WO2008131960A2 - Improved acoustic and impact performance of etic-systems - Google Patents

Improved acoustic and impact performance of etic-systems Download PDF

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Publication number
WO2008131960A2
WO2008131960A2 PCT/EP2008/003464 EP2008003464W WO2008131960A2 WO 2008131960 A2 WO2008131960 A2 WO 2008131960A2 EP 2008003464 W EP2008003464 W EP 2008003464W WO 2008131960 A2 WO2008131960 A2 WO 2008131960A2
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WO
WIPO (PCT)
Prior art keywords
composite system
less
layer
flexible adhesive
adhesive
Prior art date
Application number
PCT/EP2008/003464
Other languages
French (fr)
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WO2008131960A3 (en
Inventor
Ludovic Harelle
Holger Merkel
Martin Frank Reimers
Original Assignee
Dow Global Technologies Inc.
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Publication date
Application filed by Dow Global Technologies Inc. filed Critical Dow Global Technologies Inc.
Publication of WO2008131960A2 publication Critical patent/WO2008131960A2/en
Publication of WO2008131960A3 publication Critical patent/WO2008131960A3/en

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Classifications

    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F13/00—Coverings or linings, e.g. for walls or ceilings
    • E04F13/02—Coverings or linings, e.g. for walls or ceilings of plastic materials hardening after applying, e.g. plaster
    • E04F13/04—Bases for plaster
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B13/00—Layered products comprising a a layer of water-setting substance, e.g. concrete, plaster, asbestos cement, or like builders' material
    • B32B13/14—Layered products comprising a a layer of water-setting substance, e.g. concrete, plaster, asbestos cement, or like builders' material next to a fibrous or filamentary layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B17/00—Layered products essentially comprising sheet glass, or glass, slag, or like fibres
    • B32B17/02—Layered products essentially comprising sheet glass, or glass, slag, or like fibres in the form of fibres or filaments
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
    • B32B7/04—Interconnection of layers
    • B32B7/12—Interconnection of layers using interposed adhesives or interposed materials with bonding properties
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
    • B32B7/04—Interconnection of layers
    • B32B7/12—Interconnection of layers using interposed adhesives or interposed materials with bonding properties
    • B32B7/14—Interconnection of layers using interposed adhesives or interposed materials with bonding properties applied in spaced arrangements, e.g. in stripes
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/62—Insulation or other protection; Elements or use of specified material therefor
    • E04B1/74—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls
    • E04B1/82—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls specifically with respect to sound only
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/62—Insulation or other protection; Elements or use of specified material therefor
    • E04B1/74—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls
    • E04B1/82—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls specifically with respect to sound only
    • E04B1/84—Sound-absorbing elements
    • E04B1/86—Sound-absorbing elements slab-shaped
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F13/00—Coverings or linings, e.g. for walls or ceilings
    • E04F13/02—Coverings or linings, e.g. for walls or ceilings of plastic materials hardening after applying, e.g. plaster
    • E04F13/04—Bases for plaster
    • E04F13/047—Plaster carrying meshes
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F13/00—Coverings or linings, e.g. for walls or ceilings
    • E04F13/07—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor
    • E04F13/08—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F13/00—Coverings or linings, e.g. for walls or ceilings
    • E04F13/07—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor
    • E04F13/08—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements
    • E04F13/0867—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements having acoustic absorption means on the visible surface
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F13/00—Coverings or linings, e.g. for walls or ceilings
    • E04F13/07—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor
    • E04F13/08—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements
    • E04F13/0885—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements specially adapted for being adhesively fixed to the wall; Fastening means therefor; Fixing by means of plastics materials hardening after application
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/62—Insulation or other protection; Elements or use of specified material therefor
    • E04B1/74—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls
    • E04B1/82—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls specifically with respect to sound only
    • E04B2001/8263—Mounting of acoustical elements on supporting structure, e.g. framework or wall surface
    • E04B2001/8272—Resiliently mounted wall cladding acting as a diaphragmatic sound damper
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/62—Insulation or other protection; Elements or use of specified material therefor
    • E04B1/74—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls
    • E04B1/82—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls specifically with respect to sound only
    • E04B1/84—Sound-absorbing elements
    • E04B2001/8457—Solid slabs or blocks
    • E04B2001/8461—Solid slabs or blocks layered
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F2290/00—Specially adapted covering, lining or flooring elements not otherwise provided for
    • E04F2290/04—Specially adapted covering, lining or flooring elements not otherwise provided for for insulation or surface protection, e.g. against noise, impact or fire
    • E04F2290/041—Specially adapted covering, lining or flooring elements not otherwise provided for for insulation or surface protection, e.g. against noise, impact or fire against noise

Definitions

  • the present invention relates to a composite system useful for the acoustic insulation of the inner and/or outer side of a building, a component or a wall element wherein the composite system provides good acoustic performance as well as improved impact resistance.
  • EIFS External Insulation and Finish Systems
  • ETICS External Thermal Insulation Composite Systems
  • the EIFS/ETICS-systems comprise a foam board typically made of expanded polystyrene (EPS) or special, soft elastified EPS, or mineral fibre insulation board and an adhesive system, which is normally a standard mineral based adhesive system.
