of synthetic fibers, solid and / or hollow, optionally with a helical crimp, selected from the following families of polymers: polyethylene terephthalate (polyester), polyamide, polypropylene, polyethylene. Hollow fibers having a helical crimp are known for their excellent sound insulation properties. The hollow fibers having a helical crimp have a length ranging from 40 mm to 80 mm, preferably from 50 mm to 70 mm. The stiffness of the upper and lower layers can be obtained by adding fusible fibers or spraying charges in said layers followed by heat treatment for melting said fibers or fillers. The fillers may be, for example, powders chosen from the following polymer (s): polyethylene terephthalate (polyester), polyamide, polypropylene, polyethylene. The proportion by weight of fillers is preferably determined in the same amounts as the proportion by weight of fusible fibers in the upper and lower layers. The upper and lower layers must be rigid so as to meet the essential mechanical performance expected for a soundproofing material, which must also remain light in the context of the present invention.

In a variant, the upper and lower layers comprise from 35% by weight to 60% by weight of fusible fibers, preferably of the core-coat type, said fibers being thermally bonded and ensuring the rigidity of said layers. The upper, intermediate, and lower layers have a similar weight [g / m 2], which is about 30% -35% by weight of the total weight of the soundproofing material. The fusible fibers have a length ranging from 40 mm to 80 mm, preferably from 50 mm to 70 mm. The upper and lower layers comprise hot-melt polyester fibers, preferably of the core-coat type, the core being formed of a polymer having a melting temperature well above the melting temperature of the mantle polymer. Core-coat type fibers improve the distribution of bonding points in the thickness of the upper and lower layers. Advantageously, this stiffening method makes it possible to obtain a soundproofing material which is sufficiently strong and light to satisfy mechanical performance. The upper and lower layers thus comprise a mixture of fusible fibers and non-fusible fibers, especially hollow fibers having a helical crimp. The proportion by weight of hot melt fibers contained in the upper and lower layers makes it possible to adjust the rigidity of the upper and lower layers and to thermolier the non-fusible fibers together, possibly with the non-fusible core of the core-coat type fusible fibers. The cohesion of the upper and lower layers and their resistance to creep are also improved.

The non-fusible fibers in the upper and lower layers comprise hollow fibers having a helical crimp and single solid fibers, preferably polyester and colored. The proportion of said single fibers is less than 30% by weight. Said fibers have a length ranging from 40 mm to 80 mm, preferably ranging from 55 mm to 75 mm. Said fibers make it possible to ensure a given mass per unit area, a given volume and to improve the mechanical strength of said upper and lower layers while lowering their cost. They behave like loads. In one variant, the upper layer, and optionally the lower layer, comprises at least 90% by weight, preferably at least 95% by weight, of fusible fibers, preferably of the core-coat type, said fibers being thermally bonded and ensuring rigidity of said layers. In a variant, the upper layer being intended to be oriented towards the floor covering to be soundproof, represents less than 40% by weight of the total weight of the soundproofing material, and the lower layer represents less than 20% by weight of the total weight. soundproofing material. The lower layer may have the same composition as the top layer or comprise from 35% by weight to 60% by weight of fusible fibers and from 20% by weight to 50% by weight of hollow fibers having a helical crimp.

The upper layer thus ensures the mechanical performance required by the specifications. The lower layer makes it possible, in combination with the rigid upper layer, to facilitate cutting, in particular with the cutter, and thus the application of the soundproofing material. The intermediate layer represents more than 35% by weight, preferably more than 50% by weight, of the total weight of the soundproofing material. In the latter case, the sound insulation properties of the soundproofing material should be improved since the amount of hollow helical fibers contained therein is increased. In a variant, the upper layer, and optionally the lower layer, comprises more than 10% by weight, preferably more than 30% by weight, of fibers treated with a hydrophobic primer. This arrangement makes it possible to slow or even prevent the penetration of the adhesive-mortar applied to the upper layer, or possibly the lower layer, when laying the floor covering, in particular the tiles.

