GB2327689A

GB2327689A - Acoustic insulation systems for buildings

Info

Publication number: GB2327689A
Application number: GB9715956A
Authority: GB
Inventors: Paul Alan Dennis
Original assignee: EXTON
Current assignee: EXTON
Priority date: 1997-07-30
Filing date: 1997-07-30
Publication date: 1999-02-03
Anticipated expiration: 2017-07-30
Also published as: GB9715956D0; GB2327689B

Abstract

An acoustic insulation system for application to an existing surface of a building comprises layers of the following, in order; a felt, foam or fibre underlay (10), a first metal layer (20), a damping layer (22), a second metal layer (16) and a board layer (14). In use the underlay (10) is placed nearest the existing surface. Preferably one or both of the metal layers (20, 16) is made of acoustic deadening metal, eg zintec. The damping layer (22) may be a polyviscoelastic sealant which bonds the metal layers (20,16) together. Additionally, the second metal layer (16) may be bonded to the board layer (14) by a adhesive (18). The underlay (10) may be of jute underlay felt, and the board layer (14) chipboard or medium-density fibreboard.

Description

TITTLE Acoustic Insulation Systems for Buildings DESCRIPTION This invention relates to (a) an acoustic insulation system for application to an existing surface of a building, such as an existing floor, (b) such a system when applied to an existing floor, (c) kit of parts for constructing such an acoustic insulation system, and (d) a method of applying such a system to such a surface.

It is well known to apply cladding to existing walls, floors and ceilings of a building in order to improve the acoustic insulation of a room in the building. Various forms of cladding are known, usually made up of a plurality of layers including a structural layer, such as chipboard, medium density fibreboard ("MDF"), plasterboard or cement-particle board, and a layer whose prime function is insulation, such as a layer of Rockwool, felt fibre or foam. Typically, the heavier and thicker the cladding, the better is the insulation.

However, especially when considering floor insulation, the thicker the cladding, the more difficult it is to make existing doors fit, and the heavier the cladding, the more load is placed on the existing floor.

In accordance with a first aspect of the present invention, there is provided an acoustic insulation system for application to an existing surface of a building, comprising a series of layers including, in the following order: a felt, foam or fibre underlay layer, a first metal layer, a damping layer, a second metal layer, and a board layer, in use the underlay layer being placed nearer the existing surface. The use of the two metal layers separated by the damping layer has been found to produce exceptionally good sound insulating properties.

Preferably, one or each of the metal layers is made of acoustic deadening metal, such as zintec. The thickness of one or each of the metal layers is preferably between 1/3 and 1 mm, and more preferably about mm.

Preferably,the damping layer is provided by a polyviscoelastic sealant which bonds the first and second metal layers together, and preferably has a thickness of between 4 and l/2 mm. It is believed that the use of the polyviscoelastic sealant produces a significant acoustic damping effect on the metal layers.

Preferably, the system further includes an adhesive layer which bonds the second metal layer to the board layer. The adhesive layer may be provided by a contact adhesive, such as a synthetic rubber-based adhesive.

Preferably, the underlay layer is provided by a heavy-duty jute underlay felt, and preferably has a nominal uncompressed thickness of about 10 mm.

Preferably, the board layer is made of chipboard or medium-density fibreboard, and preferably has a thickness of between 15 and 21 mm, more preferably about 18 mm.

In accordance with a second aspect of the present invention, there is provided a system as defined above, in combination with an existing floor of a building, the underlay layer being placed nearer the existing surface than the board layer.

In accordance with a third aspect of the present invention, there is provided a kit of parts for constructing an acoustic insulation system according to the first aspect of the invention, the kit comprising one or more rolls of the underlay layer, and a plurality of panels each having such a first metal layer, damping layer, second metal layer and board layer In accordance with a fourth aspect of the present invention, there is provided a method of applying a system as defined above to an existing floor of a building, comprising the steps of: laying the underlay layer on the existing floor; and laying panels contiguously on the underlay layer, each panel having such a first metal layer, damping layer, second metal layer and board layer, and the first metal layer facing the underlay layer.

The panels are preferably tongue-and-grooved.

Specific embodiments of the present invention will now be described, purely by way of example, with reference to the accompanying drawings, in which: Figure 1 is a partial cross-sectional view through an embodiment of the acoustic insulation system, together with an enlarged view of part of the cross-section; and Figure 2 is a cut-away isometric view of a floor and wall to which the acoustic insulation system has been applied.