  • EPS expanded polystyrene
  • Elastified EPS based EIFS/ETICS-systems have the advantage that they have both thermal insulation properties as well as good acoustic insulation properties.
  • XPS extruded polystyrene foam
  • XPS extruded polystyrene foam
  • XPS based EIFS/ETICS-systems The impact resistance of XPS based EIFS/ETICS-systems is therefore, often a preferred advantage in order to reduce risk of render damages of the said systems.
  • XPS boards normally have poorer acoustic performance as a result of their rigid structure.
  • a composite system useful for the acoustic insulation of the inner and/or outer side of a building, a component or a wall element comprising: a) a flexible adhesive, and b) a rigid board intended to be adhered to the building, the component or the wall element by the flexible adhesive, wherein the composite system has a dynamic modulus of elasticity (E dyn ) of less than 1.5 N/mm 2 , preferably of less than 1.2 N/rara 2 , more preferably of less than 1.0 N/mm 2 , even more preferably of less than 0.8 N/mm 2 , and most preferably of less than 0.6 N/mm 2 .
  • E dyn dynamic modulus of elasticity
  • a composite system useful for the acoustic insulation of the inner and/or outer side of a building, a component or a wall element comprising: a) a flexible adhesive, and b) a rigid board intended to be adhered to the building, the component or the wall element by the flexible adhesive, wherein the flexible adhesive has a dynamic stiffness S' a dhesiv e of less than 250 MN/m 3 , preferably of less than 200 MN/m 3 , more preferably of less than 150 MNVm 3 , even more preferably of less than 100 MN/m 3 , and most preferably of less than 70 MN/m 3 .
  • a render layer external to the rigid board optionally, c) a render layer external to the rigid board.
  • the inventive combination of the rigid XPS board and the flexible adhesive described herein provides desirable properties for both impact resistance and acoustic performance.
  • This acoustic performance improvement is because the softness (low dynamic modulus) of the flexible adhesive decouples the rigid board acoustically from the building, the component, or the wall element. This can be understood when one imagines a mass- spring-mass system as explained below.
  • the flexibility of the adhesive also enhances the impact resistance.
  • the mass-spring-mass principle is a well kown physical principle. It can be illustrated by two steel balls separated through a spring. If one takes this system up by holding one ball and slowly moving it up and down, both balls will move at the same speed. When increasing the moving frequency, both balls will hit at a certain frequency (i.e. the "resonance frequency"). This is, for example, known when soldiers walk in a defined walking frequency over a bridge which could cause collapse of the bridge. Now, moving the balls quicker and quicker it will become obvious that the movement of the second ball will be more and more reduced which means that the system becomes decoupled. Transferring this principle to the inventive system, the first mass is the building wall, the flexible adhesive represents the spring and the rigid board represents the second mass. Depending on the hardness of the spring, the resonance frequency will be higher or lower. The lower the dynamic stiffness (S';), the lower the resonance frequency will be. The lower the resonance frequency, the better the acoustic decoupling function.
  • S' dynamic stiffness
  • the measurement of the dynamic stiffness (S'i) of a material is defined according to EN29052-1.
  • the dynamic stiffness (S',) is defined as the quotient of the dynamic modulus of elasticity (E d yn) divided by the thickness of the substrate and the lower the dynamic stiffness (S'i), the better the acoustic performance is going to be.
  • the inventive composite system provides a good acoustic performance when the composite system has a dynamic modulus of the elasticity (E dyn ) of less than 1.5 N/mm 2 , preferably less than 1.2 N/mm 2 , more preferably less than 1.0 N/mm 2 , even more preferably less than 0.8 N/mm 2 , and most preferably less than 0.6 N/mm 2 .
  • E dyn dynamic modulus of the elasticity
  • the inventive composite system provides a good acoustic performance when the flexible adhesive used in this composite system has a dynamic stiffness S'a d h es iv e of less than 250 1 "X 1
  • MN/m preferably of less than 200 MN/m , more preferably of less than 150 MN/m , even more preferably of less than 100 MN/m 3 , and most preferably of less than 70 MN/m 3 .
  • the composite system comprises a rigid board preferably having a compressive strength of more than 80 kPa, more preferably more than 100 kPa, even more preferably more than 150 kPa, and most preferably more than 200 kPa.
  • the rigid board of the present invention preferably has a thickness of 1 to 300 mm.
  • the rigid board may be an insulation board having a density of less than 500 kg/m 3 .
  • the rigid board may have a thickness of 10 to 300 mm, preferably of 20 to 200 mm, more preferably of 30 to 150 mm, and most preferably of 40 to 100 mm.
  • Insulation boards may have thermal and/or acoustic insulating properties. Examples for such boards are XPS boards, EPS boards, XPS plasterboard laminates, EPS plasterboard laminates or the like.
  • a preferred rigid board used as a component of the inventive composite system is an XPS board, especially due to its rigidity.
  • the rigid board has a density of 500 kg/m 3 or more, hi these cases, thermal insulation is typically not an issue or may be an issue of lesser priority.
  • Typical examples for rigid boards having a higher density are wood particle- boards, any kind of wooden boards, boards made of plastics, metal sheets and boards, any kind of laminate boards, and oriented strand boards (OSB).
  • OSB oriented strand boards
  • XPS boards, EPS boards, and the corresponding plasterboard laminates may be useful examples if these boards have higher densities.
