GB2584144A

GB2584144A - Laminates for insulation against airborne sound

Info

Publication number: GB2584144A
Application number: GB1907296.6A
Authority: GB
Inventors: Mcgowan Mann Robert
Original assignee: Millerran Res & Manufacturing Associates Ltd
Current assignee: Millerran Res & Manufacturing Associates Ltd
Priority date: 2019-05-23
Filing date: 2019-05-23
Publication date: 2020-11-25
Anticipated expiration: 2039-05-23
Also published as: GB2584144B; GB201907296D0

Abstract

A laminate comprising a filled polymer material first layer 2 comprising at least 70 wt% of a mineral filler which has a density of greater than 3 g/cm3 within a polymer matrix and second layer 4 comprising a viscoelastic material with substantially no filler. The polymer may further include a lubricant, ideally at a weight percentage of 0.1 to 5 %. The viscoelastic material may be a pressure sensitive and may have an elongation at break of at least 200% and/or a Shore A hardness of up to 80. The laminate may contain multiple first layers and may comprising multiple B layers. Also included are claims to a panel comprising the laminate with a further facing sheet disposed on the surface, a door leaf comprising said panel and a method of manufacturing the laminates comprising combining filler and powdered polymer to form a filled polymer material layer and applying a viscoelastic material with no filler to said polymer material.

Description

Laminates for insulation against airborne sound Background [0001] It is desirable to utilise materials providing a high degree of sound insulation in the construction of buildings and vehicles. Many sound insulating construction materials have a high thickness or weight which makes them difficult to incorporate into some parts of vehicles and also buildings, such as architectural doors.

[0002] Conventionally when improved acoustic performance of an architectural door is required, for example providing at least a 35 dB Rw reduction, for example a 40 dB Rw reduction (where Rw is the "weighted sound reduction index", for example determined according to BS EN ISO 717-1:2013), a sheet of lead is incorporated in the door leaf construction at great cost and increase in weight. Conventional high performance acoustic door leaves typically have a thickness in the region of 65-75 mm and weigh in excess of 90 kg. Alternative attempts at providing architectural doors with improved airborne sound insulation have included incorporating complex perimeter sealing systems which may use latching devices that rely on heavy leverage to achieve compression of specialised perimeter seals. Such complex systems are undesirable for everyday use.

[0003] There is a desire to provide an alternative to, preferably an improvement upon, airborne sound insulating materials, particularly airborne sound insulating materials useful in the construction of architectural doors, of the prior art.

Field of the Invention

[0004] Described herein are laminate materials, methods for producing laminate materials and related aspects. The laminate materials described herein are useful as acoustic materials, for example useful in the production of architectural door leaves having airborne sound reduction characteristics to provide improved acoustic performance.

Summary of the Invention

[0005] Described herein is a laminate comprising: (A) a layer of a filled polymer material comprising at least about 70 wt.% of a mineral filler by weight of the material and a polymer matrix; and (B) a layer of a viscoelastic material comprising substantially no mineral filler.

[0006] In a first aspect, provided herein is a laminate comprising: an A-layer composed of a filled polymer material comprising: at least about 70 wt.% of a mineral filler by weight of the material; and a polymer matrix, wherein the mineral filler has a density of greater than about 3 g/cm3; and a B-layer comprising a viscoelastic material comprising substantially no mineral filler.

[0007] In a second aspect, provided herein is a method of producing a laminate, the method comprising: providing an A-layer composed of a filled polymer material; providing a B-layer composed of a viscoelastic material; providing a laminate comprising the A-layer and the B-layer, wherein providing the A-layer comprises combining a mineral filler having a density of greater than about 3 g/cm3 and a powdered polymer to form a filled polymer material layer comprising at least about 70 wt.% of the mineral filled by weight of the material, and wherein the viscoelastic material comprises substantially no mineral filler.

[0008] In a third aspect, provided herein is a panel comprising a laminate of the first aspect.

[0009] In a fourth aspect, provided herein is a door leaf comprising a laminate of the first aspect, or a panel of the third aspect.

[00010] In a fifth aspect, provided herein is a method of producing a panel comprising a laminate produced according to the second aspect.

[00011] In a sixth aspect, provided herein is a method of producing a door leaf comprising a laminate produced according to the second aspect, or a panel produced according to the fifth aspect.

Brief Description of the Figures

[00012] Figure 1 is a schematic diagram of a cross-section of a laminate described herein: [00013] Figure 2 is a schematic diagram of a cross-section of a laminate described herein: [00014] Figure 3 is a schematic diagram of a cross-section of a laminate described herein; [00015] Figure 4 is a schematic diagram of a cross-section through a solid-core flush door leaf comprising a laminate as described herein; [00016] Figure 5a is an illustration of a single-panel joinery door leaf; [00017] Figure 5b is an illustration of a four-panel joinery door leaf; [00018] Figure 5c is an illustration of a six-panel joinery door leaf: [00019] Figure 6 is a schematic diagram of a partial cross-section through an example of a joinery door leaf.

Detailed Description

[00020] Optional and preferred features of the laminates, methods and related aspects will be described below. Any optional or preferred feature may be combined with any other optional or preferred feature, and any aspect of the invention as described herein.

Laminate [00021] The laminates described herein may be referred to as acoustic laminates, that is laminates which may be used to improve acoustic performance of structures such as doors, and/or airborne sound insulating laminates.

[00022] Described herein is a laminate 100 as shown in figure 1 comprising an "A-layer" 2 and a "B-layer" 4. In embodiments, the "A-layer" is a layer of a filled polymer material comprising: at least about 70 wt.% of a mineral filler by weight of the material; and a polymer matrix, wherein the mineral filler has a density of greater than about 3 g/cm3. In embodiments, the "B-layer" is a layer comprising a viscoelastic material comprising substantially no mineral filler.

[00023] In certain embodiments, the laminate comprises a plurality of A-layers. For example, as shown in figure 2, the laminate 200 may comprise a first A-layer 2a and a second A-layer 2b with a B-layer 4 being disposed between the first A-layer 2a and the second A-layer 2b (this configuration may be referred to as an A-B-A laminate).

[00024] In certain embodiments, the laminate comprises a plurality of B-layers. For example, the laminate may comprise a first B-layer and a second B-layer with an A-layer being disposed between the first B-layer and the second B-layer (this configuration may be referred to as a B-A-B laminate).

[00025] In certain embodiments, the laminate comprises a plurality of A-layers and a plurality of B-layers. For example, as shown in figure 3, the laminate 300 may comprise first, second and third A-layers 2a, 2b, 2c and first and second B-layers 4a, 4b, where the first B-layer 4a is disposed between first and second A-layers 2a, 2b and the second B-layer 4b is disposed between second and third A-layers 2b. 2c.

