TWI766772B - Floor structure and manufacturing method thereof - Google Patents

Abstract

The present disclosure provides a floor structure and a manufacturing method thereof. The floor structure includes a sound insulation layer, a concrete layer, a plate, and a decorative layer. The sound insulation layer has a first surface and a second surface opposite to each other. The roughness of the first surface is greater than the roughness of the second surface. The concrete layer is disposed on the first surface. The plate is disposed on the second surface. The decoration layer is disposed on the plate. In the floor structure, the rough surface of the concrete layer may be firmly attached to the second surface of the sound insulation layer by directly disposing the sound insulation layer with deformability on the concrete layer. Further, the plate and the decorative layer sequentially stacked on the second surface of the sound insulation layer will not be affected by the rough surface of the concrete layer, thereby achieving a beautiful and smooth effect.

Description

Floor structure and preparation method thereof

The present application relates to the technical field of building structures, in particular to a floor structure and its preparation method.

With the change of economic structure, social structure and spatial structure, the population begins to concentrate in the city. Rising population means more noise from people. Therefore, the current "Building Technical Regulations" requires that in new or additional buildings of townhouses and complex houses, the floor used to separate the upper and lower floors must have a certain sound insulation effect.

In the prior art, generally, a floor structure with a sound insulation function is prepared by sequentially stacking a board, a sound insulation material and a tile on a concrete layer serving as a floor slab. In order to ensure that the boards, sound insulation materials and tiles stacked on the concrete layer can be firmly attached, cement mortar is also laid on the concrete layer to fill the unevenness of the surface of the concrete layer. In addition, cement mortar can also improve the problem that the concrete layer is not level, so that the boards, sound insulation materials and tiles stacked on it can be kept level to achieve a beautiful and smooth effect.

However, after laying the cement mortar, it may take some time for the cement mortar to cure. In addition, the laying thickness and level of cement mortar will be affected by the technical skills of the construction personnel. because Therefore, in the case of tight human resources, the existing technology takes a long time, the labor cost is high, and it is difficult to avoid the problem of the technical gap of construction personnel.

The embodiments of the present application provide a floor structure and a preparation method thereof, which solve the problems that the current floor structure takes a long time to construct and is affected by the technical gap of construction personnel.

In order to solve the above technical problems, this application is implemented as follows:

In a first aspect, a floor structure is provided, which includes a sound insulation layer, a concrete layer, a board layer and a decorative layer. The sound insulation layer has a first surface and a second surface opposite to each other, and the roughness of the first surface is greater than that of the second surface. The concrete layer is disposed on the first surface. The board layer is disposed on the second surface. The decoration layer is arranged on the board layer.

In a second aspect, a method for preparing a floor structure is provided, which includes providing a concrete layer; disposing a sound insulation layer on the concrete layer, wherein the sound insulation layer has a corresponding first surface and a second surface, and the roughness of the first surface is greater than that of the second surface. The first surface is in contact with the concrete layer; the board layer is arranged on the second surface; and the decorative layer is arranged on the board layer.

In the floor structure of the present application, by directly disposing the deformable sound insulation layer on the concrete layer, the rough surface of the concrete layer can be firmly attached to the first surface of the sound insulation layer. Further, the board layer and the decorative layer sequentially stacked on the second surface of the sound insulation layer will not be affected by the rough surface of the concrete layer, so as to achieve a beautiful and smooth effect. Therefore, the present application realizes a floor structure with simple construction and smooth appearance, so as to improve the problems in the prior art that the concrete layer needs to be filled by laying cement mortar, which leads to time-consuming, labor-intensive, and technical gaps.

1a-1c: Floor structure

10: Sound insulation layer

10a: First surface

10b: Second surface

11: Concrete layer

12: Sheet Layer

13: Decorative layer

14: Waterproof layer

15: Adhesive layer

S10-S18: Steps

1 is a schematic diagram of a floor structure of an embodiment of the present application; FIG. 2 is a schematic diagram of a floor structure of another embodiment of the present application; FIG. 3 is a schematic diagram of a floor structure of another embodiment of the present application; and FIG. 4 is a schematic diagram of the present application A flow chart of a method for preparing a floor structure according to an embodiment.

In order to facilitate the understanding of the technical features, content and advantages of the present application and the effects that can be achieved, the present application is described in detail as follows with the accompanying drawings and in the form of embodiments, and the drawings used therein are only for the purpose For the purpose of illustrating and assisting the description, it may not necessarily be the actual scale and exact configuration after the application is implemented. Therefore, the proportion and configuration relationship of the attached drawings should not be interpreted or limited to the scope of the right of the application in actual implementation. Say Ming.

Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this application belongs. It will be further understood that terms such as those defined in commonly used dictionaries should be construed as having meanings consistent with their meanings in the context of the related art and this application, and are not to be construed as idealized or excessive Formal meaning unless expressly so defined herein.