Referring to figure 1, the acoustic insulation system comprises a layer of heavy-density jute needleloom underlay felt 10, which is supplied in rolls, and panels 12 which are supplied in a size of 2400 mm x 600 mm and which are laid on the felt layer 10. The felt layer 10 has a nominal uncompressed thickness of 10.5 mm, and in use is compressed to a thickness of about 9 mm. The panel 12 has an upper layer 14 of flooring-grade chipboard which is 18 mm thick. To the lower face of the chipboard layer 14, a sheet-metal layer 16 is attached using a layer 18 of synthetic rubber-based contact adhesive in a non-flammable solvent. The sheet-metal layer 16 is made of zintec and is 0.5 mm thick, and the adhesive layer 18 is about 0.25 to 0.5 mm thick. To the lower face of the zintec layer 16, a lower sheet-metal layer 20 is attached using a layer 22 of polyviscoelastic sealant. Again, the lower sheet-metal layer 20 is made of zintec and is 0.5 mm thick, and the sealant layer 22 is about 0.25 to 0.5 mm thick. In use, the lower face of the lower zintec layer 20 is placed on the upper surface of the felt layer 10, but without being bonded to it. It will be noted that the thickness of the panel 12 is about 19.5 to 20 mm, and that the total thickness of the acoustic insulation system is, in use, about 28.5 to 29 mm.

Referring to figure 2, an existing floor is shown which butts up against an existing wall 24 and comprises a series of timber joists 26, across which are laid tongue-and-grooved wooden floorboards 28 (the tongues and grooves of which are not shown for reasons of clarity). In order to apply the acoustic insulation system to the floor, first the felt layer 10 is laid from the supplied rolls of it and cut to size, but, adjacent the wall 24, an upwardly folded return 30 is formed, about 20 mm or more high. The panels 12 are then cut to size, if necessary, and laid on the felt layer 10 (with the metal layer 20 lowermost) in a staggered contiguous fashion with their tongues and grooves (not shown) interengaging. The return 30 of the felt layer 10 is then trimmed level with the upper surface of the panels 12. If desired, a skirting board may then be affixed to the wall 24, but preferably with a gap of at least 5 mm between the lower edge of the skirting board and the upper surface of the panel 12 / felt return 30.

It should be noted that the embodiment of the invention has been described above purely by way of example, and that many modifications and developments may be made thereto.

For example, more than two of the metal layers 16, 20 may be employed, and metals other than zintec (although preferably sound deadening metals) may be used.

Furthermore, other types of felt may be used for the layer 10, and foam or fibre may also be used. Moreover, other materials may be used for the board 14, such as MDF.

The layers 14 to 20 need not necessarily be supplied as panels, but may be supplied loose, and a sheet of damping material may be used instead of the sealant layer 22. Also, the adhesive layer 18 may be omitted.

Claims

1. An acoustic insulation system for application to an existing surface of a building, comprising a series of layers including, in the following order: a felt, foam or fibre underlay layer, a first metal layer, a damping layer, a second metal layer, and a board layer, in use the underlay layer being placed nearer the existing surface.

2. A system as claimed in claim 1, wherein one or each of the metal layers is made of acoustic deadening metal.

3. A system as claimed in claim 1 or 2, wherein one or each of the metal layers is made of zintec.

4. A system as claimed in any preceding claim, wherein the thickness of one or each of the metal layers is between 1/3 and 1 mm.

5. A system as claimed in claim 4, wherein the thickness of one or each of the metal layers is about 1/2 mm.

6. A system as claimed in any preceding claim, wherein the damping layer is provided by a polyviscoelastic sealant which bonds the first and second metal layers together.

7. A system as claimed in any preceding claim, wherein the thickness of the damping layer is between 4 and 1/2 mm.

8. A system as claimed in any preceding claim, further including an adhesive layer which bonds the second metal layer to the board layer.

9. A system as claimed in claim 8, wherein the adhesive layer is provided by a contact adhesive.

10. A system as claimed in any preceding claim, wherein the underlay layer is provided by a heavy-duty jute underlay felt.

11. A system as claimed in any preceding claim, wherein the nominal uncompressed thickness of the underlay layer is about 10 mm.

12. A system as claimed in any preceding claim, wherein the board layer is made of chipboard or medium-density fibreboard.

13. A system as claimed in any preceding claim, wherein the thickness of the board layer is between 15 and 21 mm.

14. A system as claimed in claim 13, wherein the thickness of the board layer is about 18 mm.

15. A system as claimed in any preceding claim when applied to an existing floor of a building, the underlay layer being placed nearer the existing surface than the board layer.

16. An acoustic insulation system for application to an existing surface of a building, substantially as described with reference to the drawings.

17. A kit of parts for constructing an acoustic insulation system as claimed in any preceding claim, the kit comprising one or more rolls of the underlay layer, and a plurality of panels each having such a first metal layer, damping layer, second metal layer and board layer.

18. A kit of parts for constructing an acoustic insulation system, substantially as described with reference to the drawings.

19. A method of applying a system as claimed in any of claims 1 to 14 to an existing floor of a building, comprising the steps of: laying the underlay layer on the existing floor; and laying panels contiguously on the underlay layer, each panel having such a first metal layer, damping layer, second metal layer and board layer, and the first metal layer facing the underlay layer.

20. A kit as claimed in claim 17 or a method as claimed in claim 19, wherein the panels are tongue-and-grooved.

21. A method of applying an acoustic insulation system to an existing floor of a building, substantially as described with reference to the drawings.