  • the rigid boards may have a thickness of 1 to 50 mm, preferably of 2 to 40 mm, more preferably of 3 to 30 mm, and most preferably of 4 to 20 mm.
  • the composite system is useful for acoustic insulation of the inner side of a building, a component or a wall element and the rigid board is a plasterboard laminate comprising: a) a plaster board, preferably a paper faced gypsum bord, having a thickness of 4 to 20 mm, preferably of 8 to 16 mm, and b) a rigid insulation board having a thickness of 1 to 20 cm, preferably of 2 to 15 cm, more preferably of 3 to 12 cm.
  • This is a type of insulation system which is predominant in some locations (e.g. France) where it is fixed to the inner side of a building wall which faces the outside. In such a system the same acoustic principles will apply as explained above.
  • the flexible adhesive of the composite system has a dynamic modulus of elasticity (Edyn) of less than 1.5 N/mm 2 , preferably of less than 1.2 N/mm 2 , more preferably of less than 1.0 N/mm 2 , even more preferably of less than 0.8 N/mm , and most preferably of less than 0.6 N/mm .
  • the dynamic modulus of elasticity (E dyn ) of the whole composite system as defined above is mainly based on the dynamic modulus of elasticity (E d y n ) of the flexible adhesive while the rigid board has only a little contribution to the dynamic modulus of elasticity (E d yn) of the whole composite system.
  • the flexible adhesive consequently has a dynamic stiffness (S' a dhesive) more or less equal to the dynamic stiffness of the whole composite system (S' to tai), namely of less than 250 MN/m 3 , preferably of less than 200 MN/m 3 , more preferably of less than 150 MN/m 3 , even more preferably of less than 100 MN/m , and most preferably of less than 70 MN/m 3 .
  • the flexible adhesive is preferably provided in a thickness of 1 to 30 mm, more preferably of 2 to 25 mm, even more preferably of 3 to 20 mm, and most preferably of 4 to 15 mm.
  • the flexible adhesive covers less than 100%, preferably 10 to 80%, more preferably 20 to 70%, and most preferably 30 to 60%, of the surface of the rigid board. It is preferred to not cover the entire back side surface of the rigid board with the flexible adhesive in order to save adhesive material and to reduce installation costs.
  • the flexible adhesive used as the adhesive component in the composite system according to the present invention may be any flexible adhesive known in the art as long as the condition is fulfilled that the final composite system has a dynamic modulus of elasticity (E dyn ) of less than 1.5 N/mm 2 , preferably of less than 1.2 N/mm 2 , more preferably of less than 1.0 N/mm , even more preferably of less than 0.8 N/mm , and most preferably of less than 0.6 N/mm 2 .
  • E dyn dynamic modulus of elasticity
  • the flexible adhesive used in the composite system according to the invention may be any flexible adhesive known in the art having a dynamic stiffness S' adhes iv e of less than 250 MN/m 3 , preferably of less than 200 MN/m 3 , more preferably of less than 150 MN/m 3 , even more preferably of less than 100 MN/m 3 , and most preferably of less than 70 MN/m 3 .
  • Examples for flexible adhesives suitable for the present invention are any kind of foam adhesives, silicone adhesives and hot melt or cold melt adhesives.
  • Preferred adhesives are polyurethane foam adhesives, more preferred are polyurethane one-component foam adhesives and most preferred is Insta-StikTM from The Dow Chemical Company (for details, see Examples).
  • a covering layer covers the front side of the rigid board.
  • the covering layer may be selected from the group comprising a render layer, a metal layer, a wooden layer, a plastic layer or a composite layer.
  • the composite system may further comprise a finishing system which covers the front side of the rigid board.
  • the finishing system may comprise a render layer.
  • the render layer again may comprise a first render layer, a reinforcement mesh layer, and a second render layer wherein each of said layers may have a thickness of independently typically 1 to 5 mm, but such thickness can be more.
  • the first and/or the second render layer is a cement- or gypsum based render layer and more preferably a polymer modified cement- or gypsum based render layer while the reinforcement mesh layer is preferably a polymer coated glass-fibre mesh ' fabric having a weight of 100 to 220 g/m , more preferably having a weight of 140 to 180 g/m .
  • the finishing system may comprise or, in addition to the above described render layer system, may additionally comprise a base coat layer, preferably based on a water based emulsion comprising silicon additives, and/or a coating or paint layer, preferably based on an acrylic emulsion, whereby the coating or paint layer is preferably alkali-resistant.
  • the silicone additives may be used in order to increase the bonding strength between the coating and the render layer or the rigid board, respectively.
  • the covering layer or the finishing system may have a thickness of 1 to 20 mm, preferably 2 to 15 mm, more preferably of 3 to 10 mm and most preferably of 4 to 8 mm.
  • the rigid board and the optional covering layer or the finishing system may have a total weight of 1 to 40 kg/m , preferably of 2 to 30 kg/m 2 , more preferably of 3 to 20 kg/m 2 and most preferably of 4 to 10 kg/m 2 .
  • the involved mass of the rigid board and the optional finishing system influences the acoustic benefit which can be achieved by the composite system according to the present invention.
  • a further aspect of the invention is a construction comprising a) a substrate, preferably a building, a component or a wall element; b) a composite system as described above which is adhered by the flexible adhesive to the substrate; and c) optionally, one or more functional layers and/or interspaces being located between the substrate and the composite system.
