Floating floor system

Abstract

A composite structure for a floating floor system including at least one layer of force muting material and a layer of formwork, wherein the layer of formwork is located on the at least one layer of force muting material wherein the layer of formwork is a half closed folded honeycomb structure or a relaxed honeycomb structure.

Claims

1. A composite structure for a floating floor system comprising: at least one layer of force muting material and a layer of formwork, wherein the layer of formwork is located on the at least one layer of force muting material, the at least one layer of force muting material being parallel to a plane and wherein the layer of formwork is a relaxed honeycomb structure, said relaxed honeycomb structure being composed of a thermoplastic polymer or thermoplastic elastomeric polymer, by plastic deformation perpendicular to the plane such that three-dimensional structures and connection areas are formed comprising half hexagonal cell walls and the connection areas are formed, and the three-dimensional-structures being folded towards each other, so that the half hexagonal cell walls are at an angle alpha to each other, the angle alpha being selected from between 20° and 100°, between 35° and 95° and between 50° and 90°, the relaxed honeycomb structure being water impermeable and void volumes on one side of the layer of formwork not being connected to void volumes on the other side of the layer of formwork.

2. The composite structure according to claim 1, wherein the at least one layer of force muting material has a thickness of 1 to 10 mm.

3. The composite structure according to claim 1, wherein the at least one layer of force muting material is composed of a material selected from the group consisting of a woven, a spunbonded or spun laid nonwoven, a melt blown nonwoven, a carded nonwoven, an air laid nonwoven, a wet laid nonwoven, a knitted fabric, a net, a scrim, a two-dimensional mat of extruded entangled filaments, a consolidated layer of unidirectional fibers, a layer of foam material, a layer of rubbermaterial and a three-dimensional structured mat of entangled filaments.

4. The composite structure according to claim 1, wherein the layer of formwork has a thickness of 3 to 20 mm.

5. The composite structure according to claim 1, wherein the layer of formwork comprises a cover layer attached to at least one side of the relaxed honeycomb structure.

6. The composite structure according to claim 5, wherein the cover layer is a two-dimensional layer and optionally consists of or comprises a material selected from the group consisting of a woven, a spunbonded or spun laid nonwoven, a melt blown nonwoven, a carded nonwoven, an air laid nonwoven, a wet laid nonwoven, a knitted fabric, a net, a scrim, a two-dimensional mat of extruded entangled filaments, a consolidated layer of unidirectional fibers, a continuous layer and a combination thereof.

7. The composite structure according to claim 1, wherein the at least one layer of force muting material, the layer of formwork and the cover layer are composed of a thermoplastic polymer and/or a thermoplastic elastomeric polymer.

8. A floating floor system comprising the composite structure according to claim 1 and a layer of floating screed on the side of the layer of formwork which is not faced to the at least one layer of force muting material.

9. The floating floor system according to claim 8, wherein the layer of floating screed has a thickness of at most 4.0 cm.

10. A method for producing a floating floor system, comprising the layers of the floating floor system according to claim 8, the method comprising: supplying at first the at least one layer of force muting material onto a floor slab, followed by the layer of formwork and finally by the layer of floating screed, wherein the at least one layer of force muting material being parallel to a plane, wherein the layer of formwork is a relaxed honeycomb structure, said relaxed honeycomb structure being produced from a continuous film, which can be composed of a thermoplastic polymer or thermoplastic elastomeric polymer, by plastic deformation perpendicular to the plane of the film such that three-dimensional structures and connection areas are formed, so that half-hexagonal cell walls and small connection areas are formed, and subsequently, the three-dimensional-structures are folded towards each other, so that the half hexagonal cell walls are at an angle alpha to each other, the relaxed honeycomb structure being water impermeable and void volumes on one side of the layer of formwork not being connected to void volumes on the other side of the layer of formwork, wherein the at least one layer of force muting material is parallel to the plane, and the angle alpha is selected from between 200 and 1000, between 350 and 950 and between 500 and 900.

11. The method according to claim 10, wherein the supplying of the at least one layer of force muting material onto a floor slab and the supplying of the layer of formwork is performed by rolling off the layers from a roll onto the floor slab or by laying down pieces of the layers step by step on the floor slab.