[00026] Generally, a B-layer 4 may be disposed on a A-layer 2. The A-layer(s) may be joined to the B-layer(s) directly (for example the A-layer(s) and B-layer(s) may be coextruded or the B-layer may be an adhesive viscoelastic material (for example a viscoelastic adhesive) which may be applied directly to the A-layer(s)), or the A-layer(s) and B-layer(s) may be joined using an adhesive (for example any adhesive that is compatible with the A-layer(s) and the B-layer(s), such as doubled sided adhesive film, or a wet adhesive such as a rubberised contact adhesive, polyurethane, or water-based ethylene vinyl acetate (EVA)).

[00027] In certain embodiments, the laminate has a thickness of less than about 50 mm, for example less than about 40 mm, less than about 30 mm, less than about 20 mm, less than about 10 mm, or less than about 5 mm. for example about 3 mm.

[00028] In certain embodiments, the laminate has a thickness of at least about 1 mm, for example at least about 1.5 mm, at least about 2 mm, or at least about 3 mm.

[00029] In certain embodiments, the laminate has a thickness in the range of about 1 mm to about 50 mm, for example about 1 mm to about 40 mm, about 1 mm to about 30 mm, about 1 mm to about 20 mm, about 1 mm to about 10 mm, about 2 mm to about 10 mm, or about 1 mm to about 5 mm.

[00030] In certain embodiments, the laminate consists of or consists essentially of A-layer(s) and B-layer(s) described herein. In certain embodiments, the laminate consists of A-layer(s), B-layer(s) and optionally adhesive layers to join A and B layers.

[00031] In certain embodiments, the laminate comprises. consists essentially of, or consists of: an A-layer composed of a filled polymer material comprising at least about 70 wt.% of a mineral filler by weight of the material, the mineral filler having a density of greater than about 3 g/cm7, and about 5 wt.% to about 30 wt.% of a polymer matrix by weight of the material; and a B-layer composed of a viscoelastic material comprising substantially no mineral filler, the viscoelastic material having an elongation at break of at least about 150%.

[00032] In certain embodiments, the laminate comprises, consists essentially of, or consists of: an A-layer composed of a filled polymer material comprising at least about 70 wt.% of a mineral filler by weight of the material, the mineral filler having a density of greater than about 3 g/cm2, and about 5 wt.% to about 30 wt.% of a polymer matrix by weight of the material; and a 13-layer composed of a viscoelastic material comprising substantially no mineral filler, the viscoelastic material having a Shore A hardness in the range of about 10 to about 80.

[00033] In certain embodiments, the laminate comprises, consists essentially of, or consists of: an A-layer composed of a filled polymer material comprising at least about 70 wt.% of a mineral filler by weight of the material, the mineral filler having a density of greater than about 3 g/cm2, and about 5 wt.% to about 30 wt.% of a polymer matrix by weight of the material; and a [3-layer composed of a viscoelastic material comprising substantially no mineral filler, the viscoelastic material having an elongation at break of at least about 150% and a Shore A hardness in the range of about 10 to about 80.

[00034] In certain embodiments, the laminate comprises, consists essentially of, or consists of: an A-layer composed of a filled polymer material comprising at least about 70 wt.% of a mineral filler by weight of the material, the mineral filler having a density of greater than about 3 g/cm2. and about 5 wt.% to about 30 wt.% of a polymer matrix by weight of the material; and a B-layer composed of a viscoelastic material comprising substantially no mineral filler, the A-layer having a thickness in the range of about 0.5 mm to about 5 mm, the B-layer having a thickness in the range of about 0.1 mm to about 5 mm.

[00035] In certain embodiments, the laminate comprises, consists essentially of, or consists of: an A-layer composed of a filled polymer material comprising at least about 70 wt.% of a mineral filler by weight of the material, the mineral filler having a density of greater than about 3 g/cm2, and about 5 wt.% to about 30 wt.% of a polymer matrix by weight of the material; and a B-layer composed of a viscoelastic material comprising substantially no mineral filler, the A-layer having a thickness in the range of about 0.5 mm to about 5 mm, the B-layer having a thickness in the range of about 0.1 mm to about 5 mm, the laminate having a thickness in the range of about 1 mm to about 50 mm.

"A-layer" [00036] The "A-layer" is a layer composed of a filled polymer material. The filled polymer material comprises, consists essentially of, or consists of: at least about 70 wt.% of a mineral filler by weight of the material; and a polymer matrix, wherein the mineral filler has a density of greater than about 3 gfcm3.

[00037] In certain embodiments the filled polymer material comprises at least about 72 wt.% of the mineral filler (e.g. a mineral filler having a density greater than about 3 g/cm3) by weight of the material, for example at least about 75 wt.%, at least about 77 wt.%, at least about 78 wt.%, at least about 79 wt.%, at least about 80 wt.%, at least about 81 wt.%, at least about 82 wt.%, at least about 83 wt.%, at least about 84 wt.%, or at least about 85 wt.% of the mineral filler by weight of the material [00038] In certain embodiments, the filled polymer material comprises up to about 95 wt.% of the mineral filler (e.g. the mineral filler having a density greater than about 3 gicm3) by weight of the material, for example up to about 90 wt.% of the mineral filler by weight of the material.

[00039] In certain embodiments, the filled polymer material comprises at least about 50 vol% of the mineral filler by total volume of the filled polymer material, for example at least about 55 vol%, at least about 60 vol%, or about 65 vol% or greater by total volume of the filled polymer material.

[00040] In certain embodiments the mineral filler of the filled polymer material has a density of about 3.5 g/cm3 or above, for example a density of about 4 g/cm3 or above, or a density of about 4.5 g/cm3 or above. The density of the mineral filler referred to herein is the true density of the mineral filler (i.e. opposed to the bulk density of the mineral filler).

[00041] Examples of mineral filler having a density of greater than about 3 Wan' include barium sulphate (e.g. PortarytetM B45 (available from SibelcoTM Europe), density of 4.5 g/cm3), ferrous oxide (density of 5.7 g/cm3), cupric oxide (density of 6.3 gicm3), bismuth trioxide (density of 8.9 g/cm3), and bismuth oxy-chloride (density of 7.5 g/cm3). The mineral filler may include a combination of different mineral fillers having a density of greater than about 3 g/cm3. In certain embodiments, the mineral filler comprises barium sulphate (e.g. PortaryteTM B45 (available from SibelcoTM Europe)), ferrous oxide, cupric oxide, bismuth trioxide, bismuth oxy-chloride, or combinations thereof. In certain embodiments, the mineral filler comprises barium sulphate and/or bismuth trioxide. In certain embodiments, the mineral filler comprises barium sulphate or bismuth trioxide. In certain embodiments, the mineral filler comprises barium sulphate and bismuth trioxide. In certain embodiments, the mineral filler comprises, consists essentially of, or consists of, barium sulphate.

[00042] In certain embodiments, the polymer matrix comprises a thermoplastic polymer.

Examples of suitable polymers include, polypropylene, polyethylene (such as LDPE). PVC, and ethylene butyl acrylate.

