WO2002048478A1 - Soundproof floor-filling structure - Google Patents

Soundproof floor-filling structure Download PDF

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Publication number
WO2002048478A1
WO2002048478A1 PCT/EP2001/014090 EP0114090W WO0248478A1 WO 2002048478 A1 WO2002048478 A1 WO 2002048478A1 EP 0114090 W EP0114090 W EP 0114090W WO 0248478 A1 WO0248478 A1 WO 0248478A1
Authority
WO
WIPO (PCT)
Prior art keywords
floor
filling structure
matrix
grains
filling
Prior art date
Application number
PCT/EP2001/014090
Other languages
French (fr)
Inventor
Maurizio Mason
Original Assignee
Isolcem Italia S.R.L.
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Isolcem Italia S.R.L. filed Critical Isolcem Italia S.R.L.
Priority to AU2002221918A priority Critical patent/AU2002221918A1/en
Publication of WO2002048478A1 publication Critical patent/WO2002048478A1/en

Links

Classifications

    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F15/00—Flooring
    • E04F15/18—Separately-laid insulating layers; Other additional insulating measures; Floating floors
    • E04F15/20—Separately-laid insulating layers; Other additional insulating measures; Floating floors for sound insulation
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B28/00—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
    • C04B28/02—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing hydraulic cements other than calcium sulfates
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F15/00—Flooring
    • E04F15/18—Separately-laid insulating layers; Other additional insulating measures; Floating floors
    • E04F15/20—Separately-laid insulating layers; Other additional insulating measures; Floating floors for sound insulation
    • E04F15/206—Layered panels for sound insulation
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
    • C04B2111/52—Sound-insulating materials
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
    • C04B2111/60—Flooring materials

