EP1418292A1 - Impact sound insulating felt from mineral fibres - Google Patents

Abstract

The assembly comprises parquet and a material including a mineral fiber felt.

Description

The invention relates to a material comprising mineral fibers for to be placed under a parquet so as in particular to absorb impact noise emitted inside the room in which it is placed. The invention relates to in particular a set juxtaposed with parquet and a material comprising a felt of mineral fibers.

Improving the soundproofing of buildings (of all types, offices, housing, etc.) concerns not only the reduction of noise passing through floor or the partitions, but also the attenuation of the noises emitted in a room for people inside the same room. The invention first concerns this second type of insulation - soundproofing. It is therefore including mitigating against a person in a room, the impact sounds with the floor ("drum sound" in English) emitted in the same room and in particular those emitted by said person, for example the noise of his steps and more generally the noise of any impact with the ground. In the context of this demand, these noises are called "direct impact noises". However, the material according to the invention also acts to attenuate the noise passing through the floors or the partitions (“impact sound” in English) which are called within the framework of the present request "impact noise transmitted".

To reduce direct impact noise in a room, we have already proposed place cork sheets, polyethylene foam, polyurethane mat, eraser. However, these materials are generally heavy and expensive or inefficient.

The material according to the invention contributes to the attenuation of impact noises direct and impact noise transmitted. The material according to the invention comprises a mineral fiber felt. This material has a thickness of a few mm and can be placed from plates or a roll (if its flexibility allows) under the entire surface of a parquet floor. The term parquet is to be taken in the broad sense since the floors concerned are not only solid wood floors but more particularly laminate floors ("laminate" in English) floating (comprising a wood fiber plate agglomerated in a binder, associated by pressure bonding to a decorative surface sheet) from plates assembled by tenons and mortises. We can call in the part of this application a laminate parquet by "laminate".

The material according to the invention is in the form of a sheet comprising two parallel main faces. Mineral fibers can be glass fibers or rock fibers.

The felt of the material according to the invention comprises mineral fibers which can be prepared by the so-called centrifugation fiberizing process internal, or the so-called “Aerocor” process or the so-called “Rex” process (the latter plus particularly for rock fiber). The internal centrifugation process is preferred because it leads to a particularly stable and particularly resistant felt good at stretching and folding.

• formation des fibres (plus particulièrement en verre) par un dispositif mettant en oeuvre le procédé dit de centrifugation interne, puis
• pulvérisation d'un précurseur d'un liant sur les fibres, puis
• réception des fibres sur un tapis défilant pour former une nappe, puis
• traitement thermique de la nappe selon une épaisseur contrôlée de façon à transformer le précurseur de liant en liant.

The material according to the invention can in particular be prepared by a process comprising the following steps:

• fiber formation (more particularly in glass) by a device implementing the so-called internal centrifugation process, then
• spraying a precursor of a binder on the fibers, then
• receiving fibers on a moving belt to form a sheet, then
• heat treatment of the web according to a controlled thickness so as to transform the precursor from binder to binder.

If necessary, a veil can be placed before fiberizing on the moving belt, the fibers then being received on said veil. According to this variant, the material according to the invention comprises a felt and the veil glued to one of the faces of the felt. Generally, the veil is glued to the felt by the same binder contained in the felt. The veil offers in particular a comfort of use for people who handle the material according to the invention because it limits direct contact between the skin and mineral fibers.

This process can also be carried out by receiving the fibers directly on a moving carpet (no veil at this stage) and then it add at least one veil, i.e. a veil on a main face or a veil on each main face. The veil (s) can be applied to the mass of fibers before or after heat treatment. If at least one veil is applied before heat treatment, binder precursor can be added between the veil and the fibers, and the heat treatment will be used to transform the binder precursor by binding both for that contained in the felt and for that used to attach the veil to the felt. If at least one veil is applied after heat treatment, the veil can be fixed with any suitable product including in particular a hot-melt polymer (“hot-melt” in English) in which case the application of said hot-melt polymer is carried out hot.

The precursor of a binder sprayed just after the drawing of the fibers is transforms into a binder during heat treatment, said binder being used to bind the fibers between them to give them a felt structure, which can also be used when gluing the possible veil with the felt. The binder bridges between fibers. It is not necessarily evenly distributed around the fibers elementary.

The moving belt is provided with holes so that a suction crossing can attract said fibers to it. If fiber reception is planned on a veil driven by the carpet, the suction crosses the carpet and the veil.