  • Example 1 (comparative example): a) 6 mm of a mineral adhesive layer, mostly cement based, with 100% of the adhesion surface coverered; b) 8 cm STYROFOAMTM LB board (STYROFOAMTM is extruded polystyrene (XPS) and available from The Dow Chemical Company, Midland, U.S.A.), planed product; c) about 2 mm of a first cement-based render layer; d) about 0.5 mm of an embedded reinforcement mesh; e) about 2 mm of a second cement-based render layer; and f) about 1 mm of a finishing layer (colour and grain).
  • STYROFOAMTM is extruded polystyrene (XPS) and available from The Dow Chemical Company, Midland, U.S.A.
  • Example 1 represents the standard fixation of thermally insulating materials to a wall.
  • Example 2 (according to the invention): a) 10 mm of a flexible adhesive layer (INSTA STIKTM Polyurethane foam adhesive, available from The Dow Chemical Company, Midland, U.S.A.).
  • INSTA STIKTM is a one component polyurethane adhesive having the approximate composition as follows:
  • Dynamic stiffness (S'i) is an acoustic property, measured on a special measurement device, using a vibration table, an accelerometer and an analysis tool.
  • the top steel plate was 0.2 x 0.2 m in size and had a mass of 8 kg, with a surface weight of 200 kg/m2. Out of the masses in the system and the measured resonance of the system the properties can be measured.
  • the final acoustic performance of ETICS/EIFS systems will depend on further element characteristics, such as the mass of the supporting wall structure, and the type and mass of render being applied.
  • the measured properties mainly relate to the elasticity of the adhesive layer in combination with the rigid XPS board.
  • the impact resistance of the specimens was also tested using the method described below with the results are shown in Table 2.
  • the impact tests have been carried out consistent with ETA004, Guideline for European Technical Approval of External Thermal Insulation Composite Systems with Rendering, chapter 5.1.3.3.. This corresponds to the test described in ISO 7892. During those tests an impactor with a diameter of 4 cm was dropped onto the render with different impact energies. The energy levels were 3 Joules, 6 Joules and 10 Joules.
  • Double circular crack means double circular crack without damage of reinforcement mesh
  • the test results were consistent on all load levels.
  • the ETICS/EIFS systems according to the invention having a flexible adhesive layer showed an average indentation of 1.88 mm and the mineral adhesive bonded systems showed an indentation of 2.35 mm, meaning 25% greater indentation. Comparing only the 3 Joule impact values, the impact depth of the mineral adhesive bonded systems was 65 % greater than the impact depth of the ETICS/EIFS systems according to the invention using the flexible adhesive. This is clear evidence for the impact strength improvement through the flexible adhesive.

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  • Engineering & Computer Science (AREA)
  • Architecture (AREA)
  • Structural Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Civil Engineering (AREA)
  • Acoustics & Sound (AREA)
  • Electromagnetism (AREA)
  • Building Environments (AREA)
  • Laminated Bodies (AREA)

Abstract

A composite system useful for the acoustic insulation of the inner and/or outer side of a building, a component or a wall element is provided, the system comprising: a) a flexible adhesive; and a rigid board intended to be adhered to the building, the component or the wall element by the flexible adhesive; wherein the composite system has a dynamic modulus of elasticity (Edyn) of less than 1.5 N/mm2 or wherein the flexible adhesive has a dynamic stiffness S'adhesive of less than 250 MN/m3, and, optionally, wherein the composite system has a render layer external to the rigid board.

Description

IMPROVED ACOUSTIC AND IMPACT PERFORMANCE OF ETIC-SYSTEMS
FIELD OF THE INVENTION
The present invention relates to a composite system useful for the acoustic insulation of the inner and/or outer side of a building, a component or a wall element wherein the composite system provides good acoustic performance as well as improved impact resistance.
BACKGROUND OF THE INVENTION
External Insulation and Finish Systems (EIFS) or External Thermal Insulation Composite Systems (ETICS), respectively, and construction techniques therefore were known in the art. In general, the EIFS/ETICS-systems comprise a foam board typically made of expanded polystyrene (EPS) or special, soft elastified EPS, or mineral fibre insulation board and an adhesive system, which is normally a standard mineral based adhesive system. Elastified EPS based EIFS/ETICS-systems have the advantage that they have both thermal insulation properties as well as good acoustic insulation properties. However, various markets traditionally prefer extruded polystyrene foam (XPS) based systems because XPS is more rigid than EPS and, therefore, has better impact reaction behaviour. The impact resistance of XPS based EIFS/ETICS-systems is therefore, often a preferred advantage in order to reduce risk of render damages of the said systems. However, XPS boards normally have poorer acoustic performance as a result of their rigid structure.
So, there is a need for EIFS/ETICS-systems which provide good acoustic properties and good impact resistance properties as compared to XPS based systems. Therefore, it is an object of the present invention to provide a composite system having improved properties with respect to both good acoustic and good impact resistance performance. DETAILED DESCRIPTION OF THE INVENTION
The above object of the present invention is met by a composite system useful for the acoustic insulation of the inner and/or outer side of a building, a component or a wall element comprising: a) a flexible adhesive, and b) a rigid board intended to be adhered to the building, the component or the wall element by the flexible adhesive, wherein the composite system has a dynamic modulus of elasticity (Edyn) of less than 1.5 N/mm2, preferably of less than 1.2 N/rara2, more preferably of less than 1.0 N/mm2, even more preferably of less than 0.8 N/mm2, and most preferably of less than 0.6 N/mm2. And optionally, c) a render layer external to the rigid board.