[00043] In certain embodiments, the polymer matrix comprises any polymer that can be provided in powdered form, for example any thermoplastic polymer that can be provided in powdered form.

[00044] In certain embodiments, the filled polymer material comprises from about 5 wt.% to about 30 wt.% of a polymer matrix by total weight of the filled polymer material, for example from about 5 wt.% to about 20 wt.% of a polymer matrix, from about 5 wt.% to to about 15 wt.%, or from about 10 wt.% to about 15 wt.% of a polymer matrix by total weight of the filled polymer material.

[00045] In certain embodiments, the filled polymer material comprises, consists essentially of, or consists of: at least about 70 wt.% of a mineral filler by weight of the material; and from about 5 wt.% to about 30 wt.% of a polymer matrix by weight of the is material, wherein the mineral filler has a density of greater than about 3 g/cm3.

[00046] In certain embodiments the polymer material comprises substantially no filler before the mineral filler described herein (i.e. the mineral filler having a density of greater than about 3 g/cm3) is added. In certain embodiments a polymer material comprising substantially no filler before the mineral filler described herein is added is a polymer material described herein comprising less than about 10 wt.% of a filler (for example fillers other than the mineral filler as described herein), for example a polymer material comprising less than about 5 wt.% of a filler, a polymer material comprising less than about 3 wt.% of a filler, a polymer material comprising less than about 2 wt.% of a filler, a polymer material comprising less than about 1 wt.% of a filler, a polymer material comprising less than about 0.5 wt.% of a filler, or a polymer material comprising less than about 0.1 wt.% of a filler before the mineral filler described herein is added.

[00047] In certain embodiments the filled polymer material comprises a lubricant, for example a lubricant that can be provided in powdered form. A lubricant may be employed to improve or provide more uniform dispersion of the mineral filler in the polymer matric.

Examples of suitable lubricants include oleamides (e.g. Crodamide VRX available from Croda), erucamides, and metallic stearates. In certain embodiments, the filled polymer material comprises lubricant in an amount of at least about 0.1 wt.% by total weight of the material, for example at least about 0.5 wt.%, at least about 1 wt.%, at least about 1.5 wt%, or at least about 2 wt.% by total weight of the material. In certain embodiments, the filled polymer material comprises lubricant in an amount of up to about 5 wt.% by total weight of the material, for example up to about 3 wt.%, or up to about 2.5 wt.% by total weight of the material. In certain embodiments, the filled polymer material comprises lubricant in an amount in the range of about 0.1 wt.% to about 5 wt.%, for example about 0.5 wt.% to about 3 wt.% by total weight of the filled polymer material.

[00048] In certain embodiments the filled polymer material comprises, consists essentially of, or consists of, at least about 70 wt% of a mineral filler by weight of the material, a lubricant and a polymer matrix, wherein the mineral filler has a density of at least about 3 g/cm3. In certain embodiments, the filled polymer material comprises, consists essentially of, or consists of: at least about 70 wt.% of a mineral filler by weight of the material; from about 5 wt.% to about 30 wt.% of a polymer matrix by weight of the material; and from about 0.1 wt.% to about 5 wt.% of a lubricant by weight of the material, wherein the mineral filler has a density of greater than about 3 g/cm3.

[00049] In certain embodiments, the A-layer has a thickness of up to about 10 mm, for example up to about 5 mm, up to about 3 mm, up to about 2 mm, or up to about 1.5 mm. In certain embodiments, the A-layer has a thickness of at least about 0.5 mm, for example at least about 1 mm. In certain embodiments. the A-layer has a thickness in the range of about 0.5 mm to about 10mm, for example about 0.5 mm to about 5 mm, about 1 mm to about 3 mm, or about 1 mm to about 2 mm.

[00050] In certain embodiments, the laminate comprises a plurality of A-layers. Each of the plurality of A-layers may be the same or different. In certain embodiments each of the plurality of A-layers are composed of the same filled polymer material.

[00051] In certain embodiments, the or each A-layer is an extruded sheet composed of the filled polymer material described herein.

"B-layer" [00052] The "B-layer" is a layer composed of a viscoelastic material comprising substantially no mineral filler.

[00053] A viscoelastic material may be described as a material that exhibits both viscous and elastic characteristics under stress and deformation, e.g. the material can be described as having properties of both solid and liquid phases, or a material which temporarily deforms under the application of stress and permanently deforms if stress application is maintained.

[00054] In certain embodiments, the viscoelastic material (or cured viscoelastic material if suitable, e.g. where a viscoelastic adhesive such as Red GIueTM is used as the viscoelastic material) has an elongation at break of at least about 150%, for example at least about 200% or at least about 250%. In certain embodiments, the viscoelastic material (or cured viscoelastic material if suitable) has an elongation at break of at least about 300%, for example at least about 400%, at least about 500%, at least about 600%, at least about 700%, or at least about 800%. Elongation at break of the viscoelastic material may be determined according to ASTM D638.

[00055] In certain embodiments, the viscoelastic material has a Shore A hardness (for example a Shore A hardness as determined according to ASTM D2240) of up to about 80, for example up to about 70, up to about 60, up to about 50, up to about 40, up to about 30, up to about 20. In certain embodiments, the viscoelastic material has a Shore A hardness (for example a Shore A hardness as determined according to ASTM D2240) of greater than about 10, for example greater than about 20. It is noted that although ASTM D2240 refers to the hardness of elastomeric materials, this test method is widely used for determining the hardness of other polymers. In certain embodiments, the viscoelastic material has a Shore A hardness in the range of about 10 to about 80, for example about 20 to about 60, or about 20 to about 50.

[00056] In certain embodiments, the viscoelastic material may comprise, consist essentially of, or consist of a viscoelastic adhesive, for example a pressure-sensitive adhesive. Examples of viscoelastic adhesives that may be used as the viscoelastic material in the "B-layer" include Red Glue T" (available from SRU InsulationTM, UK), Green GIueTM (produced by SaintGobainTM) and an acrylic gel adhesive film (such as Techniflex TM THB available from TechnibondTM Ltd, UK).

[00057] Examples of materials suitable as viscoelastic materials include Red GIueTM (available from SRU InsulationTM, UK,), Green Glue TM (produced by Saint-Gobain T"), polyvinyl butyral (PVB) film (for example, SafIexTM PVB clear available from Qdel laminating supplies, NL, Shore A hardness of about 80 when cured and elongation at break around 200-250), acrylic gel adhesive film (such as TechniflexTm THB available from TechnibondT" Ltd, UK), styrene ethylene butylene styrene block co-polymer (such as CawitonTM PR10955C available from Wittenburg B.V., Shore A hardness 48 and elongation at break 660%), and ethylene vinyl acetate (such as Evatanerm available from ArkemaTM, Shore A hardness 67 and elongation at break 900-1100%).