The principle of the internal centrifugation process is well known in itself of the skilled person. Schematically, this process consists in introducing a drizzle of mineral matter melted in a centrifuge, also called a plate of fiberizing, rotating at high speed and pierced at its periphery by a very large number of orifices through which the molten material is projected in the form of filaments under the effect of centrifugal force. These filaments are then subjected to the action of an annular drawing current at high temperature and speed along the wall of the centrifuge, a current which thins them and transforms them into fibers. The fibers formed are entrained by this gaseous stretching stream towards a device reception generally consisting of a gas permeable strip. This known process has been the subject of numerous improvements including in particular those taught in patents EP 0189534, EP 0519797 or EP 1087912. This internal centrifugation process has been implemented according to the prior art in the part of the manufacture of thermal insulation materials. This process is in somehow deviated from its original purpose in the context of the present invention since it is above all a question of reducing impact noise. Compared to these felts made for thermal insulation, felts used for this invention have a high density, a high binder rate and a very thin thickness.

As a document of the prior art, one can also cite the request for French patent n ° 0206547 filed May 27, 2002.

Preferably, the fibers of the felt have a fineness index ranging from 3 to 25 liters per minute and preferably ranging from 10 to 15 I / min. These values preferred correspond approximately to the following “micronaire” values: 2.3 / 5g at 2.7 / 5g.

Preferably, the felt has a density ranging from 40 to 120 kg / m ³ and preferably from 60 to 100 kg / m ³ , for example around 80 kg / m ³ . The surface mass of the felt is generally between 80 and 1200 g / m ² , and is preferably at least equal to 130 g / m ² , in particular ranging from 130 to 700 g / m ² , and more preferably goes from 180 at 700 g / m ² .

In general, the felt includes binder at a rate of 3 to 30 and more generally at a rate of 5 to 25% by weight, especially 6 to 16% by weight.

The material according to the invention can have a thickness ranging from 2 to 10 mm, preferably ranging from 3 to 7 mm, for example around 4 mm. It is the same felt.

Thus, the felt comprising mineral fibers can be of thickness ranging from 2 to 10 mm and of areal mass at least equal to 130 g / m ² .

The fiberizing parameters are adapted so that the fibers obtained by the fiberizing process have the desired fineness index, said fineness being measured by the technique described in the French patent application n ° 0206252 filed on May 22, 2002. This French patent application n ° 0206252 indeed relates to a device for determining the fineness index of fibers comprising a device for measuring the fineness index, said device for measuring the fineness index being provided on the one hand with at least a first orifice connected to a measuring cell adapted to receive a constituted sample of a plurality of fibers and on the other hand, of a second orifice connected to a device for measurement of a differential pressure located on either side of said sample, said differential pressure measuring device being intended to be connected to a device for producing fluid flow, characterized in that the device for measuring the fineness index includes at least one flow meter volumetric of the fluid passing through said cell. This device gives correspondences between “micronaire” values and liters per minute, from when the fiber is thick enough for micronaire values exist.

The precursor of the sprayed binder can be of the phenolic or acrylic type or epoxy. Depending on its nature, this precursor can be sprayed in the form of a solution or emulsion. The sprayed mass generally contains a strong proportion of water, for example ranging from 70 to 98% of water, in particular of the order of 90% water. The rest of the sprayed mass comprises the precursor of the binder and possibly an oil and possibly additives such as for example a silane to optimize the interface between the fiber and the binder, or a biocide. The sum amounts of oil and additive generally range from 0 to 5% by weight of the mass of precursor, in particular from 1 to 3% by weight of the mass of precursor. oil may in particular be that of the Mulrex 88 brand. Generally, the binder is thermosetting type.

The mineral material that is transformed into fiber is generally glass. Any type of glass which can be transformed by the so-called internal centrifugation process can suit. It can in particular be a borosilicocalcic glass, and in particular a biosoluble glass. The mineral fiber can also be a rock fiber.

The heat treatment serves to transform the precursor from binder into binder into causing the chemical solidification reactions (crosslinking or polymerization) and by evaporating the volatile species (solvent, reaction, etc.). At the end of this heat treatment, the fibers are linked together in the felt and if necessary, the felt is linked to the possible veil. This operation is carried out while maintaining the thickness of the felt during the reaction of solidification, which is usually achieved by maintaining it (if applicable associated with the possible veil) between two scrolling belts placed at a distance constant of each other, said distance corresponding to that desired in the final material. The felt is actually compressed from the start of the passage between the two carpets so that the felt generally decreases in thickness when passing through heat treatment.