In an alternative embodiment of the invention the above object is met by a composite system useful for the acoustic insulation of the inner and/or outer side of a building, a component or a wall element comprising: a) a flexible adhesive, and b) a rigid board intended to be adhered to the building, the component or the wall element by the flexible adhesive, wherein the flexible adhesive has a dynamic stiffness S'adhesive of less than 250 MN/m3, preferably of less than 200 MN/m3, more preferably of less than 150 MNVm3, even more preferably of less than 100 MN/m3, and most preferably of less than 70 MN/m3.
And optionally, c) a render layer external to the rigid board.
The inventive combination of the rigid XPS board and the flexible adhesive described herein provides desirable properties for both impact resistance and acoustic performance. This acoustic performance improvement is because the softness (low dynamic modulus) of the flexible adhesive decouples the rigid board acoustically from the building, the component, or the wall element. This can be understood when one imagines a mass- spring-mass system as explained below. Furthermore, the flexibility of the adhesive also enhances the the impact resistance.
The mass-spring-mass principle is a well kown physical principle. It can be illustrated by two steel balls separated through a spring. If one takes this system up by holding one ball and slowly moving it up and down, both balls will move at the same speed. When increasing the moving frequency, both balls will hit at a certain frequency (i.e. the "resonance frequency"). This is, for example, known when soldiers walk in a defined walking frequency over a bridge which could cause collapse of the bridge. Now, moving the balls quicker and quicker it will become obvious that the movement of the second ball will be more and more reduced which means that the system becomes decoupled. Transferring this principle to the inventive system, the first mass is the building wall, the flexible adhesive represents the spring and the rigid board represents the second mass. Depending on the hardness of the spring, the resonance frequency will be higher or lower. The lower the dynamic stiffness (S';), the lower the resonance frequency will be. The lower the resonance frequency, the better the acoustic decoupling function.
The measurement of the dynamic stiffness (S'i) of a material is defined according to EN29052-1. According to this standard, the dynamic stiffness (S',) is defined as the quotient of the dynamic modulus of elasticity (Edyn) divided by the thickness of the substrate and the lower the dynamic stiffness (S'i), the better the acoustic performance is going to be.
Surprisingly, according to this invention, it has been discovered that the inventive composite system provides a good acoustic performance when the composite system has a dynamic modulus of the elasticity (Edyn) of less than 1.5 N/mm2, preferably less than 1.2 N/mm2, more preferably less than 1.0 N/mm2, even more preferably less than 0.8 N/mm2, and most preferably less than 0.6 N/mm2.
Furthermore surprisingly, according to this invention, it has also been discovered that the inventive composite system provides a good acoustic performance when the flexible adhesive used in this composite system has a dynamic stiffness S'adhesive of less than 250 1 "X 1
MN/m , preferably of less than 200 MN/m , more preferably of less than 150 MN/m , even more preferably of less than 100 MN/m3, and most preferably of less than 70 MN/m3.
In order to meet the requirement of a good impact resistance, the composite system, according to the invention, comprises a rigid board preferably having a compressive strength of more than 80 kPa, more preferably more than 100 kPa, even more preferably more than 150 kPa, and most preferably more than 200 kPa.
The rigid board of the present invention preferably has a thickness of 1 to 300 mm. In one aspect of the invention the rigid board may be an insulation board having a density of less than 500 kg/m3. In this case the rigid board may have a thickness of 10 to 300 mm, preferably of 20 to 200 mm, more preferably of 30 to 150 mm, and most preferably of 40 to 100 mm.
Insulation boards may have thermal and/or acoustic insulating properties. Examples for such boards are XPS boards, EPS boards, XPS plasterboard laminates, EPS plasterboard laminates or the like. A preferred rigid board used as a component of the inventive composite system is an XPS board, especially due to its rigidity.
hi another aspect of the invention the rigid board has a density of 500 kg/m3 or more, hi these cases, thermal insulation is typically not an issue or may be an issue of lesser priority. Typical examples for rigid boards having a higher density are wood particle- boards, any kind of wooden boards, boards made of plastics, metal sheets and boards, any kind of laminate boards, and oriented strand boards (OSB). However, also XPS boards, EPS boards, and the corresponding plasterboard laminates may be useful examples if these boards have higher densities. In these cases the rigid boards may have a thickness of 1 to 50 mm, preferably of 2 to 40 mm, more preferably of 3 to 30 mm, and most preferably of 4 to 20 mm.
In a further embodiment of the invention, the composite system is useful for acoustic insulation of the inner side of a building, a component or a wall element and the rigid board is a plasterboard laminate comprising: a) a plaster board, preferably a paper faced gypsum bord, having a thickness of 4 to 20 mm, preferably of 8 to 16 mm, and b) a rigid insulation board having a thickness of 1 to 20 cm, preferably of 2 to 15 cm, more preferably of 3 to 12 cm. This is a type of insulation system which is predominant in some locations (e.g. France) where it is fixed to the inner side of a building wall which faces the outside. In such a system the same acoustic principles will apply as explained above.