Please refer to FIG. 1 , which is a schematic diagram of a floor structure according to an embodiment of the present application. As shown in the figure, the floor structure 1 a includes a sound insulation layer 10 , a concrete layer 11 , a board layer 12 and a decorative layer 13 . The sound insulation layer 10 has a first surface 10a and a second surface 10b opposite to each other, and the roughness of the first surface 10a is greater than that of the second surface 10b. The concrete layer 11 is provided on the first surface 10a. The plate layer 12 is disposed on the second surface 10b. The decoration layer 13 is disposed on the board layer 12 . In the case of stacking the concrete layer 11 , the sound insulation layer 10 , the board layer 12 and the decorative layer 13 in sequence, the sound insulation layer 10 can compensate the rough surface of the concrete layer 11 by partial deformation on one side, thereby avoiding stacking on the other side The board layer 12 and the decorative layer 13 are affected by the unevenness of the concrete layer 11 . Wherein, "partial deformation" means that the first surface 10a of the sound insulation layer 10 can be deformed corresponding to the concave or convex of the concrete layer 11, so as to make the two closely fit. Further, the above-mentioned "partial deformation" only occurs in the region adjacent to the first surface 10a, and will not affect the second surface 10b. Besides, the floor structure of the present application may not need to use studs, so that the construction process is faster.

In addition to compensating for the rough surface of the concrete layer 11 , the sound insulation layer 10 can also smoothly support the board layer 12 and the decorative layer 13 located thereon. In some embodiments, when the concrete layer 11 is not in a horizontal state, the first surface 10a of the sound insulation layer 10 may exhibit a non-horizontal shape corresponding to the concrete layer 11 , and the second surface 10b may exhibit a horizontal shape. For example, the distance between the concrete layer 11 and the horizontal line may be 0.1 degree, 1 degree, 2 degree, 3 degree, 4 degree, 5 degree, 6 degree, 7 degree, 8 degree, 9 degree, 10 degree, or at the above-mentioned value. any range of angles in . In this case, the sound insulation layer 10 provided on the concrete layer 11 may be partially deformed so that the first surface 10a in contact with the concrete layer 11 has a corresponding angle. Similar to the "partial deformation" corresponding to the roughness above, the "partial deformation" corresponding to the degree of inclination occurs only in the region adjacent to the first surface 10a, and does not affect the second surface 10b. In this way, the second surface 10b can still remain substantially horizontal (ie, having an included angle of 0 degrees with the horizontal). It is worth mentioning that, as the angle between the concrete layer 11 and the horizontal line is larger, the volume of the partial deformation of the sound insulation layer 10 is larger. Therefore, the sound insulating layer 10 needs to have a certain thickness to cope with the various angles mentioned above.

In some embodiments, the sound insulating layer 10 may comprise a flexible material such as rubber, plastic or textile, or any combination thereof, and be partially deformed by the flexible material. For example, plastic can To include polypropylene, polyethylene, polyurethane (Polyurethane, PU), thermoplastic polyurethane elastomer (Thermoplastic Urethane, TPU), any combination thereof or the like. Textiles may include blankets, fabrics, any combination thereof, or the like. It is worth mentioning that the above-mentioned materials are only examples, and the present application is not limited thereto. Under the premise that the unevenness of the concrete layer 11 can be compensated by partial deformation, all sound insulation materials known to those skilled in the art can be applied in the present application.

In some embodiments, the sound insulation layer 10 with better sound insulation effect can also be obtained by changing the porosity, density or ratio of the above-mentioned materials according to actual use conditions. Alternatively, the porous material can also be used directly to prepare the sound insulating layer 10 . Porous material refers to a material that contains many pores. The transfer of sound and/or thermal energy can be impeded (eg, absorbed or irregularly diffused) by the large number of two-phase interfaces formed by the porosity. For example, the porous material may be Styrofoam, organic fiber material, inorganic fiber material, foam, glass wool, rock wool, mineral wool, urea-formaldehyde resin, or polyurethane, but not limited thereto. In other embodiments, the sound insulation layer 10 with a high damping coefficient can also be selected, so that the entire floor structure becomes an over-damping system, thereby avoiding the occurrence of resonance phenomenon.

In some embodiments, the sound insulation layer 10 can be measured according to CNS15160-8:2009 (Acoustics-Insulation Measurement of Buildings and Building Components-Laboratory Measurement of Impact Sound Reduction of Surface Materials of Heavy Standard Floors), And obtained the sound insulation material declared by CNS8465-2: 2007 (Acoustics-Evaluation of Sound Insulation of Buildings and Building Components-Impact Sound Insulation). Taking volume reduction as an example, the materials selected for the sound insulation layer 10 are mainly those that can reduce the volume by 17dB to 21dB, and the material that can reduce the volume by 21dB is preferred.