Part or all of the non-fusible fibers contained in the upper layer, and optionally the lower layer, is preferably selected so as to be hydrophobic in nature; this is the case of synthetic fibers. Their hydrophobic character can be amplified by a hydrophobic treatment so as to improve the barrier effect of the upper layer, or lower, with respect to the adhesive mortar. Preferably, the lower layer also comprises a proportion by weight of hydrophobic treated fibers similar to that of the upper layer so that the operator during the application of the adhesive-mortar does not have to distinguish said upper and lower layers soundproofing material, which facilitates installation. Such hydrophobic primers are well known in the state of the art, and are generally made by impregnating said fibers with a silicone-based dispersion or a fluoropolymer. In a variant, the upper and lower layers comprise from about 20% by weight to 50% by weight of hollow fibers having a helical crimp. The upper and lower layers also provide a part of the sound insulation function, provided mainly by the intermediate layer.

In a variant, the intermediate layer comprises at least 90% by weight, preferably at least 95% by weight, of hollow fibers having a helical crimp. Preferably, the intermediate layer is prepared, before being secured to the upper and lower layers, so as to be made of hollow synthetic fibers having a helical crimp, selected from the following polymers: polyethylene terephthalate (polyester), polyamide, polypropylene , polyethylene. In a variant, the soundproofing material has a thickness ranging from 10 4 mm to 15 mm, preferably from 6 mm to 12 mm. The thickness of the upper, lower and intermediate layers is between 0.5 mm and 6 mm, preferably the upper and lower layers have a thickness of between 0.5 mm and 3 mm and the intermediate layer has a thickness of between 3 and 6 mm. mm and 5 mm. Preferably, the thickness of the different layers of the soundproofing material before their joining is adjustable by varying the density of the needling [number of strokes / cm2] of the various layers of carded fibers constituting them individually. Thus, the upper and lower layers being intended to form rigid layers, can receive a higher needling density than the intermediate layer. It is important to be able to adjust the thickness of the soundproofing material to match the dimensions of the floor covering and the rooms to be soundproofed. In a variant, the soundproofing material has a basis weight of between 1000 g / m 2 and 2000 g / m 2, preferably of the order of 1500 g / m 2. The soundproofing material according to the invention is light and easy to install. This surface mass is sufficient to meet the specifications for mechanical performance and sound insulation. In a variant, the soundproofing material consists of the upper, lower and intermediate layers and the upper and lower layers have substantially the same composition of carded fibers.

With a substantially identical composition, the upper and lower layers can thus have the same weight [g / m2] or different weights [g / m2]. In a variant, the upper, lower and intermediate layers 5 are assembled by gluing or ultrasonic welding. Preferably, the intermediate layer consists of hollow fibers having a helical crimp. In a variant, the upper, intermediate and lower layers are assembled by needling. This method of assembly provides good resistance to delamination between the layers and avoids the formation of rigid films interposed between each layer (obtained by gluing or ultrasound) harmful to the sound insulation properties of the soundproofing material. In a sub-variant, the intermediate layer comprises in its thickness needled fusible fibers from the upper and lower layers, said fibers being thermally bonded and ensuring bonding between the layers. Thermobonding strengthens the bond between the upper, lower and intermediate layers. When the upper and lower layers comprise fusible fibers, the latter are found in the intermediate layer. The intermediate layer thus comprises, for the most part, hollow synthetic fibers having a thermo-fused helical crimp, optionally with the non-fusible core of the core-coat type fusible fibers. The needled fusible fibers during assembly thus pass through the three layers of the soundproofing material and improve its mechanical performance when they are thermally bonded (tear resistance, puncture resistance, etc.). In a variant, the lower layer, and optionally the upper layer, comprises non-fusible fibers, preferably of the order of 20% by weight to 50% by weight, having a titration [dtex] at least 10 times greater, preferably at least 15 times higher, at the lower titration of the hollow fibers having a helical crimp employed in the intermediate layer. Advantageously, the outer surface of the lower layer has an irregular surface which allows to leave air between said outer surface and the floor to be soundproofed when the soundproofing material is attached by gluing on the outer face of its lower layer on the floor to soundproof. The air layer thus formed makes it possible to capture a portion of the acoustic waves. This advantage is found when the upper layer comprises non-fusible fibers with a [dtex] titration as described above.