[00058] The B-layer may be a film of a viscoelastic material (e.g. an extruded film of a viscoelastic material) which may be adhered to an A-layer, or the B-layer may be applied to an A-layer by coating the A-layer with a viscoelastic material to form a B-layer disposed on the A-layer.

[00059] In certain embodiments, a layer of a viscoelastic material comprising substantially no mineral filler is a layer of viscoelastic material comprising less than about 10 wt.% of a mineral filler (for example a mineral filler as described above in relation to the A-layer), for example a layer of viscoelastic material comprising less than about 5 wt.% of a mineral filler, a layer of viscoelastic material comprising less than about 3 wt.% of a mineral filler, a layer of viscoelastic material comprising less than about 2 wt.% of a mineral filler, a layer of viscoelastic material comprising less than about 1 wt.% of a mineral filler, a layer of viscoelastic material comprising less than about 0.5 wt.% of a mineral filler, a layer of viscoelastic material comprising less than about 0.1 wt.% of a mineral filler, or a layer of viscoelastic material comprising about 0 wt.% of a mineral filler.

[00060] In certain embodiments, the B-layer has a thickness of up to about 5 mm, for example up to about 3 mm, up to about 2 mm, up to about 1 mm, or up to about 0.5 mm. In certain embodiments, the B-layer has a thickness of at least about 0.1 mm, for example at least about 0.5 mm. In certain embodiments, the B-layer has a thickness in the range of about 0.1 mm to about 5 mm, for example about 0.1 mm to about 2mm, about 0.1 mm to about 1.5 mm, about 0.1 mm to about 1 mm, or about 0.5 mm to about 1 mm.

[00061] In certain embodiments, the laminate comprises a plurality of B-layers. Each of the plurality of 8-layers may be the same or different. In certain embodiments each of the plurality of B-layers comprise, consist essentially of or consist of, the same viscoelastic material.

[00062] In certain embodiments, the B-layer comprises, consists essentially of, or consists of a viscoelastic material. In certain embodiments, the B-layer comprises, consists essentially of, or consists of a continuous layer of a viscoelastic material. In certain embodiments, the B-layer comprises, consists essentially of, or consists of a viscoelastic material having a cellular structure.

Panels [00063] The laminate materials described herein may be incorporated into panels to be used as building materials, for example in the construction of buildings and/or vehicles. The panels may be useful for incorporation into door leaves to improve the airborne sound insulating properties of the door leaves.

[00064] In certain embodiments, a panel comprises a laminate as described herein and a facing sheet (for example a MDF sheet, a hardboard sheet, a sheet of paper or cardboard (for example, paper or cardboard having a weight in the range of about 75-300 g/m2, for example about 100-300 g/m2. or about 150-250 g/m2) disposed on a surface of the laminate.

[00065] In certain embodiments, a panel comprises a laminate as described herein and a facing sheet disposed on an A-layer of the laminate, for example an A-layer on the surface of the laminate.

[00066] In certain embodiments, a panel comprises a laminate as described herein and a facing sheet disposed on a B-layer on the laminate, for example a B-layer on the surface of the laminate.

[00067] In certain embodiments, a panel comprises a laminate having first and second A-layers and a B-layer disposed between the first and second A-layers (i.e. an A-B-A laminate as described herein), and a facing sheet disposed on either the first or second A-layer of the laminate.

[00068] In certain embodiments, a panel comprises a core disposed between a first laminate described herein and a second laminate as described herein. In certain embodiments, a panel comprises a first facing sheet and a second facing sheet, for example a first facing sheet disposed on a surface of the first laminate and a second facing sheet disposed on a surface of the second laminate. In certain embodiments, the panel comprises a core disposed between a first laminate and a second laminate, a first facing sheet disposed on an outer surface of the first laminate (the outer surface of the first laminate being a surface other than the surface of the first laminate disposed on the core) and a second facing sheet disposed on an outer surface of the second laminate (the outer surface of the second laminate being a surface other than the surface of the second laminate disposed on the core).

Door Leaves [00069] The laminate materials described herein may be incorporated into door leaves to improve the airborne sound insulating properties of the door leaves. The laminates described herein may be incorporated into any type of door leaf.

[00070] Described herein is a door leaf comprising a laminate as described herein. In certain embodiments, a door leaf comprises a panel as described herein, for example a laminate as described herein and a facing sheet (for example a MDF sheet, a hardboard sheet, a sheet of paper or cardboard) disposed on a surface of the laminate. In certain embodiments, a door leaf comprises a core disposed between a first laminate and a second laminate. In certain embodiments, a door leaf comprises a core disposed between two panels described herein, (for example, a door leaf comprising a core, a first and second laminate, a first facing sheet and a second facing sheet). In certain embodiments, the door leaf comprises a core disposed between a first laminate and a second laminate, a first facing sheet disposed on an outer surface of the first laminate (the outer surface of the first laminate being a surface other than the surface of the first laminate disposed on the core) and a second facing sheet disposed on an outer surface of the second laminate (the outer surface of the second laminate being a surface other than the surface of the second laminate disposed on the core).

[00071] In certain embodiments, the door leaf into which the laminate is incorporated is a solid-core flush door leaf. An example of a cross-section through a solid-core flush door leaf 401 is shown in figure 4. The solid-core flush door leaf 401 shown in figure 4 comprises a core 410 (for example a chipboard core such as a HaIspan T" Optima TM door blank, or a laminated solid timber core such as a HalspanTM ProtechTM door blank) between two laminates as described herein (for example, two A-B-A laminates 200 as described in relation to figure 2 herein, other laminates described herein may also be incorporated into a solid-core flush door leaf in place of the laminate 200 or in addition to the laminate 200). The laminates 200 may be attached to the core 410 using an adhesive (such as a woodworking adhesive, e.g. a polyurethane woodworking adhesive, or a viscoelastic adhesive as described herein). The example of a solid-core flush door leaf 401 shown in figure 4 also comprises two facing sheets 415 (e.g. MDF sheets) disposed either side of the solid-core flush door leaf 401 as shown in figure 4 and hardwood lippings 420 (e.g. Sapele hardwood lippings) on all four perimeter edges of the door leaf 401. An adhesive (such as a woodworking adhesive (e.g. PU or EVA woodworking adhesive) or a viscoelastic adhesive) may be used to attach the facing sheets 415 and the hardwood lippings 420 in the configuration shown in figure 4.

[00072] In certain examples, the door leaf into which the laminate is incorporated is a joinery door leaf, for example a single-panel joinery door leaf 501 (as illustrated in figure 5a), or a multi-panel joinery door leaf. Examples of multi-panel joinery door leaves are four-panel joinery door leaves (see, for example the four-panel joinery door leaf 502 illustrated in figure 5b) and six-panel joinery door leaves (see, for example the six-panel joinery door leaf 503 illustrated in figure 5c).