In some embodiments, the board layer 12 may comprise fiber cement board, fireproof board, calcium silicate board, gypsum board, compact floor, wood core board, artificial plywood, riser board or plywood, or any combination thereof. The board layer 12 may be a single-layer structure, and any of the above-mentioned boards may be selected according to actual use conditions. Alternatively, the board layer 12 can also be a multi-layer structure, and various functional layers are stacked in sequence to achieve multi-functional use. way. For example, the board layer 12 may include a fireproof board and a calcium silicate board. Wherein, the fireproof board may be composed of a halogen-containing fireproof material or a fire-resistant material. Alternatively, phosphorus-based, antimony-based or hydroxide-based halogen elements can also be used in the fireproof board to meet environmental regulations while being flame-resistant. Calcium silicate board is a lightweight board made of quartz powder, diatomite, cement, lime, pulp, glass fiber and other materials through pulping, molding, steam curing, surface sanding and other procedures. It has excellent moisture resistance. , sound insulation, anti-insect and high durability and other characteristics. That is, by combining different types of materials, the fireproof board can have the advantages of the above-mentioned materials at the same time.

In some embodiments, the decorative layer 13 may comprise ceramic tile, quartz tile or wood flooring, or any combination thereof. The decorative layer 13 can be selected from different materials according to the application. For example, in some embodiments, the decorative layer 13 may include quartz tiles to provide a hard, wear-resistant effect. Alternatively, in some embodiments, the decorative layer 13 may comprise a wooden floor to provide a comfortable, aesthetically pleasing effect. Alternatively, the decorative layer 13 may also be a composite material, such as Stone Plastic Composite. Further, the stone-plastic floor can include an anti-UV layer, a wear-resistant layer, a vinyl coating, a core layer and a backing layer stacked in sequence, so as to have good waterproof, stable, wood-like appearance and mute effect. It is worth mentioning that the present application is not limited to the above-mentioned materials, and all materials of the decorative layer recognized by those skilled in the art can be used in the present application.

Please refer to FIG. 2 , which is a schematic diagram of a floor structure according to another embodiment of the present application. As shown, the floor structure 1b has a composition similar to that of the floor structure 1a, with the difference that the floor structure 1b may further include a waterproof layer 14 disposed between the sound insulation layer 10 and the board layer 12 . For example, the waterproof layer 14 may be a cloth including plastic or resin, so as to block the penetration of water by a high-density and hydrophobic material. Alternatively, the waterproof layer 14 may be formed on the sound insulation layer 10 or the board layer 12 by coating. on the film. In actual use, the thickness and material of the waterproof layer 14 can be adjusted according to requirements, and should not be limited by the above.

Please refer to FIG. 3 , which is a schematic diagram of a floor structure according to another embodiment of the present application. As shown in the figure, the floor structure 1c has a composition similar to that of the floor structure 1a, with the difference that the floor structure 1c may further include an adhesive layer 15, and the adhesive layer 15 is disposed between the sound insulation layer 10 and the board layer 12, and is used for Adhere the sound insulation layer 10 and the board layer 12 . The adhesive layer 15 may be a single layer or a multi-layer film. For example, if the thermal expansion coefficients of the sound insulation layer 10 and the board layer 12 are greatly different, the adhesive layer 15 may include a first adhesive layer and a second adhesive layer, and the first adhesive layer and the second adhesive layer The layers can each have different thermal expansion coefficients. More specifically, the sound insulation layer 10 is first pasted with a first adhesive layer with a similar thermal expansion coefficient, and the board layer 12 is pasted with a second adhesive layer with a similar thermal expansion coefficient, and finally the first adhesive layer and the second adhesive layer are pasted. The layers are glued to each other. By arranging multi-layer films with different thermal expansion coefficients, the bonding between the sound insulation layer 10 and the board layer 12 can be more stable. However, the above-mentioned 2 layers are only examples, and the present application is not limited thereto. In other embodiments, the adhesive layer 15 may be a multi-layer film with more than 2 layers, for example, the adhesive layer 15 may be a multi-layer film with more than 5 layers. In addition, the above-mentioned coefficient of thermal expansion is only an example, and the present application is not limited thereto. In other embodiments, the adhesive layer 15 may also include a plurality of film layers with different surface tensions, materials or physical properties to match the different sound insulation layers 10 and the board layers 12 .

In some embodiments, the material of the adhesive layer 15 may comprise resin. That is, the adhesive layer 15 may be an adhesive composed of a resin-based material. For example, the resin adhesive may include phenolics, urea formaldehyde resin, melamine formaldehyde resin, polyvinyl acetate resin, polyacrylic resin (eg , poly (methyl methacrylate) resin, PMMA), polyurethane (polyurethane), epoxy resin (epoxy resins) or any combination thereof. However, the above-mentioned types of adhesives It is only an example, and the present application is not limited thereto. Any material known to one of ordinary skill in the art can be used in this application. For example, commercially available super glue (including cyanoacrylate) can be used for the adhesive layer 15 of the present application. Alternatively, in some specific cases, UV curable resin can also be used for the adhesive layer 15 of the present application.