Definitions

  • the present invention refers to floor-filling structures, i.e. the structures that, in buildings, fill the space between a floor and the floor covering, and more particularly it concerns a soundproof, lightweight and load resistant floor-filling structure.
  • the conventional floor-filling structures in order to have a reduced weight, are obtained by mixing an air-hardening binder (e.g. concrete) with granular material of different kinds.
  • an air-hardening binder e.g. concrete
  • vermiculite was used as the material added to the binder.
  • grains of foamed clay, cork, polystyrene or polyurethane have been used, individually or in admixture. Said additional elements, besides making the filling structure light, also exhibited sound-absorbing properties.
  • the prior art floor-filling structures however give rise to a number of problems.
  • metal ducts for sanitary equipment, or rough or smooth ducts for housing electrical and telephone lines and so on can be present within the floor-filling structure.
  • Water coming into contact with metal ducts embedded in the filling structure can cause corrosion and, in case of discontinuities in the ducts, it can penetrate into the ducts under liquid or gaseous (vapour) form.
  • Other problems affecting the floor-filling structures conventionally made of concrete concern hygrometric shrinkage and bleeding.
  • the green concrete in the filling structure shrinks if relative humidity decreases below a given value. This occurs because water contained in the concrete evaporates and the material shortens. Moreover, evaporation does not take place in uniform manner across the whole structure, so that also shrinkage takes place in differential manner. In particular, the upper surface (exposed to air) dries and tends to shrink, whereas the lower surface (protected from evaporation) does not undergo shrinkage and remains stable. Thus, the surface layer cracks. As to bleeding, the green concrete has a higher water-to- binder ratio in the upper layers than in the lower layers, because water moves up towards the surface. This causes sedimentation of the bigger stony elements towards the lower part of the structure, resulting in stronger surface shrinkage and higher porosity in the uppermost layer.
  • the floor-filling structure is obtained by mixing, with a conventional air-hardening binder, grains obtained from various resins, in particular polyvinyl resins or similar cheap resins, such as polypropylene, polyethylene, PVC, caoutchouc, rubbers in general, polycarbon, silicon resins, plastics of different kinds, etc.
  • the floor-filling structure can include metal elements such as tin and copper, as pure metals and/ or alloys. If the above mentioned metal elements are present at the structure surface and if the overlaid floor covering is made of a material such as linoleum, moquette or wood, emission of metal ions into the room can take place. According to some scientific sources, said emission has anti-stress properties, whereby it contributes to the attainment of a better comfort in the room where the floor-filling structure of the present invention has been made.
  • the grains included in the floor-filling structure of the invention are compact and mechanically resistant and they do not absorb water. Moreover, said grains poorly conduct mechanical waves so that, depending on their percentage, they confer to the floor-fining structure a non-negligible degree of soundproofing in respect of tramping. Furthermore, the grains are not toxic or harmful nor they emit harmful gases. Still further, the grains cannot be attacked by mildews, since they do not contain organic materials, and they are environmentally compatible with the binders (contrary to polystyrene and polyurethane).
  • the amount of stony components replaced by resin grains is considerably reduced. Sedimentation of heavy stony components of bigger size is hindered by the diffuse presence of the resin grains that, thanks to their lightness, counterbalance gravitational forces. Water amount in the concrete mixture is reduced, so that the mixture itself is rather solid and tends to be dry, and it does not promote separation of stony and resin grains. Thus the structure is substantially homogeneous from the uppermost layer to the lowermost layer, and neither shrinkage nor cracking take place.
  • the resin grain percentage together with the lightness of the resin material is determined so as to obtain the highest soundproofing compatible with the load resistance.
  • the resin percentage is 30% to 60% of the binder, with grain size in the range of 0 to 4-6 mm.
  • FIG. 1 schematically shows a portion of a horizontal building structure where a conventional floor-filling structure is provided between the floor and the laying plane of the walking-on floor covering;
  • FIG. 2 is a schematical view similar to Fig. 1, showing a floor- filling structure according to the invention.
  • a floor-filling structure 1 is arranged between a substrate 2, consisting of the bearing floor, and floor covering 8. The latter is applied onto the . levelled upper surface 6 of floor-filling structure 1 by means of an adhesive 7.
  • a polyethylene sheet 4 is possibly provided to separate floor-filling structure 1 from underlying floor 2.
  • the drawing also shows iron rods 3 of the floor armature and a service duct 5 (e. g. a duct for sanitary equipment or a duct housing electrical or telephone lines).
  • Floor-filling structure 1 shown in Fig. 1 is a conventional filling structure, with stony grains 10 embedded into a concrete matrix 9.
  • the Figure clearly shows the lack of homogeneity of the conventional structure, due to sedimentation of the heavy stony grains in the lower layers.
  • Fig. 2 shows a floor-filling structure 1 according to the invention.
  • Matrix 9 made of concrete still includes stony grains 10, besides a mass of resin grains 11, in particular polyvinyl resin grains, distributed in substantially homogeneous manner throughout the whole matrix.
  • the drawing clearly shows that, thanks to the presence of the resin grains, also the stony grains remain distributed in substantially homogeneous manner throughout the matrix.

Landscapes

  • Engineering & Computer Science (AREA)
  • Architecture (AREA)
  • Chemical & Material Sciences (AREA)
  • Structural Engineering (AREA)
  • Ceramic Engineering (AREA)
  • Civil Engineering (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Inorganic Chemistry (AREA)
  • Materials Engineering (AREA)
  • Organic Chemistry (AREA)
  • Floor Finish (AREA)
  • Vehicle Interior And Exterior Ornaments, Soundproofing, And Insulation (AREA)

Abstract

A light and soundproof floor-filling structure for filling the space between a floor surface and the level of the laying plane of the walking-on floor covering is disclosed. The structure consists of a mixture of an air-hardening binder and a given amount of grains of resin materials, generally of a polyvinyl resin. Metal elements such as copper and tin can be present as either pure metals or alloys. The features of the structure are lightness, soundproofing, compactness, workability, mechanical strength and environmental compatibility.