[00073] Figure 6 is a schematic diagram of a partial cross-section through an example of a joinery door leaf 601 comprising a panel 605 supported by a perimeter frame 608 (for example, a solid hardwood perimeter frame). The panel 605 may comprise a core 610 (for example a composite panel, such as a fire-resistant composite panel, e.g. a PalusolTM glass reinforced sodium silicate panel (available from BASF) disposed between a first laminate 200 and a second laminate 200 (for example, the first and second laminates may be two A-B-A laminates 200 as described in relation to figure 2 herein, other laminates described herein may also be incorporated into a joinery door leaf in place of the laminate 200 or in addition to the laminate 200), and first and second facing sheets 615 disposed on an outer surface of the first and second laminates 200 respectively. In embodiments where the door leaf is a multi-panel door, the door leaf may comprise multiple panels 605 as described in relation to figure 6.

[00074] In certain embodiments, the door leaf is a fire door leaf, for example a door leaf comprising a core comprising a fire resistant material.

Method [00075] Described herein is a method of producing a laminate. The method comprises: providing an A-layer composed of a filled polymer material; providing a B-layer composed of a viscoelastic material; providing a laminate comprising the A-layer and the B-layer, wherein providing the A-layer comprises combining a mineral filler having a density of greater than about 3 g/cm3 and a powdered polymer to form a filled polymer material layer comprising at least about 70 wt.% of the mineral filled by weight of the material, wherein providing the 13-layer comprises providing a viscoelastic material comprising substantially no mineral filler.

[00076] The present inventors have found that providing the polymer material in powdered form, for example rather than in pellet form, allows high amounts (for example at least about 70 wt.%, or at least about 80 wt.%) of a mineral filler as described herein to be incorporated in to the layer of filled polymer material.

[00077] In certain embodiments, providing a filled polymer material comprises mixing a mineral filler having a density of greater than about 3 g/cm3 and a powdered polymer to form mixture.

[00078] In certain embodiments, providing a filled polymer material comprises mixing a mineral filler having a density of greater than about 3 g/cm3, a powdered polymer, and a lubricant (e.g. a solid powdered lubricant as described above) to form mixture.

[00079] In certain embodiments, providing a filled polymer material further comprises homogenising the mixture, for example using an extruder such as a twin-screw extruder.

[00080] In certain embodiments, providing a filled polymer material further comprises pelletizing the mixture or the homogenised mixture to produce pellets comprising the mineral filler in a polymer matrix. for example pellets comprising the lubricant and mineral filler in a polymer matrix.

[00081] In certain embodiments, providing the A-layer composed of a filled polymer material comprises extruding the mixture, homogenised mixture, or pellets (for example using a single-screw extruder) to form a sheet/layer of filled polymer material, for example having a thickness as described above.

[00082] In certain embodiments, providing the B-layer composed of a viscoelastic material comprises providing a viscoelastic material described herein. The B-layer may be a film of a viscoelastic material (e.g. an extruded film of a viscoelastic material) which may be adhered to an A-layer, or the B-layer may be applied to an A-layer by coating the A-layer with a viscoelastic material to form a B-layer disposed on the A-layer. In certain embodiments in which the B-layer is a film of a viscoelastic material, the film may be adhered to an A-layer using an adhesive (e.g. a double sided adhesive film).

[00083] In certain embodiments, providing the laminate comprising an A-layer and a S-layer comprises applying a layer of a viscoelastic material to an A-layer. In certain embodiments, a layer of a viscoelastic material is applied to an A-layer by adhering a layer of a viscoelastic material to an A-layer composed of a filled polymer material. For example, a B-layer may be applied to an A-layer by using an adhesive to adhere a layer of viscoelastic material to an A-layer composed of a filled polymer material, or a viscoelastic material may be applied to the 13-layer directly using a coating method such as rod, roller, blade, spray, slot-die, or another coating process. Any conventional coating method may be used which allows for a controlled thickness of the deposited viscoelastic material. In certain embodiments, the B-layer is applied to the A-layer by co-extruding the filled polymer material and the viscoelastic material to produce a co-extruded laminate.

[000841 In certain embodiments, the method comprises: providing a first layer of a filled polymer material and a second layer of filled polymer material; and providing a layer of a viscoelastic material disposed between the first and second layers of filled polymer material.

[000851 In certain embodiments, a foaming additive may be added to the viscoelastic material to provide a viscoelastic material having a cellular structure. For example, the viscoelastic material may comprise at least about 1 wt.% of a foaming additive by weight of the viscoelastic material, for example at least about 2 wt.%, or about 5 wt.% of a foaming additive by weight of the viscoelastic material. The viscoelastic material may comprise up to about 10 wt.% of a foaming additive by weight of the viscoelastic material, for example from about 1 to about 10 wt.% of a foaming additive by weight of the viscoelastic material.

In certain embodiments, the B-layer comprising a viscoelastic material has a cellular structure, e.g. the cellular structure of the viscoelastic material may be formed by employing the foaming additive.

Examples

[00086] The following illustrates examples of the laminates and related aspects described herein. Thus, these examples should not be considered to restrict the present disclosure, but are merely in place to teach how to make examples of the present

disclosure.

"A-Layer"

Example 1

[00087] A layer of a filled polymer material was produced containing 86.3 wt.% (65 vol.%) barium sulphate and a EBA polymer matrix, by firstly mixing 22.5 kg of barium sulphate powder (PortaryteTM B, available from Sibelco Europe) and 3.0 kg of powdered ethylene butyl acrylate polymer (LucofinTM 1400MN Powder available from Lucobit) and then adding 0.575 kg of a lubricant (Crodamide VRX, available from Croda) to the mixture. The mixture was then homogenized using a twin-screw extruder (Labtech co-rotating twin-screw extruder) and pelletized for subsequent conversion into a sheet. For conversion of the pelletized composition into a sheet, the pellets were fed to a Deltaplast single-screw extruder (the screw having the characteristics of 24:1 Length/Diameter ratio with 3:1 compression) and the extruder was coupled to a laboratory size sheet die (75 mm finished product width) and a series of chrome plated water-cooled finishing rolls. The Deltaplast single-screw extruder was run with a melt pressure of 2300 psi and an output rate of 1.0 m/min. The thickness of the sheet (layer of filled polymer material) produced was 1.6 mm and the width of the sheet was 75 mm.

Comparative Example 2 [00088] A layer of a filled polymer material was produced containing 60 wt.% (13 vol.%) barium sulphate in a polypropylene matrix by feeding polypropylene in pellet form (Ineos 203NA02) at a rate of 8 kg per hour and barium sulphate at a rate of 12 kg/hour into a twin-screw extruder (Labtech co-rotating twin-screw extruder) and pelletized for subsequent conversion into a sheet. For conversion of the pelletized composition into a sheet, the pellets were fed to a Deltaplast single-screw extruder (the screw having the characteristics of 24:1 Length/Diameter ratio with 3:1 compression) and the extruder was coupled to a laboratory size sheet die (75 mm finished product width) and a series of chrome plated water-cooled finishing rolls. The Deltaplast single-screw extruder was run with a melt pressure of 1900 psi and an output rate of 1.0 m/min. The thickness of the sheet (layer of filled polymer material) produced was 1.35 mm and the width of the sheet was 75 mm.