To obtain a given final felt thickness, it is generally necessary to deposit a layer of fibers on the moving carpet (before compression during heat treatment), with a thickness ranging from 15 to 60 times the desired final thickness. For example, for a thick felt finally about 4 mm, we can deposit a layer of fibers 100 to 150 mm thick before heat treatment.

The material according to the invention can consist of bonded felt, and does not understand no other layer. However, it can also include a veil on one side or a veil on both sides.

Generally, the material according to the invention comprises 2 to 12% by weight of veil, the rest being generally made up of felt (we consider here that the mass of the felt includes the mass of the binder, including that used to bond the felt veil).

We have already seen above a method of preparing a material comprising the felt and a veil, the latter being unwound on a mat to receive the fibers that have just formed. It is also possible to manufacture the felt separately and without a veil, then to glue the veil (s) on one or both sides. The veil (s), if any, is generally made of polyester or polypropylene or glass and generally has a surface mass (or grammage) ranging from 5 to 100 g / m ² .

For its storage, the material according to the invention can be rolled up or cut into square or rectangular plates (for example with an area ranging from 0.1 to 0.4 m ² ).

• on prépare des plaques du matériau selon l'invention ayant les mêmes longueurs et largeurs que les plaques de stratifié que l'on souhaite poser, puis
• on prépare des ensembles comprenant chacun une plaque de stratifié et une plaque du matériau selon l'invention en collant des plaques du matériau selon l'invention sous des plaques de stratifié, puis
• on pose sur le sol les ensembles précédemment réalisés.

To equip a floor according to the invention, the procedure is generally as follows:

• plates of the material according to the invention are prepared having the same lengths and widths as the laminate plates which it is desired to lay, then
• assemblies are each prepared comprising a laminate plate and a plate of the material according to the invention by bonding plates of the material according to the invention under laminate plates, then
• the previously made assemblies are placed on the ground.

In this case, and if the material according to the invention comprises a veil, the veil is generally on an external face of the assembly so that it is the veil which comes into contact with the ground.

The parquet can be glued or not glued to the material according to the invention. To do this, you can for example use a classic wood glue. We can in particular use the brand adhesive INSTAWELD 6621. Preferably, the parquet is glued to the material according to the invention. Generally, we stick beforehand the material according to the invention and the parquet together, and we proceed then in a second step when laying the bi-material thus obtained on the ground. This installation on the ground is generally carried out without glue. Indeed, this allows including soil moisture (e.g. residual concrete moisture) of better escape.

If the flexibility of the material according to the invention allows it to be wound, it is possible also lay the material according to the invention on the ground from a roller, then lay parquet (with or without glue).

The material according to the invention is used for sound insulation of any building and in particular apartment buildings. The invention therefore also relates to a building comprising a parquet / material assembly according to the invention.

The material according to the invention reduces impact noise, in particular by frequency between 50 and 5000 Hz. The material according to the invention is particularly effective in reducing high frequency impact noise, particular of frequency higher than 700 Hz, and even higher than 1000 Hz, and even greater than 1500 Hz, for example between 1500 and 5000. These measures impact noise can be performed according to EN-IS0140-8 standards and ISO 717/2.

Figure 1 shows schematically a method of manufacturing a material according to the invention comprising a felt and a veil. It is here called upon internal centrifugation process. A drizzle of melted mineral matter 1 (especially glass) falls in the center of the hollow shaft 2 of the centrifuge, touches basket 3, then said material is projected by centrifugation towards the plate of fiber drawing 4 provided with orifices. The molten material passes through the orifices in the form of fibers which are then drawn using the burners 5. The nozzles of spray 6 projects the precursor of the binder onto the fibers, which are then received on the veil 7, itself driven by a band 8 permeable to gases. A suction not shown in Figure 1, acts through the strip to attract and hold the fibers on the surface of the veil. All fibers / veil is then dragged into an oven 9 for processing the binder precursor in binder. In this oven, the material is sandwiched between two moving belts 10 and 11, distant from each other by the desired distance for the final thickness of the material. After solidification of the binder, the material according to the invention can be wound in 12.

FIG. 2 represents the material according to the invention, which here comprises a veil 13, on which a fiber felt 14 is glued.

EXAMPLES

• indice de finesse de 10 I/min,
• densité de 80 kg/m³,
• teneur en liant : 10% en poids,
• épaisseur : 4 mm.

A felt of bonded glass fibers is prepared by the internal centrifugation process, the characteristics of which are as follows:

• fineness index of 10 I / min,
• density of 80 kg / m ³ ,
• binder content: 10% by weight,
• thickness: 4 mm.