Description

SOUNDPROOF FLOOR-FILLING STRUCTURE
The present invention refers to floor-filling structures, i.e. the structures that, in buildings, fill the space between a floor and the floor covering, and more particularly it concerns a soundproof, lightweight and load resistant floor-filling structure.
It is known that, in buildings, the space between the surface of a floor and the level of the laying plane of the walking-on floor covering is filled by materials of various kinds. It is important that the resulting filling structure is as light as possible, so that it does not reduce the floor loading capacity.
At present, the conventional floor-filling structures, in order to have a reduced weight, are obtained by mixing an air-hardening binder (e.g. concrete) with granular material of different kinds. In the past, vermiculite was used as the material added to the binder. Subsequently, grains of foamed clay, cork, polystyrene or polyurethane have been used, individually or in admixture. Said additional elements, besides making the filling structure light, also exhibited sound-absorbing properties. The prior art floor-filling structures however give rise to a number of problems.
A first problem, common to all existing floor-filling structures, is that water in the air-hardening binder can impregnate the different grains and remain trapped therein when the binder sets. Said water, whenever possible, tends to free itself and to enter into the matrix containing the grains, thereby creating humidity.
Moreover, it is to be considered that metal ducts for sanitary equipment, or rough or smooth ducts for housing electrical and telephone lines and so on can be present within the floor-filling structure. Water coming into contact with metal ducts embedded in the filling structure can cause corrosion and, in case of discontinuities in the ducts, it can penetrate into the ducts under liquid or gaseous (vapour) form. Other problems affecting the floor-filling structures conventionally made of concrete concern hygrometric shrinkage and bleeding.
As to hygrometric shrinkage, the green concrete in the filling structure, owing to its considerably great surface if compared to thickness, shrinks if relative humidity decreases below a given value. This occurs because water contained in the concrete evaporates and the material shortens. Moreover, evaporation does not take place in uniform manner across the whole structure, so that also shrinkage takes place in differential manner. In particular, the upper surface (exposed to air) dries and tends to shrink, whereas the lower surface (protected from evaporation) does not undergo shrinkage and remains stable. Thus, the surface layer cracks. As to bleeding, the green concrete has a higher water-to- binder ratio in the upper layers than in the lower layers, because water moves up towards the surface. This causes sedimentation of the bigger stony elements towards the lower part of the structure, resulting in stronger surface shrinkage and higher porosity in the uppermost layer.
Additional problems depend on the nature of the granular material.
Some materials, such as vermiculite, considerably add to the cost of the filling structure. Organic materials, such as cork, can be attacked by mildews. Other materials, such as polystyrene and polyurethane, are not environmentally compatible with the binders or emit harmful substances (polyurethane, when decomposing, releases isocyanate; certain rocks, such as asbestos, release microf-bres). It is an object of the present invention to provide a floor-filling structure invention obviating the above drawbacks.
The floor-filling structure is obtained by mixing, with a conventional air-hardening binder, grains obtained from various resins, in particular polyvinyl resins or similar cheap resins, such as polypropylene, polyethylene, PVC, caoutchouc, rubbers in general, polycarbon, silicon resins, plastics of different kinds, etc. Besides the mixture of the binders and the resin grains (e. g. polyvinyl resin grains), the floor-filling structure can include metal elements such as tin and copper, as pure metals and/ or alloys. If the above mentioned metal elements are present at the structure surface and if the overlaid floor covering is made of a material such as linoleum, moquette or wood, emission of metal ions into the room can take place. According to some scientific sources, said emission has anti-stress properties, whereby it contributes to the attainment of a better comfort in the room where the floor-filling structure of the present invention has been made.
Besides being light, the grains included in the floor-filling structure of the invention are compact and mechanically resistant and they do not absorb water. Moreover, said grains poorly conduct mechanical waves so that, depending on their percentage, they confer to the floor-fining structure a non-negligible degree of soundproofing in respect of tramping. Furthermore, the grains are not toxic or harmful nor they emit harmful gases. Still further, the grains cannot be attacked by mildews, since they do not contain organic materials, and they are environmentally compatible with the binders (contrary to polystyrene and polyurethane).
When manufacturing the floor-filling structure according to the invention, the amount of stony components replaced by resin grains is considerably reduced. Sedimentation of heavy stony components of bigger size is hindered by the diffuse presence of the resin grains that, thanks to their lightness, counterbalance gravitational forces. Water amount in the concrete mixture is reduced, so that the mixture itself is rather solid and tends to be dry, and it does not promote separation of stony and resin grains. Thus the structure is substantially homogeneous from the uppermost layer to the lowermost layer, and neither shrinkage nor cracking take place.
The resin grain percentage together with the lightness of the resin material is determined so as to obtain the highest soundproofing compatible with the load resistance. Preferably, the resin percentage is 30% to 60% of the binder, with grain size in the range of 0 to 4-6 mm.
The above features will be better understood with reference to the accompanying drawings, in which.
- Fig. 1 schematically shows a portion of a horizontal building structure where a conventional floor-filling structure is provided between the floor and the laying plane of the walking-on floor covering; and
- Fig. 2 is a schematical view similar to Fig. 1, showing a floor- filling structure according to the invention. As shown in the drawings, a floor-filling structure 1 is arranged between a substrate 2, consisting of the bearing floor, and floor covering 8. The latter is applied onto the . levelled upper surface 6 of floor-filling structure 1 by means of an adhesive 7. A polyethylene sheet 4 is possibly provided to separate floor-filling structure 1 from underlying floor 2. The drawing also shows iron rods 3 of the floor armature and a service duct 5 (e. g. a duct for sanitary equipment or a duct housing electrical or telephone lines).
Floor-filling structure 1 shown in Fig. 1 is a conventional filling structure, with stony grains 10 embedded into a concrete matrix 9. The Figure clearly shows the lack of homogeneity of the conventional structure, due to sedimentation of the heavy stony grains in the lower layers.
Fig. 2 shows a floor-filling structure 1 according to the invention. Matrix 9 made of concrete still includes stony grains 10, besides a mass of resin grains 11, in particular polyvinyl resin grains, distributed in substantially homogeneous manner throughout the whole matrix. The drawing clearly shows that, thanks to the presence of the resin grains, also the stony grains remain distributed in substantially homogeneous manner throughout the matrix.
It is clear that the invention is not limited to the particular embodiment described and illustrated here and that any other solution, even of improving character, which a skilled in the art can conceive by using the teaching of the invention, is not a departure from the scope of the invention.