Laminates Comparative Example 3 [00089] An "A-B-A" laminate was produced by covering one surface of the sheet produced in Comparative Example 2 with a layer of Red Glue Mil (a viscoelastic adhesive obtained from SRU InsulationTM, UK) having a thickness of about 0.5 mm to form a "B-layer" and then laying a second sheet of the material produced in Comparative Example 2 on the "B-layer". The A-B-A laminate was then compressed using a hydraulic press at a pressure of 100 psi and the laminate was left overnight under this pressure and at room temperature.

Example 4

[00090] An "A-B-A" laminate was produced by covering one surface of the sheet produced in Example 1 with a layer of Red GlueTM (a viscoelastic adhesive obtained from SRU InsulationTM, UK) having a thickness of about 0.5 mm for form a "B-layer" and then laying a second sheet of the material produced in Example 1 on the "B-layer". The A-B-A laminate was then compressed using a hydraulic press at a pressure of 100 psi and the laminate was left overnight under this pressure and at room temperature.

Example 5

[00091] An "A-B-A" laminate was produced by adhering a PVB (polyvinyl butyral) film (SaflexTM PVB clear obtained from Qdel laminating supplies, NL) having a thickness of 0.7 mm (the "B-layer") to one surface of the sheet produced in Example 1 (an "A-layer") and then laying a second sheet of the material produced in Example 1 on the PVB film "B-layer". The PVB film was adhered to the A-layers using a 0.155mm thick double sided adhesive film ("Orabond" ref. R1358 available from Technibond Ltd) applied to the whole area of the surface of the A-layer. As the adhesive film is pressure sensitive, no sustained compression as described in Example 4 was employed.

Example 6

[00092] An "A-B-A" laminate was produced according to Example 4 except that the S-layer was an acrylic gel film (TechniflexTm THB 0.5 mm obtained from TechnibondTm Ltd, UK) having a thickness of 0.5 mm. As for Example 5, the sustained application of pressure as described in Example 4 was not employed.

Example 7

[00093] An "A-B-A-B-A" laminate was produced by providing three sheets of material produced according to Example 1 and providing a B-layer composed of an acrylic gel (TechniflexTM THB 0.5 mm obtained from TechnibondTM Ltd, UK) having a thickness of 0.5 mm between the first and second A-layers and between the second and third A-layers.

Door Leaves and Acoustic Testing of Door Leaves [00094] The laminates of Comparative Example 3 and Examples 4-7 were used to produce door leaves having a height of 2044 mm and a width of 828 mm (each of the cores, laminates, facing sheets etc employed had a height of 2044 mm and a width of 828 mm).

As the laminates produced in Comparative Example 3 and Examples 4-7 had a width of 75 mm, a number of laminates of each Comparative Example/Example were laid adjacent to one another to form a laminate having the same height and width as the door leaves. The specific construction of the solid-core flush door leaves tested is detailed in Table 1 below and the specific construction of the joinery door leaves tested is detailed in Table 2 below.

[00095] The general construction of the solid-core flush door leaves tested is shown in Figure 4 as described above (it is noted that the lippings 420 of each of the solid-core flush door leaves described in Table 1 were 6mm Sapele hardwood attached using a polyurethane (PU) woodworking adhesive). In the comparative examples in which no laminate was employed, the facing sheets 415 (where used) were attached directly to the core 410 using an adhesive as detailed in Table 1.

[00096] The general construction of the joinery door leaves tested is shown in figure 6 as described above. In the comparative examples in which no laminate was employed, the facing sheets 615 were attached directly to the core 610 using an adhesive as detailed in Table 2. All of the joinery doors listed in Table 2 had a frame thickness of 54 mm, each of the frames being composed of Beech hardwood of density 720 kg/m3. The panels of each of the joinery doors were fitted into the frame as shown in fig. 6 such that distance x marked on fig. 6 was 32 mm.

[00097] Each of the doors described in Tables 1 and 2 were acoustically tested to evaluate and quantify the improvements in airborne sound reduction achieved by employing the laminates of the present invention. Before undergoing acoustic testing, each of the door leaves were mounted on hinges and assembled into a common test frame within a test chamber wall, gaps between the leaves and the frame were sealed using acoustic sealing tape such that the test leaves were "fully caulked" to ensure that sound reduction performance of the leaf and frame only was measured, without any influence from a sealing system within the leaf-to-frame gap.

Measurement of Sound Transmission in accordance with BS EN ISO 10140-2:2010-TP33 [00098] Airborne sound transmission of the door leaves was determined from the difference in sound pressure levels measured across a test sample installed between two reverberant rooms.

[00099] Tests were conducted in accordance with the internationally agreed standard BS EN ISO 10140-2:2010 and performances compared by calculating the "weighted sound reduction index" (Rw) using BS EN ISO 717-1:2013 to provide a straight-forward single-figure comparison of the overall sound reduction performance of each door and expressed as dB Rw. The calculated "R,.," value for each door leaf is provided in Tables 1 to 3.

Materials [000100] The following paragraphs provide further details of the materials used to produce the door leaves described in Tables 1 to 3.

Door leaf core materials [000101] "Halspan Protech" -HalspanTM Protech door blanks are composed of a laminated solid timber core, obtained from Halspan TM UK.

[000102] "Halspan Optima" -Halspan TM Optima door blanks are made from graduated density chip board, obtained from Halspan TM UK [000103] "2 mm Palusor -fire-resistant composite sheet having a thickness of 2mm obtained from BASF.

[000104] "BASF SW board" -2 mm PalusolTM with 4mm hardboard on either side of Palusol sheet (adhered using a 2-part epoxy resin).

Adhesives [000105] Common woodworking adhesive -woodworking adhesive such as poly vinyl acetate (PVA) ethylene-vinyl acetate (EVA) or polyurethane (PU) woodworking adhesive.

[000106] Double sided adhesive film (e.g. "Orabond" ref. R1358 available from Technibond Ltd, other double sided adhesive films may be used).

"B-layer" materials [000107] "PVB film" (polyvinyl butyral film) -SaflexTM PVB clear film obtained from Qdel laminating supplies, NL having a thickness of 0.7 mm.

[000108] "Red Glue" -Red GIueTM, a viscoelastic adhesive obtained from SRU InsulationTM, UK.

[000109] "Acrylic gel" TechniflexT" THB 0.5 mm obtained from Technibond TM Ltd, UK.