In preferred embodiments of the invention, the flexible adhesive of the composite system has a dynamic modulus of elasticity (Edyn) of less than 1.5 N/mm2, preferably of less than 1.2 N/mm2, more preferably of less than 1.0 N/mm2, even more preferably of less than 0.8 N/mm , and most preferably of less than 0.6 N/mm . In these embodiments of the invention the dynamic modulus of elasticity (Edyn) of the whole composite system as defined above is mainly based on the dynamic modulus of elasticity (Edyn) of the flexible adhesive while the rigid board has only a little contribution to the dynamic modulus of elasticity (Edyn) of the whole composite system.
As mentioned above, the dynamic stiffness (S'i) is defined as the quotient of the dynamic modulus of elasticity (Edyn) divided by the thickness of the related mass. Therefore, in an alternative aspect of the invention the composite system has a dynamic stiffness (S'i = S'totai) of less than 250 MN/m3, preferably of less than 200 MN/m3, more preferably of less than 150 MN/m3, even more preferably of less than 100 MN/m3, and most preferably of less than 70 MN/m . In those cases where the dynamic stiffness of the whole composite system (S'totai) is mainly based on the dynamic stiffness of the flexible adhesive (S'adhesive) the flexible adhesive consequently has a dynamic stiffness (S'adhesive) more or less equal to the dynamic stiffness of the whole composite system (S'totai), namely of less than 250 MN/m3, preferably of less than 200 MN/m3, more preferably of less than 150 MN/m3, even more preferably of less than 100 MN/m , and most preferably of less than 70 MN/m3.
The correlation between the dynamic stiffness of the composite system (S'totai), the dynamic stiffness of the flexible adhesive (S'adhesive)> and the dynamic stiffness of the rigid board (S'board) is as follows:
1 /S'totai = (1 /S'board + 1 /S'adhesive)- As it is apparent from this correlation the contribution of the rigid board having very high degree of dynamic stiffness (S'boaπi) (i.e., being very rigid) is very small compared to the contribution of the dynamic stiffness of the flexible adhesive (S'adhesive)- The dynamic modulus of an elasticity (Edyn) which is selected to define the flexible adhesive properties directly correlates with the dynamic stiffness (S'j) via the formula:
Dynamic Modulus of Elasticity (Edyn) of a component = S'; * (thickness of the component).
Now, in order to achieve the desired dynamic modulus of elasticity, Edyn, of a composite system or in the alternative case that the flexible adhesive has a dynamic stiffness S'adhesive according to the invention the flexible adhesive is preferably provided in a thickness of 1 to 30 mm, more preferably of 2 to 25 mm, even more preferably of 3 to 20 mm, and most preferably of 4 to 15 mm.
In preferred embodiments of the invention the flexible adhesive covers less than 100%, preferably 10 to 80%, more preferably 20 to 70%, and most preferably 30 to 60%, of the surface of the rigid board. It is preferred to not cover the entire back side surface of the rigid board with the flexible adhesive in order to save adhesive material and to reduce installation costs. In order to save as much as possible of the flexible adhesive, it is desirable to use a flexible adhesive having a dynamic modulus of elasticity (Edyn) as low as reasonably possible. The lower the dynamic modulus of elasticity (Edyn) of the adhesive and/or the thicker the layer of flexible adhesive that is applied to the rigid board, the lower is the dynamic stiffness of the flexible adhesive as well as the lower is the dynamic stiffness of the whole composite system.
The flexible adhesive used as the adhesive component in the composite system according to the present invention may be any flexible adhesive known in the art as long as the condition is fulfilled that the final composite system has a dynamic modulus of elasticity (Edyn) of less than 1.5 N/mm2, preferably of less than 1.2 N/mm2, more preferably of less than 1.0 N/mm , even more preferably of less than 0.8 N/mm , and most preferably of less than 0.6 N/mm2. In the alternative case the flexible adhesive used in the composite system according to the invention may be any flexible adhesive known in the art having a dynamic stiffness S'adhesive of less than 250 MN/m3, preferably of less than 200 MN/m3, more preferably of less than 150 MN/m3, even more preferably of less than 100 MN/m3, and most preferably of less than 70 MN/m3. Examples for flexible adhesives suitable for the present invention are any kind of foam adhesives, silicone adhesives and hot melt or cold melt adhesives. Preferred adhesives are polyurethane foam adhesives, more preferred are polyurethane one-component foam adhesives and most preferred is Insta-Stik™ from The Dow Chemical Company (for details, see Examples).
In a further aspect of the invention a covering layer covers the front side of the rigid board. The covering layer may be selected from the group comprising a render layer, a metal layer, a wooden layer, a plastic layer or a composite layer.
In an alternative aspect of the invention the composite system may further comprise a finishing system which covers the front side of the rigid board. The finishing system may comprise a render layer. The render layer again may comprise a first render layer, a reinforcement mesh layer, and a second render layer wherein each of said layers may have a thickness of independently typically 1 to 5 mm, but such thickness can be more. In a preferred embodiment the first and/or the second render layer is a cement- or gypsum based render layer and more preferably a polymer modified cement- or gypsum based render layer while the reinforcement mesh layer is preferably a polymer coated glass-fibre mesh' fabric having a weight of 100 to 220 g/m , more preferably having a weight of 140 to 180 g/m .