Claims

Patent Claims
1. A soundproof floor-filling structure (1) comprising a matrix (9) loaded with granular material, characterised in that said granular material includes grains (11) of a lightweight, soundproof and load-resistant resin material, which grains are distributed in substantially homogeneous manner throughout the matrix (9).
2. A floor-filling structure (1) according to claim 1, characterised in that the resin material is chosen out of a group including polyvinyl resins, polyethylene, polypropylene, PVC, caoutchouc, rubbers in general, polycarbon, silicon resins.
3. A floor-filling structure (1) according to claim 1 or 2, characterised in that the resin material has grain size in the range 0 to 4-6 mm.
4. A floor-filling structure (1) according to any preceding claim, characterised in that it further comprises metal elements capable of emitting ions into a room including the filling structure (1).
5. A floor-filling structure (1) according to claim 4, characterised in that said metal elements include copper and/or tin.
6. A floor-filling structure (1) according to claim 4 or 5, characterised in that said metal elements are present in the form of pure metal and/or of alloy.
7. A floor-filling structure (1) according to any preceding claim, characterised in that the matrix (9) embodying the resin grains
(11) and the metal elements, if any, is a mixture obtained by using air-hardening binders.
8. A floor-filling structure (1) according to claim 7, characterised in that the matrix (9) is a compact and dry concrete matrix.
9. A floor-filling structure (1) according to claim 1 or 2, characterised in that the resin material is present in a percentage of 30% to 60% relative to the matrix (9).
PCT/EP2001/014090 2000-12-11 2001-12-03 Soundproof floor-filling structure WO2002048478A1 (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
AU2002221918A AU2002221918A1 (en) 2000-12-11 2001-12-03 Soundproof floor-filling structure