[000110] Table 1 -solid-core leaves Example Core (410) Laminates Adhesive used to attach laminates to core Facing sheets (415) Adhesive used to attach facing sheets Weight of Rw (200) leaf (kg) produced according to C. Ex. 8 Halspan Protech 54 mm standard door blank None N/A None None 52 35 C.Ex. 9 Halspan Optima 54 mm standard door blank None N/A None None 57.5 34 C. Ex. 10 Halspan Protech 44 mm standard door blank None N/A 4 mm MDF 0.5 mm thick Red Glue 54 36 C. Ex. 11 Halspan Optima 44 mm standard door blank None N/A 4 mm MDF 0.5 mm thick Red Glue 58.8 36 Example 12 Halspan Optima 44 mm standard door blank Example 4 EVA woodworking adhesive 2.5 mm MDF EVA woodworking adhesive 88 39 Example 13 Halspan Optima 44 mm standard door blank Example 4 Red Glue 2.5 mm MDF Red Glue 89.9 39 Example 14 Halspan Protech 44 mm door blank Example 4 EVA woodworking adhesive 2.5 mm MDF EVA woodworking adhesive 84.8 39 Example 15 Halspan Protech 54 mm standard door blank Example 6 Double-sided adhesive film 2.5 mm MDF Double-sided adhesive film 93.1 40 Example 16 Halspan Protech 54 mm standard door blank Example 4 Double-sided 2.5 mm MDF Double-sided adhesive film 91.9 39 adhesive film [000111] Table 2-joinery leaves Example Joinery door type Core (610) Laminates Adhesive used to attach laminates to core Facing Adhesive used to attach facing sheets Weight Total Rw (200) sheets (615) of leaf thickness produced (kg) of panel according (mm) to C. Ex. 17 Single panel 10mm BASF None N/A None N/A 34.5 10 32 "SW-Board" Example 18 Single panel BASF SW Board Example 4 Double sided 2.5 mm MDF Double sided 66.0 16 43 adhesive film adhesive film C. Ex. 19 Single panel BASF SW board No laminate, instead PVB film alone used Double-sided I 4 mm MDF Double-sided adhesive film 44.0 19 38 adhesive film used to adhere PVB film to core Example 20 Single panel BASF SW board Example 5 Double-sided adhesive film 2.5 mm MDF Double-sided adhesive film 65.6 22 44 Example 21 Single panel BASF SW board Example 6 Double-sided adhesive film 2.5 mm MDF Double-sided adhesive film 64.3 22 42 Example 22 Single panel BASF SW board Example 7 Double-sided 4 mm MDF Double-sided adhesive film 77.8 30.5 44 adhesive film Example 23 Four-panel BASF SW board Example 4 Double-sided 2.5 mm MDF Double-sided 66.4 22 43 adhesive film adhesive film Example 24 Six-panel BASF SW board Example 4 Double-sided 2.5 mm MDF Double-sided 70.8 22 44 adhesive film adhesive film [000112] The results provided in Tables 1 and 2 show that a surprisingly large reduction in airborne sound transmission is achieved by incorporating laminates described herein into a door leaf (joinery door leaves and solid-core flush door leaves) with minimal/acceptable increases in weight and/or thickness compared to standard door leaves, door leaves including layers of viscoelastic material and doors including laminates with lower mineral filler content. Furthermore, during the testing the present inventors have found that using the materials and methods described herein, it is possible to reduce the thickness of conventional acoustic solid-core doors and at least maintain Rw.

Further Examples and Tests Joinery doors with reduced thickness

Example 25

[000113] A joinery door according to Example 18 described above in Table 2 was produced except that the panel was incorporated into a joinery door having a frame thickness of 44mm instead of a frame thickness of 54 mm.

Example 26

[000114] A joinery door according to Example 21 was produced except that the panel was incorporated into a joinery door having a frame thickness of 44mm instead of a frame thickness of 54 mm.

[000115] The same acoustic tests as those described above were carried out on the reduced thickness joinery doors of Examples 25 and 26, and as shown below in Table 3.

Rw was determined to be 42 dB for both doors, showing that FR"" can be substantially maintained while the weight of the door is reduced.

[000116] As conventional "high performance" acoustic doors typically have a thickness around 65-75 mm and a weight in excess of 90 kg in order to achieve a sound reduction in the region of R" = 39-42 dB, the large improvement provided by the present invention is clear.

SEBS polymer as the viscoelastic material

Example 27

[000117] An A-B-A laminate was produced as described in Example 5, except that the B-layer was an extruded film of a SEBS polymer having a thickness of 0.5mm (Cawiton' PR10955C available from Wittenburg B.V., Shore A hardness 48 and elongation at break 660%).

Example 28

[000118] A joinery door was produced as described in Example 21 above, except that A-B-A laminates produced according to Example 27 were provided as the laminates.

[000119] The sound reduction characteristics (determined as described above) of the joinery door of Example 28 were found to be similar to those of the door of Example 20 (a joinery door containing the laminate of Example 5). Rw for the door of Example 28 was found to be of 43 dB as noted in Table 3 below.

Co-extruded A-B-A laminate

Example 29

[000120] An A-B-A laminate was produced by co-extruding the composition of the A-layer as described in Example 1 with a SEBS polymer (CawitonTM PR10955C available from Whittenburg B.V., Shore A hardness 48 and elongation at break 660%), to provide A-layers having a thickness of 1.5mm either side of a SEBS polymer B-layer having a thickness of 0.5mm.

Example 30

[000121] A joinery door was produced as described in Example 21 above, except that the A-B-A laminates employed were produced according to Example 29. The resulting door was found to have sound characteristics (determined as described above) close to that of the door of Example 28 (Rw of 42 dB as shown in Table 3 below).

[000122] The co-extrusion process resulted in improved efficiency in the manufacture of the laminate used to produce the acoustic door.

Cellular B-layer

Example 31

[000123] An A-B-A laminate was produced according to Example 27. except that a foaming additive (5 wt.% by weight of the SEBS polymer of ExpancelTM 920 MB 120 available from AkzoNobel, Sweden) was added to the SEBS polymer before extrusion to form the B-layer.

Example 32

[000124] A joinery door was produced as described in Example 28 above, except that A-B-A laminates produced according to Example 31 were provided as the laminates. The resulting door weighed 2 kg less than the door of Example 28 and had similar sound reduction characteristics.

Example 33

[000125] An A-B-A laminate was produced according to Example 29, except that a foaming additive (5 wt% by weight of the SEBS polymer of ExpancelTM 920 MB 120 available from AkzoNobel, Sweden) was added to the SEBS polymer before co-extrusion to form the B-layer.

Example 34

[000126] A joinery door was produced as described in Example 30 above, except that A-B-A laminates produced according to Example 33 were provided as the laminates. The resulting door weighed 2 kg less than the door of Example 30 and had similar sound reduction characteristics.