The subject of the present invention is also, according to a second aspect, a method of manufacturing a soundproofing material according to the invention, in particular as an underlay for a floor covering, characterized in that it comprises the following steps a) superimposing three plies of carded fibers, preferably pre-needled, so as to form an assembly, wherein the upper and lower plies comprise at least 35% by weight, preferably 35% by weight to 60% by weight fusible fibers, and optionally from 20% by weight to 50% by weight of hollow fibers having a helical crimp, and wherein the intermediate web comprises at least 90% by weight of hollow fibers having a helical crimp; b) securing said plies by needling the assembly so that fibers of the upper and lower plies pass through the intermediate ply and open into the ply which is opposite to them; c) thermoliering the assembly at a temperature and for a duration determined so as to obtain the melting of the fusible fibers in the upper and lower layers and in the intermediate layer and to form rigid upper and lower layers and a flexible intermediate layer.

Preferably, before being superimposed, the plies of fibers are slightly consolidated for their handling and have their thickness reduced by one or more passes on a single needling striker or double strike. The assigned punch density [number of strokes / cm2], the number of needles / cm2, the type of needle and the depth of penetration of the latter are all parameters to be varied to adjust the desired thickness reduction. fiber layers, taking also into account the amount (weight / m2) of carded fibers and the intended consolidation. This step, designated in the present invention by the term pre-needling, is required for the case where the carding equipment does not comprise at least three different carding inputs for superimposing the webs of carded fibers continuously. Preferably, the intermediate web comprises 100% by weight of hollow fibers having a helical crimp. Thermobonding decreases the creep tendency of the soundproofing material. Creep is understood to mean the progressive deformation of said material subjected to constant effort. The thermobonding can be obtained by passing the needle-punched assembly in a heated enclosure for a given period of time without mechanical stress exerted on said assembly or by passing under a heating press, or heating cylinders, the latter possibility of further reducing the temperature. the thickness of the soundproofing material and to be conducted so that the heat-sealed soundproofing material retains its substantially flat configuration. A soundproofing material having a non-planar configuration complicates or even makes it impossible to install flooring. The object of the present invention is, according to a third aspect, a sound-proofing coating comprising a floor covering and a soundproofing material according to one of the embodiments described above as an underlayer, bonded to the lower face of said floor covering, especially by gluing. The present invention will be better understood on reading two exemplary embodiments, cited by way of nonlimiting example, and of which only the first example is illustrated in FIG. 1 hereafter appended to the present, which is a schematic cross-sectional representation. . The soundproofing material 1 comprises upper and lower layers 4 and a flexible intermediate layer 3 disposed between and secured to said upper 2 and lower 4 layers. The upper 2 and lower 4 layers comprise from 50% to 60% by weight of hot-melt fibers, in particular two-component polyester-based heat-fusible fibers of the core-coat type, the mantle having a melting temperature of between 110 ° C and 190 ° C. In this example, the hot melt fibers have a titration ranging from 2 dtex to 10 dtex. The intermediate layer 3 comprises more than 95% by weight of hollow polyester-based fibers having a helical crimp, having a titration ranging from 2 dtex to 15 dtex. The upper and lower layers 2 comprise from about 20% by weight to 50% by weight of hollow fibers having a helical crimp of polyester identical to those used for the intermediate layer 3. Said layers 2,4 also comprise less than 30% by weight of colored polyester solid fibers. The weight of the intermediate layer 3 is between 300 g / m 2 and 700 g / m 2, and preferably of the order of 500 g / m 2. The upper 2 and lower 4 layers have a basis weight of the order of 500 g / m2. The soundproofing material 1 thus has a weight of between 1300 g / m2 and 1700 g / m2, preferably of the order of 1500 g / m2. The layers 2,4 have a thickness of the order of 2.5 mm each, the layer 3 has a thickness of the order of 4 mm so as to form a soundproofing material 1 having a total thickness of the order 9 mm.