In an alternative embodiment of the inventive composite system the finishing system may comprise or, in addition to the above described render layer system, may additionally comprise a base coat layer, preferably based on a water based emulsion comprising silicon additives, and/or a coating or paint layer, preferably based on an acrylic emulsion, whereby the coating or paint layer is preferably alkali-resistant. The silicone additives may be used in order to increase the bonding strength between the coating and the render layer or the rigid board, respectively.
In preferred embodiments of the invention the covering layer or the finishing system may have a thickness of 1 to 20 mm, preferably 2 to 15 mm, more preferably of 3 to 10 mm and most preferably of 4 to 8 mm. In a further aspect of the invention the rigid board and the optional covering layer or the finishing system may have a total weight of 1 to 40 kg/m , preferably of 2 to 30 kg/m2, more preferably of 3 to 20 kg/m2 and most preferably of 4 to 10 kg/m2. The involved mass of the rigid board and the optional finishing system influences the acoustic benefit which can be achieved by the composite system according to the present invention. The higher the mass of the rigid board and the optional covering layer, or finishing system, adhered by the flexible adhesives to the, for example, building wall, the greater will be the acoustic benefit. On the other hand, the higher the mass of the rigid board and the optional finishing system is the more weight has to be held by the flexible adhesive. This could make it necessary to use anchors which fix the rigid board to the, for example, building wall, thereby assisting the holding force of the flexible adhesive.
A further aspect of the invention is a construction comprising a) a substrate, preferably a building, a component or a wall element; b) a composite system as described above which is adhered by the flexible adhesive to the substrate; and c) optionally, one or more functional layers and/or interspaces being located between the substrate and the composite system.
EXAMPLES
Two ETICS/EIFS systems were prepared with the following build-ups:
Example 1 (comparative example): a) 6 mm of a mineral adhesive layer, mostly cement based, with 100% of the adhesion surface coverered; b) 8 cm STYROFOAM™ LB board (STYROFOAM™ is extruded polystyrene (XPS) and available from The Dow Chemical Company, Midland, U.S.A.), planed product; c) about 2 mm of a first cement-based render layer; d) about 0.5 mm of an embedded reinforcement mesh; e) about 2 mm of a second cement-based render layer; and f) about 1 mm of a finishing layer (colour and grain).
Example 1 represents the standard fixation of thermally insulating materials to a wall.
Example 2 (according to the invention): a) 10 mm of a flexible adhesive layer (INSTA STIK™ Polyurethane foam adhesive, available from The Dow Chemical Company, Midland, U.S.A.). INSTA STIK™ is a one component polyurethane adhesive having the approximate composition as follows:
10 to 30 weight % of polymethylene polyphenyl isocyanate containing 4,4'-methylene bisphenyl isocyanate at approximately 40-50 %; 30 to 60 weight % of prepolymer of 4,4'-methylene bisphenyl isocyanate and polyether polyol; chlorodifluoromethane; and morpholine, 4,4'-(oxydi-2,l-ethanediyl)bis). Of the flexible adhesive layer, only 50% of the potential adhesion surface is covered; b) 8 cm STYROFOAM™ LB board, planed product; c) about 2 mm of a first cement-based render layer; d) about 0.5 mm of an embedded reinforcement mesh; e) about 2 mm of a second cement-based render layer; and f) about 1 mm of a finishing layer (colour and grain). Two specimens of each of the examples (specimens IA, IB, 2 A, 2B) were prepared in order to test the acoustic performance and the impact resistance of the systems.
The dynamic stiffness (S'i) and the dynamic modulus of elasticity (Edyn) of the specimens were tested according to EN 29052-1 with the results as shown in Table 1. Dynamic stiffness (S'i) is an acoustic property, measured on a special measurement device, using a vibration table, an accelerometer and an analysis tool. The top steel plate was 0.2 x 0.2 m in size and had a mass of 8 kg, with a surface weight of 200 kg/m2. Out of the masses in the system and the measured resonance of the system the properties can be measured. The lower the dynamic stiffness (S1;), the better the acoustic performance is going to be.
TABLE 1 : Acoustic performance of ETICS/EIFS systems
Figure imgf000011_0001
* comparative examples
The final acoustic performance of ETICS/EIFS systems will depend on further element characteristics, such as the mass of the supporting wall structure, and the type and mass of render being applied. The measured properties mainly relate to the elasticity of the adhesive layer in combination with the rigid XPS board. The impact resistance of the specimens was also tested using the method described below with the results are shown in Table 2. The impact tests have been carried out consistent with ETA004, Guideline for European Technical Approval of External Thermal Insulation Composite Systems with Rendering, chapter 5.1.3.3.. This corresponds to the test described in ISO 7892. During those tests an impactor with a diameter of 4 cm was dropped onto the render with different impact energies. The energy levels were 3 Joules, 6 Joules and 10 Joules.
TABLE 1 : Impact resistance of ETICS/EIFS systems
Figure imgf000012_0001
* comparative examples
1 "Circular crack" means circular crack without damage of reinforcement mesh
2 "Double circular crack" means double circular crack without damage of reinforcement mesh The test results were consistent on all load levels. The ETICS/EIFS systems according to the invention having a flexible adhesive layer showed an average indentation of 1.88 mm and the mineral adhesive bonded systems showed an indentation of 2.35 mm, meaning 25% greater indentation. Comparing only the 3 Joule impact values, the impact depth of the mineral adhesive bonded systems was 65 % greater than the impact depth of the ETICS/EIFS systems according to the invention using the flexible adhesive. This is clear evidence for the impact strength improvement through the flexible adhesive.