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
IT2000PD000275A IT1315767B1 (en) 2000-12-11 2000-12-11 SOUNDPROOFING SCREED
ITPD2000A000275 2000-12-11

Publications (1)

Publication Number Publication Date
WO2002048478A1 true WO2002048478A1 (en) 2002-06-20

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PCT/EP2001/014090 WO2002048478A1 (en) 2000-12-11 2001-12-03 Soundproof floor-filling structure

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AU (1) AU2002221918A1 (en)
IT (1) IT1315767B1 (en)
WO (1) WO2002048478A1 (en)

Cited By (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP1420128A1 (en) * 2002-10-22 2004-05-19 FTI Faserbetontechnik GmbH Concrete surface and its method of production
EP1582654A1 (en) * 2004-03-24 2005-10-05 BAUMBACH Metall GmbH Concrete surface and its method of production
WO2006094523A1 (en) * 2005-03-04 2006-09-14 Pirelli & C. S.P.A. Method for making a sound-insulatiing load-bearing floor
US7861477B2 (en) 2005-06-10 2011-01-04 Pirelli & C. S.P.A. Method for making a sound-insulating load-bearing floor
IT1426203B1 (en) * 2014-09-19 2016-12-02

Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE2213034A1 (en) * 1971-03-19 1972-10-05 Orszagos Gumiipari Vall Concrete or mortar for heat and sound insulating building - elements - based on binder and ground rubber
FR2437478A1 (en) * 1978-06-26 1980-04-25 Boulenger Ets Structural sound-proofing of rubber-filled cement - bound by aq. resin emulsion for compatibility with conventional water-based building materials
US4261756A (en) * 1975-05-06 1981-04-14 Bermat S.A. Lead alloy and granulate concrete containing the same
WO1998050318A1 (en) * 1997-05-01 1998-11-12 Plascrete Ltd. A cementitious composition
WO2000026485A1 (en) * 1998-11-04 2000-05-11 Ludovic Molenaers Acoustic insulating material and floating floor provided with such material
DE20108311U1 (en) * 2000-05-20 2001-08-16 Alcopor Man Ag Steinhausen Impact sound insulation

Patent Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE2213034A1 (en) * 1971-03-19 1972-10-05 Orszagos Gumiipari Vall Concrete or mortar for heat and sound insulating building - elements - based on binder and ground rubber
US4261756A (en) * 1975-05-06 1981-04-14 Bermat S.A. Lead alloy and granulate concrete containing the same
FR2437478A1 (en) * 1978-06-26 1980-04-25 Boulenger Ets Structural sound-proofing of rubber-filled cement - bound by aq. resin emulsion for compatibility with conventional water-based building materials
WO1998050318A1 (en) * 1997-05-01 1998-11-12 Plascrete Ltd. A cementitious composition
WO2000026485A1 (en) * 1998-11-04 2000-05-11 Ludovic Molenaers Acoustic insulating material and floating floor provided with such material
DE20108311U1 (en) * 2000-05-20 2001-08-16 Alcopor Man Ag Steinhausen Impact sound insulation

Cited By (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP1420128A1 (en) * 2002-10-22 2004-05-19 FTI Faserbetontechnik GmbH Concrete surface and its method of production
EP1582654A1 (en) * 2004-03-24 2005-10-05 BAUMBACH Metall GmbH Concrete surface and its method of production
WO2006094523A1 (en) * 2005-03-04 2006-09-14 Pirelli & C. S.P.A. Method for making a sound-insulatiing load-bearing floor
US7861484B2 (en) 2005-03-04 2011-01-04 Pirelli & C. S.P.A. Method for making a sound-insulating load-bearing floor
US7861477B2 (en) 2005-06-10 2011-01-04 Pirelli & C. S.P.A. Method for making a sound-insulating load-bearing floor
IT1426203B1 (en) * 2014-09-19 2016-12-02

Also Published As

Publication number Publication date
AU2002221918A1 (en) 2002-06-24
ITPD20000275A1 (en) 2002-06-11
IT1315767B1 (en) 2003-03-18

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