During the manufacture of the soundproofing material 1, three plies of individually carded and pre-needled fibers are superimposed and then needled together, preferably on a double needling needle therefore on the two outer faces of the assembly, so that fibers upper and lower layers pass through the intermediate layer and open into the sheet opposite them. Consolidation lines 5 are thus obtained between the three layers 2, 3, 4 corresponding to partially heat-fusible fibers extending right through the soundproofing material 1. The three needled layers are then thermolated by passing through a at a temperature and for a specified time, preferably at a temperature between 180 ° C and 240 ° C, so as to obtain the melting of the fusible fibers in the upper and lower layers and in the intermediate layer and form said layers upper 2 and lower rigid 4 and a flexible intermediate layer 3. The upper 2 and lower 4 layers have a thickness less than that of the intermediate layer 3 because they are subjected to direct needling during assembly of the layers together. The upper and lower layers 4 comprising hollow fibers having a helical crimp participate in the sound insulation function of the soundproofing material, which function is provided essentially by the intermediate layer 3 comprising a proportion of hollow fibers having a helical crimp tending to 100% by weight since they also include thermally bonded fusible fibers. The flexible intermediate layer 3 thus makes it possible to absorb the noise while the upper 2 and lower 4 layers provide the essential mechanical performance required by the specifications. The soundproofing material 1 offers excellent soundproofing properties since the measurement of the reduction of the weighted impact noise level OLw, measured according to the NF EN ISO 140: 8 standard, is greater than or equal to 18 dB.

The second example of soundproofing material according to the invention differs from the first example of material by the composition and the surface mass of its different layers. The manufacturing method and the different fibers may be identical to that described in the first example. The upper layer comprises of the order of 90% by weight of fusible fibers, with a weight per unit area in the range [300 g / m 2; 700 g / m2], preferably of the order of 500 g / m2, and a thickness of the order of 1.5-2 mm. The intermediate layer comprises at least 90% by weight of hollow fibers having a helical crimp, a basis weight in the range [600 g / m 2; 1000 g / m2], preferably of the order of 800 g / m2, and a thickness of about 6 mm. The lower layer comprises between 50% to 60% fusible fibers and 20% to 40% hollow fibers having a helical crimp. The lower layer has a thickness of the order of 0.5 mm to 1 mm. Each of the layers of the soundproofing material may comprise single fibers, preferably polyester and colored. The amount of colored fibers per layer is a function of the final appearance intended for the soundproofing material, and in particular to distinguish the upper layer from the lower layer. The colored fibers may be hollow fibers having a helical crimp, fusible fibers or other known simple known fibers. The second example of soundproofing material has better sound insulation performance than said first material since it comprises more hollow fibers having a helical crimp. The basis weight and the thickness of the lower layer have been reduced in order to maintain a final material weight of the order of 1500 g / m 2, while allowing easy cutting in combination with the also rigid top layer. Optionally, some or all of the hollow fibers having a helical crimp used in the upper and lower layers for the first example of soundproofing material, and the lower layer for the second example of soundproofing material, are titrated 10 times. higher, preferably at least 15 times higher, than the lowest titration of the hollow fibers having a helical crimp employed in the intermediate layer. This arrangement makes it possible to generate an outer surface for the lower layer, and possibly the upper layer, irregular, able to create a layer of air when it is reported by gluing on the floor to soundproof. The air layer thus formed slows the propagation of acoustic waves.