Claims

WHAT IS CLAIMED IS:
1. A composite system useful for the acoustic insulation of the inner and/or outer side of a building, a component, or a wall element, comprising: a) a flexible adhesive; and b) a rigid board intended to be adhered to the building, the component, or the wall element, by the flexible adhesive; wherein the composite system has a dynamic modulus of elasticity Edyn of less than 1.5 N/mm2.
2. A composite system useful for the acoustic insulation of the inner and/or outer side of a building, a component, or a wall element, comprising: a) a flexible adhesive; and b) a rigid board intended to be adhered to the building, the component, or the wall element, by the flexible adhesive; wherein the flexible adhesive has a dynamic stiffness S'adhesive of less than 250 MN/m3.
3. The composite system according to claim 1 , wherein the dynamic modulus of elasticity Edyn is less than 0.6 N/mm2.
4. The composite system according to claim 1 , wherein the rigid board has a compressive strength of more than lOOkPa.
5. The composite system according to claim 1, wherein the rigid board has a compressive strength of more than 200 kPa.
6. The composite system according to any of the preceding claims, wherein the flexible adhesive has a dynamic modulus of elasticity Edyn of less than 1.0 N/mm2.
7. The composite system according to any of the preceding claims, wherein the layer defined by the flexible adhesive has a thickness of 1 to 30 mm.
8. The composite system according to any of the preceding claims, wherein the layer defined by the flexible adhesive has a thickness 4 to 10 mm.
9. The composite system according to any of the preceding claims, wherein the composite system has a dynamic stiffness S'totai of less than 250 MN/m3 or the flexible adhesive has a dynamic stiffness S'adhesive of less than 250 MN/m3.
10. The composite system according to any of the preceding claims, wherein the composite system has a dynamic stiffness S'totai of less than 250 MN/m3 or the flexible adhesive has a dynamic stiffness S'adhesive of less 100 MN/m3.
11. The composite system according to any of the preceding claims, wherein the rigid board has a thickness of 1 to 300 mm.
12. The composite system according to claim 11, wherein the rigid board is an insulation board having a density of less than 500 kg/m3 and having a thickness of 40 to 100 mm.
13. The composite system according to claim 11 , wherein the rigid board has a density of 500 kg/m3 or more and a thickness of 1 to 50 mm.
14. The composite system according to claim 11, wherein the composite system is useful for the acoustic insulation of the inner side of a building, a component or a wall element and the rigid board is a plasterboard laminate comprising: a) a plaster board having a thickness of 4 to 20 mm, and b) a rigid insulation board having a thickness of 1 to 20 cm.
15. The composite system according to any of the preceding claims, wherein the composite system further comprises a covering layer or a finishing system over the rigid board.
16. The composite system according to claim 15, wherein the covering layer or the finishing system has a thickness of 1 to 20 mm.
17. The composite system according to any of the preceding claims, wherein the rigid board and the optional covering layer or finishing system have a total weight of
1 to 40 kg/m2.
18. The composite system according to any of the claims 15 to 17, wherein the covering layer is selected from the group comprising a render layer, a metal layer, a wooden layer, a plastic layer or a composite layer.
19. The composite system according to any of the claims 15 to 18, wherein the finishing system comprises: a) a first render layer; and b) a reinforcement mesh layer; and c) a second render layer.
20. The composite system according to any of the claims 15 to 19, wherein the finishing system comprises: a) a cement or gypsum based render; and b) a polymer coated glass fibre mesh fabric having a weight of 100 to 220 gr/m2; and c) a cement or gypsum based render, wherein each of the layers a) to c) has a thickness of independently 1 to 5 mm.
21. The composite system according to any of the claims 15 to 20, wherein the finishing system comprises: a) a polymer modified cement or gypsum based render; and b) a polymer coated glass fibre mesh fabric having a weight of 140 to 180 gr/m2; and c) a polymer modified cement or gypsum based render, wherein each of the layers a) to c) has a thickness of independently 1 to 5 mm; and d) a base coat layer; and e) a coating or paint layer.
22. Use of a composite system according to any of the preceding claims for the acoustic insulation of the inner and/or outer side of a building, a component or a wall element.
23. Use of a polyurethane foam adhesive or an adhesive which is based thereon as part of a composite system useful for the acoustic insulation of the inner or outer side of a building, a component or a wall element, wherein the flexible adhesive has a dynamic modulus of elasticity Edyn of less than 1.2 N/mm2.
24. Use of a polyurethane foam adhesive or an adhesive which is based thereon as part of a composite system useful for the acoustic insulation of the inner or outer side of a building, a component or a wall element, wherein the flexible adhesive has a dynamic stiffness S'adhesive of less than 250 MN/m3.
25. A construction comprising: a) a substrate; b) a composite system according to any of the claims 1 to 21 adhered by the flexible adhesive to the substrate.
26. A construction comprising: a) a building, a component or a wall element; b) a composite system according to any of the claims 1 to 21 adhered by the flexible adhesive to the substrate, and c) one or more functional layers or interspaces being located between the building, the component or the wall element and the composite system.
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