Bismuth trioxide filler Example 35 [000127] A layer of a filled polymer material was produced containing 90.7 wt.% bismuth trioxide and a EBA polymer matrix, by firstly mixing 34.8 kg of bismuth trioxide powder and 3.0 kg of powdered ethylene butyl acrylate polymer (Lucofin TM 1400MN Powder available from Lucobit) and then adding 0.575 kg of a lubricant (Crodamide VRX, available from Croda) to the mixture. The mixture was then homogenized using a twin-screw extruder (Labtech co-rotating twin-screw extruder) and pelletized for subsequent conversion into a sheet. For conversion of the pelletized composition into a sheet, the pellets were fed to a Deltaplast single-screw extruder (the screw having the characteristics of 24:1 Length/Diameter ratio with 3:1 compression) and the extruder was coupled to a laboratory size sheet die (75 mm finished product width) and a series of chrome plated water-cooled finishing rolls. The Deltaplast single-screw extruder was run with a melt pressure of 1460 psi at a screw speed of 34 rpm. The thickness of the sheet (layer of filled polymer material) produced was 1.6 mm and the width of the sheet was 75 mm.

Example 36

[000128] An A-B-A laminate was produced according to Example 6 except that the A layers used were produced according to Example 35.

Example 37

[000129] A joinery door was produced according to Example 21, except that the laminates used were produced according to Example 36.The resulting door had a weight of 80 kg and provided a RN of 45 dB (i.e. an additional 3 dB Rv, reduction compared to the door of Example 24 which employed barium sulphate as the mineral filler in the A-layer of the A-B-A laminate.

A-B laminates

Example 38

[000130] A laminate was produced according to Example 36, except that the laminate was an A-B laminate rather than an A-B-A laminate (i.e. only one A layer and one B-layer were combined to provide the laminate).

Example 39

[000131] .A joinery door was produced according to Example 37, except that the laminates used were produced according to Example 38 (i.e. A-B laminates). The joinery door was found to provide a RN of 42 dB (i.e. the same as the door of Example 21).

[000132] Table 3-joinery leaves [Example Joinery door type Core (610) Laminates Adhesive used to attach laminates to core Facing Adhesive used to attach facing sheets Weight Total Rw (200) sheets (615) of leaf thickness produced (kg) of panel according (mm) to Example 25 Single panel BASF SW board Example 4 Double-sided adhesive film 2.5 mm MDF Double-sided adhesive film 61.7 22 42 Example 26 Single panel BASF SW board Example 6 Double-sided adhesive film 2.5 mm MDF Double-sided adhesive film 60.0 22 42 Example 28 Single panel BASF SW board Example 27 Double-sided adhesive film 2.5 mm MDF Double-sided adhesive film 66.7 22 43 Example 30 Single panel BASF SW board Example 29 Double-sided adhesive film 2.5 mm MDF Double-sided 60.2 22 42 adhesive film Example 32 Single panel BASF SW board Example 31 Double-sided 2.5 mm MDF Double-sided 64.8 22 43 adhesive film adhesive film Example 34 Single panel BASF SW board Example 33 Double-sided 2.5 mm MDF Double-sided 57.9 22 42 adhesive film adhesive film Example 37 Single panel BASF SW board Example 36 Double-sided adhesive film 2.5 mm MDF Double-sided adhesive film 80 22 45 Example 39 Single panel BASF SW board Example 38 Double-sided 2.5 mm MDF Double-sided adhesive film 62.0 I 19 42 adhesive film [000133] While the laminates, methods and related aspects have been described with reference to certain examples, it will be appreciated that various modifications, changes, omissions, and substitutions can be made without departing from the scope of the invention. It is intended, therefore, that the laminates, methods and related aspects be limited only by the scope of the following claims. Unless otherwise stated, the features of any dependent claim can be combined with the features of any of the other dependent claims, and any other independent claim.

[000134] If a standard test is mentioned herein, unless otherwise stated, the version of the test to be referred to is the most recent at the time of filing this patent application.

Claims

CLAIMSA laminate comprising: an A-layer composed of a filled polymer material comprising: at least about 70 wt.% of a mineral filler by weight of the material; and a polymer matrix, wherein the mineral filler has a density of greater than about 3 g/cm3; and a B-layer composed of a viscoelastic material comprising substantially no mineral filler.
2. A laminate according to claim 1, wherein the filled polymer material comprises: at least about 70 wt.% of the mineral filler by weight of the material; and about 5 wt.% to about 30 wt.% of the polymer matrix by weight of the material.
3. A laminate according to claim 1 or claim 2, wherein the filled polymer material further comprises a lubricant.
4. A laminate according to claim 3, wherein the filled polymer material comprises: at least about 70 wt.% of the mineral filler by weight of the material; about 5 wt.% to about 30 wt.% of the polymer matrix by weight of the material; and about 0.1 wt.% to about 5 wt.% of a lubricant by weight of the material.
5. A laminate according to any of the preceding claims herein the viscoelastic material is a pressure sensitive adhesive.
6. A laminate according to any of the preceding claims, wherein the viscoelastic material has an elongation at break of at least about 200 %.
7. A laminate according to any of the preceding claims, wherein the viscoelastic material has a Shore A hardness of up to about 80, optionally up to about 60.
8. A laminate according to any of the preceding claims comprising a plurality of A-layers.
9. A laminate according to claim 8, wherein the laminate comprises a first A-layer and a second A layer, the B-layer being disposed between the first and second A-layers.
10. A laminate according to any of the preceding claims, wherein the laminate comprises a plurality of B-layers.
11. A laminate according to claim 10, wherein the laminate comprises a first B-layer and a second B-layer, the A-layer being disposed between the first and second B-layers.
12. A laminate according to any of the preceding claims, wherein the or each A-layer has a thickness in the range of about 0.5 mm to about 5 mm.
13. A laminate according to any of the preceding claims, wherein the or each B-layer has a thickness in the range of about 0.1 mm to about 5 mm.
14. A laminate according to any of the preceding claims, having a thickness in the range of about 1 mm to about 20 mm.
15. A laminate according to any of the preceding claims, wherein the viscoelastic material is a continuous material.
16. A laminate according to any of the preceding claims, wherein the viscoelastic material is a cellular material.
17. A panel comprising a laminate of any of the preceding claims and a facing sheet disposed on a surface of the laminate.
18. A panel comprising a laminate according to claim 17 when dependent on claim 9, wherein the facing sheet is disposed on either the first or second A-layer of the laminate.
19. A door leaf comprising a laminate or a panel of any of the preceding claims.
20. A method of producing a laminate, the method comprising: providing an A-layer composed of a filled polymer material; providing a B-layer composed of a viscoelastic material; providing a laminate comprising the A-layer and the B-layer, wherein providing the A-layer comprises combining a mineral having a density of greater than about 3 g/cm3 and a powdered polymer to form a filled polymer material layer comprising at least about 70 wt.% of the mineral filled by weight of the material, and wherein providing the B-layer comprises providing a viscoelastic material comprising substantially no mineral filler.
21. A method according to claim 20 comprising providing a first A-layer and a second A-layer, wherein providing the laminate comprises disposing the B-layer between the first and second A-layers.