Please refer to FIG. 4 , which is a flowchart of a method for preparing a floor structure according to an embodiment of the present application. As shown in the figure, the preparation method of the floor structure 1a includes:

Step S10: The concrete layer 11 is provided.

Step S12: Disposing the sound insulation layer 10 on the concrete layer 11, wherein the sound insulation layer 10 has a corresponding first surface 10a and a second surface 10b, the roughness of the first surface 10a is greater than that of the second surface 10b, and the first surface 10a and the concrete Layer 11 contacts.

Step S14: Compress the sound insulation layer 10 so that the second surface 10b is horizontal. The method of compressing the sound insulation layer 10 may be by applying an external force on the sound insulation layer 10 , or it may be compressed by the self weight of the sound insulation layer 10 . By compressing the sound insulating layer 10, the sound insulating layer 10 can be partially deformed as described above, thereby compensating for the roughness and/or the level of improvement.

Step S16: disposing the plate layer 12 on the second surface 10b. Wherein, the second surface 10b has been rendered substantially horizontal by compression. That is, the board layer 12 and/or other layers stacked on the second surface 10b will not be affected by the unevenness of the concrete layer 11, and thus present a beautiful and flat state. On the other hand, the arrangement of the board layer 12 may be as described above by adhering by an adhesive layer, or may be directly placed on the second surface 10b of the sound insulation layer 10 , but not limited thereto.

Step S18: Disposing the decorative layer 13 on the board layer 12 to form the floor structure 1a. Wherein, the arrangement of the decorative layer 13 can be made by using glue, cement mortar, etc. a way that is known to those who know. In some embodiments, the decorative layers 13 can also be closely joined and placed on the board layer 12 by being fitted with each other, instead of being necessarily disposed on the board layer 12 by adhering.

To sum up, in the floor structure of the present application, by directly disposing the deformable sound insulation layer on the concrete layer, the rough surface of the concrete layer can be firmly attached to the first surface of the sound insulation layer. Further, the board layer and the decorative layer sequentially stacked on the second surface of the sound insulation layer will not be affected by the rough surface of the concrete layer, so as to achieve a beautiful and smooth effect. Therefore, the present application realizes a floor structure with simple construction and smooth appearance, so as to improve the problem that the concrete layer needs to be filled by laying cement mortar in the prior art, which leads to time-consuming, labor-consuming and technical gaps.

However, the above descriptions are only examples of the present application, and are not intended to limit the scope of implementation of the present application. For example, all equivalent changes and modifications made according to the shape, structure, characteristics and spirit described in the scope of the patent application of the present application, All should be included in the scope of the patent application of this application.

1a: Floor structure

10: Sound insulation layer

10a: First surface

10b: Second surface

11: Concrete layer

12: Sheet Layer

13: Decorative layer

Claims (9)

A floor structure, comprising: a sound insulation layer, the sound insulation layer has a first surface and a second surface opposite; a concrete layer, arranged on the first surface; a board layer, arranged on the second surface ; and a decoration layer arranged on the board layer; wherein, the sound insulation layer compensates for the rough surface of the concrete layer through partial deformation, and makes the roughness of the first surface greater than the roughness of the second surface. The floor structure of claim 1, wherein the first surface is non-level and the second surface is level. The floor structure of claim 1, wherein the sound insulation layer comprises rubber, foam, polypropylene, polyethylene or textile, or any combination thereof. The floor structure of claim 1, wherein the board layer comprises cement fiber board, fireproof board, calcium silicate board, gypsum board, dense bottom board, wood core board, artificial plywood, vertical sheet board or plastic composite material, or any of them combination. The floor structure of claim 1, wherein the decorative layer comprises ceramic tiles, quartz tiles or wood floors, or any combination thereof. The floor structure of claim 1, further comprising a waterproof layer disposed between the sound insulation layer and the board layer. The floor structure of claim 1, further comprising an adhesive layer disposed between the sound insulation layer and the board layer. A preparation method of a floor structure, comprising: A concrete layer is provided; a sound insulation layer is arranged on the concrete layer, wherein the sound insulation layer has a corresponding first surface and a second surface, the first surface is in contact with the concrete layer, and the sound insulation layer is partially deforming to make up the rough surface of the concrete layer and making the roughness of the first surface larger than that of the second surface; disposing a plate layer on the second surface; and disposing a decoration layer on the plate layer. The method for preparing a floor structure according to claim 8, after the step of disposing a sound insulation layer on the concrete, further comprising: compressing the sound insulation layer to make the second surface appear horizontal.

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