Claims (15)

REVENDICATIONS1. Soundproofing material (1), in particular underlay for flooring, characterized in that it comprises rigid upper (2) and lower (4) layers and a flexible intermediate layer (3) arranged between and secured to said layers upper (2) and lower (4) and in that said layers (2,3,4) are based carded and needled nonwovens. Soundproofing material (1) according to Claim 1, characterized in that the upper (2) and lower (4) layers comprise from 35% by weight to 60% by weight of fusible fibers, preferably of the core-type. mantle, said fibers being thermolated and ensuring the rigidity of said layers (2,4). 3. Soundproofing material (1) according to either of claims 1 and 2, characterized in that the upper (2) and lower (4) layers comprise of the order of 20% by weight to 50% by weight. % by weight of hollow fibers having a helical crimp. Sound insulation material according to Claim 1, characterized in that the upper layer, and optionally the lower layer, comprises at least 90% by weight, preferably at least 95% by weight, of fusible fibers, preferably of the type core-coat, said fibers being heat-sealed and ensuring the rigidity of said layers. Soundproofing material according to either of Claims 1 and 4, characterized in that the upper layer, intended to be oriented towards the floor covering to be soundproofed, represents less than 40% by weight of the weight total of the soundproofing material and in that the lower layer is less than 20% by weight of the total weight of the soundproofing material. Soundproofing material (1) according to one of Claims 1 to 5, characterized in that the intermediate layer (3) comprises at least 90% by weight, preferably at least 95% by weight, of hollow fibers having a helical crimp. Soundproofing material (1) according to one of Claims 1 to 6, characterized in that the upper layer (2), and optionally the lower layer (4), comprises more than 10% by weight, preferably more 30% by weight, fibers treated with a hydrophobic primer. 8. Soundproofing material (1) according to one of claims 1 to 7, characterized in that it has a thickness ranging from 4 mm to 15 mm, preferably between 6 mm and 12 mm, and in that it has a basis weight of between 1000 g / m 2 and 2000 g / m 2, preferably of the order of 1500 g / m 2. 9. Soundproofing material (1) according to one of claims 1 to 8, characterized in that it consists of the upper layer (2), lower (4) and intermediate (3) and in that the upper layers (2) and lower (4) have substantially the same composition of carded fibers. 10. soundproofing material according to one of claims 1 to 9, characterized in that the upper, lower and intermediate layers are assembled by gluing or ultrasonic welding. 11. soundproofing material (1) according to one of claims 1 to 9, characterized in that the upper layers (2), intermediate (3) and lower (4) are assembled by needling. 12. Soundproofing material (1) according to claim 11, characterized in that the intermediate layer (3) comprises, in its thickness, needled fusible fibers from the upper (2) and lower (4) layers, said fibers being thermally bonded and ensuring the bonding between the layers (2,3,4). 13. soundproofing material according to one of claims 1 to 12, characterized in that the lower layer, and optionally the upper layer, comprises non-fusible fibers, preferably of the order of 20% by weight to 50% by weight, having a titration [dtex] at least 10 times higher, preferably at least 15 times higher, than the lowest titration of hollow fibers having a helical crimp employed in the intermediate layer. 14. A method of manufacturing a soundproofing material (1), especially undercoat for flooring, according to claim 11, characterized in that it comprises the following steps: a) superimposing three sheets of carded fibers, preferably pre-needled, so as to form an assembly in which the upper and lower plies comprise at least 35% by weight of fusible fibers, preferably from 35% by weight to 60% by weight of fusible fibers, and optionally from 20% by weight to 50% by weight of hollow fibers having a helical crimp, and wherein the intermediate web comprises at least 90% by weight of hollow fibers having a helical crimp; b) securing said plies by needling the assembly so that fibers of the upper and lower plies pass through the intermediate ply and open into the ply which is opposite to them; c) thermoliering the assembly at a temperature and for a time determined so as to obtain the melting of the fusible fibers in the upper and lower layers and in the intermediate layer and to form rigid upper (2) and lower (4) layers and a flexible intermediate layer (3). 15. Soundproofed coating comprising a floor covering and a soundproofing material according to one of claims 1 to 13 as an underlayer, bonded to the underside of said floor covering, in particular by gluing.