12. The method according to claim 11, wherein the supplying of the at least one layer of force muting material onto a floor slab and the supplying of the layer of formwork is performed by rolling off bath layers simultaneously from one roll onto the floor slab.

13. A floating floor system comprising the floating floor system according to claim 8 on wooden floor slab and/or concrete slab.

Description

(1) FIG. 1: FIG. 1 shows a schematic side view of an embodiment of the floating floor system.

(2) FIG. 2: FIG. 2 shows a schematic side view of another embodiment of the floating floor system.

(3) FIG. 3: FIG. 3 shows a schematic side view of a relaxed honeycomb structure.

(4) FIG. 4: FIG. 4 shows a perspective view of a section of a relaxed honeycomb structure.

(5) In FIG. 1 an embodiment of the floating floor system 100 is shown comprising at least one layer of force muting material 102 laying on top of a floor slab 101. A relaxed honeycomb structure 103 as a layer of formwork is supplied on the at least one layer of force muting material 102, further, a layer of floating screed 104 is supplied as a plate on top. By supplying the layers 102, 103 and 104 airflow channels are established in the layer of formwork 103 on the side of the layer of formwork which is facing the layer of force muting material 102 (105a and 105b) as well as the side of the layer of formwork which is not facing the layer of force muting material 102 (105c and 105d). The airflow channels 105a and 105b are connected together (not shown). Also, the air flow channels 105c and 105d are connected together (not shown).

(6) In FIG. 2 another embodiment of the floating floor system 200 is shown comprising at least one layer of force muting material 202 laying on top of a floor slab 201. A layer of formwork, for example being a relaxed honeycomb structure, 203 is supplied on the at least one layer of force muting material, further, a layer of floating screed 204 is supplied on top of the layer of formwork, wherein the floating screed 204 is in contact with the layer of formwork 203 over the entire surface. By supplying the layers 202, 203 and 204 air flow channels 205a and 205b are established on the side of the layer of formwork which is facing the layer of force muting material 202. The airflow channels 205a and 205b are connected together (not shown).

(7) In FIG. 3 a side view of a relaxed honeycomb structure 303 is shown, which has an angle α between two halves of a honeycomb 306 and 307. Thereby, it is possible to open the honeycomb on the upper side 308a and 308b as well as on the lower side 308c and 309d to establish the angle α.

(8) In FIG. 4 a perspective view of a relaxed honeycomb structure 403 is shown comprising several half hexagonal cells 406 and 407 and connection areas 408a and 408b.

EXAMPLE 1

(9) A composite structure for a floating floor system has been provided comprising a foam material having a thickness of 10 mm as a layer of force muting material and a layer of formwork, the layer of formwork consisting of a relaxed honeycomb structure made of polypropylene, wherein the angle α between two halves of a honeycomb is 60°.

(10) The performance of the composite structure has been evaluated according to EN 29052:1992, as shown in Table 1.

(11) TABLE-US-00001 TABLE 1 Example 1 Sample Thickness [mm] F.sub.R [Hz] S′t [MN/m.sup.3] 1 25 37 10.8 2 25 35 9.7 3 25 36 10.2 average 25 36 10.2

COMPARATIVE EXAMPLE

(12) A foam material having a thickness of 10 mm as a layer of force muting material has been provided without a layer of formwork.

(13) The performance of the layer of foam material has been evaluated according to EN 29052:1992, as shown in Table 2.

(14) TABLE-US-00002 TABLE 2 Comparative example Sample Thickness [mm] F.sub.R [Hz] S′t [MN/m.sup.3] 1 10 70 38.7 2 10 76 45.7 3 10 77 46.9 average 10 74 43.8

(15) The composite structure has an average resonance frequency (F.sub.R) of 36 Hz, and a dynamic stiffness of 10.2 MN/m.sup.3, which is a significant improvement over the layer of foam material having an average resonance frequency (F.sub.R) of 74 Hz, and a dynamic stiffness of 43.8 MN/m.sup.3

(16) A resonance frequency below 50 Hz is considered to be excellent for impact sound reduction, in particular with a reduced dynamic stiffness.