During its manufacture, the glass fibers were deposited on a polyester veil whose surface mass was 20 g / m ² . This veil was linked to the felt by the same binder as that contained in the felt.

• sur un tiers de la surface : on pose le matériau selon l'invention dont le voile est en contact avec le sol, puis on pose (sans colle) un parquet flottant en laminé comprenant des fibres de bois agglomérées,
• sur un autre tiers de sa surface : on pose une mousse de polyéthylène extrudé de marque « Pergo Underlay Foam », puis on pose le même parquet (sans colle),
• sur un autre tiers de sa surface : on pose directement le parquet sur la chape de béton sans interposer aucun autre matériau (donc sans colle non plus),

We install on the concrete screed of a room:

• on a third of the surface: the material according to the invention is laid, the web of which is in contact with the ground, then a floating laminate parquet floor comprising agglomerated wood fibers is laid (without glue),
• on another third of its surface: we apply an extruded polyethylene foam brand "Pergo Underlay Foam", then we apply the same parquet (without glue),
• on another third of its surface: the parquet is laid directly on the concrete screed without interposing any other material (therefore without glue either),

10 people with normal hearing are asked to walk on all three ground areas then indicate the area where they hear their least own not. Every 10 people indicate that the area equipped with the material according to the invention is the best from this point of view.

Claims (33)

Assembly juxtaposed with parquet and material comprising a mineral fiber felt. Assembly according to the preceding claim, characterized in that the felt has a thickness ranging from 2 to 10 mm. Assembly according to the preceding claim, characterized in that the felt has a thickness ranging from 3 to 7 mm. Assembly according to one of the preceding claims, characterized in that the fibers of the felt have a fineness index ranging from 3 to 25 liters per minute. Assembly according to the preceding claim, characterized in that the fibers of the felt have a fineness index ranging from 10 to 15 I / min. Assembly according to the preceding claim, characterized in that the mineral fibers are glass fibers. Assembly according to one of the preceding claims, characterized in that the felt comprises binder in an amount of 3 to 30% by weight. Assembly according to the preceding claim, characterized in that the felt comprises binder in an amount of 5 to 25% by weight. Assembly according to the preceding claim, characterized in that the felt comprises binder at a rate of 6 to 16% by weight. Assembly according to one of the preceding claims, characterized in that the binder is of the thermosetting type. Assembly according to one of the preceding claims, characterized in that the binder is of the phenolic or acrylic or epoxy type. Assembly according to one of the preceding claims, characterized in that the fibers have been prepared by the internal centrifugation process. Assembly according to one of the preceding claims, characterized in that the material comprises at least one veil. Assembly according to the preceding claim, characterized in that at least one veil is located on an external face of the assembly. Assembly according to one of the two preceding claims, characterized in that at least one veil has a surface mass ranging from 5 to 100 g / m ² . Assembly according to one of the three preceding claims, characterized in that at least one veil is made of polyester. Assembly according to one of the preceding claims, characterized in that the material and the parquet are glued to one another. Assembly according to one of the preceding claims, characterized in that the parquet is a laminate. Building comprising an assembly according to one of claims preceding. Felt comprising mineral fibers, of thickness ranging from 2 to 10 mm and of areal mass at least equal to 130 g / m ² . Felt according to the preceding claim, characterized in that its surface mass ranges from 180 to 700 g / m ² . Felt according to one of the preceding felt claims, characterized in that it has a thickness ranging from 3 to 7 mm. Felt according to one of the preceding felt claims, characterized in that its fibers have a fineness index ranging from 3 to 25 liters per minute. Felt according to the preceding claim, characterized in that its fibers have a fineness index ranging from 10 to 15 I / min. Felt according to one of the preceding felt claims, characterized in that it comprises binder in an amount of 3 to 30% by weight. Felt according to one of the preceding felt claims, characterized in that it comprises binder in an amount of 5 to 25% by weight. Felt according to the preceding claim characterized in that the felt comprises binder in an amount of 6 to 16% by weight. Felt according to one of the preceding felt claims, characterized in that the binder is of the thermosetting type. Felt according to one of the preceding felt claims, characterized in that the binder is of the phenolic or acrylic or epoxy type. Felt according to one of the preceding felt claims, characterized in that the fibers have been prepared by the internal centrifugation process. Felt according to one of the preceding felt claims, characterized in that the mineral fibers are glass fibers. Use of a material comprising a mineral fiber felt, said material material being placed on a floor and under a parquet, to reduce impact noise caused by impacts with said parquet. Use according to the preceding claim, characterized in that the material is not stuck to the ground.

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