MULTI-LAYER STRUCTURE FOR THE REALIZATION OF A FLOOR COVERING WITH ACOUSTIC INSULATION PROPERTIES

Abstract

A multi-layer structure of the tile or slat type is for the realization of a floor covering having acoustic insulation properties. The structure includes, in this order, a decorative layer, a first rigid layer made of PVC, a first damping layer made of PVC, and a second rigid layer made of PVC. The first and second rigid layers each have an elasticity modulus of between 1.5 GPa and 12 GPa, measured according to standard ISO 178:2011.

Claims

1. A multi-layer structure of tile or slat type, for realization of a floor covering having acoustic insulation properties, the structure comprising, in order: a decorative layer; a first rigid layer made of PVC; a first damping layer made of PVC; and a second rigid layer made of PVC, wherein each rigid layer comprises an elasticity modulus of between 1.5 GPa and 12 GPa, measured according to standard ISO 178:2011.

2. The multi-layer structure according to claim 1, wherein the first damping layer is a non-foam layer.

3. The multi-layer structure according to claim 1, wherein the first damping layer is a foam layer.

4. The multi-layer structure according to claim 2, wherein the first damping layer comprises a Young's modulus of between 25 MPa and 1.5 GPa.

5. The multi-layer structure according to claim 3, wherein the first damping layer comprises a storage modulus of between 0.1 MPa and 10 MPa.

6. The multi-layer structure according to claim 1, wherein the multi-layer structure comprises a thickness of between 4 and 8 mm, with the first rigid layer having a thickness of between 1 and 3.5 mm, and the second rigid layer having a thickness of between 1 and 3 mm.

7. The multi-layer structure according to claim 1, wherein the first rigid layer and/or the second rigid layer comprises a density of between 1150 kg/m.sup.3 and 2500 kg/m3.

8. The multi-layer structure according to claim 1, further comprising a second damping layer configured to contact with the floor, wherein the second damping layer comprises PVC foam or in the form of a non-woven glass fiber sheet.

9. The multi-layer structure according to claim 3, wherein the first damping layer comprises a density of between 150 and 600 kg/m.sup.3.

10. The multi-layer structure according to claim 8, wherein the second damping layer comprises a density of between 150 and 600 kg/m.sup.3.

11. The multi-layer structure according to claim 2, wherein the first damping layer comprises a thickness of between 0.5 and 1.5 mm.

12. The multi-layer structure according to claim 8, wherein the second damping layer comprises a thickness of between 0.5 and 1.5 mm.

13. The multi-layer structure according to claim 8, wherein the second damping layer in the form of a non-woven glass fiber sheet has a thickness of between 0.7 and 1.7 mm.

14. The multi-layer structure according to claim 4, wherein the first damping layer comprises a Young's modulus of between 50 and 500 MPa.

15. The multi-layer structure according to claim 7, wherein the first rigid layer and/or the second rigid layer comprises a density of between 1600 kg/m.sup.3 and 2100 kg/m.sup.3.

16. The multi-layer structure according to claim 9, wherein the first damping layer comprises a density of between 300 and 450 kg/m.sup.3.

17. The multi-layer structure according to claim 10, wherein the second damping layer comprises a density of between 300 and 450 kg/m.sup.3.

18. The multi-layer structure according to claim 11, wherein the first damping layer comprises a thickness of between 0.9 and 1.1 mm.

19. The multi-layer structure according to claim 12, wherein the second damping layer comprises a thickness of between 0.9 and 1.1 mm.

20. The multi-layer structure according to claim 13, wherein the second damping layer in the form of a non-woven glass fiber sheet has a thickness of between 1 and 1.5 mm.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0052] Other features and advantages of the invention will clearly emerge from the description of it which is made below, for information and in a totally non-limiting way, in reference to the accompanying figures, wherein:

[0053] FIG. 1 is a cross-sectional view of a first embodiment of a multi-layer structure according to the invention.

[0054] FIG. 2 is a cross-sectional view of a second embodiment of a multi-layer structure according to the invention, the second damping layer in contact with the floor being made of PVC foam.

[0055] FIG. 3 is a view similar to that of FIG. 2, the second damping layer in contact with the floor being presented in the form of a non-woven glass fiber sheet.

DETAILED DESCRIPTION OF THE INVENTION

[0056] In reference to FIGS. 1, 2 and 3, the invention relates to a multi-layer structure (1), for example of the panel, tile or slat type, for the realization of a floor covering, for example, glued-down, or floating combined with the male/female coupling means complementarily present on the edges of the structure.

[0057] The invention aims, in particular, to provide such a structure for the realization of a floor covering having good acoustic insulation performance, by enabling the attenuation of the impact noise and sound when walking, measured for example according to standard NF EN ISO 717-2, while keeping a satisfactory punching resistance according to standard NF EN ISO 24343-1.

[0058] According to the invention, to achieve this performance, the multi-layer structure (1) has a first damping layer (2) positioned between two PVC-based rigid layers (3, 4), with optionally a second damping backing layer (5), i.e. intended to be in contact with the floor.

[0059] More specifically, the multi-layer structure (1) comprises a decorative layer (6), intended to form the surface layer of the floor covering, and is for example constituted of a transparent wear layer (6a), preferably made of non-expanded plasticized PVC, and a decorative film (6b). The decorative layer (6) can also be obtained from granules made from PVC then pressed, or also by plastisol coating, by flat-die extrusion or by calendering.

[0060] In an unknown way, the decorative film (6b) can be replaced by a layer for printing décor, printed on the lower face of the wear layer (6a), or on the upper face of a first rigid layer (3) to which said decorative layer (6) is bonded.

[0061] The wear layer (6a) ensures the mechanical and chemical resistance of the product and has a thickness, for example, of between 0.1 and 1 mm, preferably between 0.3 and 0.7 mm, for example 0.5 mm, and the decorative film (6b), positioned under the wear layer (6a) has a thickness of 0.1 mm, for example. The wear layer (6a) has a density, for example, of between 1200 and 2200 kg/m.sup.3 and/or a Young's modulus of between 100 and 500 MPa.

[0062] Thus, the multi-layer structure (1) according to the invention comprises, in this order, the decorative layer (6), a first rigid layer (3) made of PVC, a first damping layer (2) made of PVC, a second rigid layer (4) made of PVC. According to a variant, the multi-layer structure comprises a second damping layer (5) made of PVC foam (5a), see FIG. 2, or in the form of a non-woven glass fiber sheet (5b), see FIG. 3.

[0063] The first and second rigid layers (3, 4) each comprise an elasticity modulus of between 1.5 GPa and 12 GPa, measured according to standard ISO 178:2011.

[0064] The different layers (6, 3, 2, 4, 5) are bonded to one another, for example by coextrusion, lamination or gluing. Bonding layers such as polyurethane (PU) or “hotmelt” glues, can also be used to bond the layers to one another. The layers (6, 3, 2, 4) are preferably heat-bonded, in particular when the first damping layer (2) is a non-foam layer.

[0065] In the case where the second damping layer (5) is a non-woven layer, the assembly will be done by gluing, for example using a PU or “hotmelt” glue.

[0066] The first rigid layer (3) and/or the second rigid layer (4) has a density of between 1150 kg/m.sup.3 and 2500 kg/m.sup.3, preferably between 1600 kg/m.sup.3 and 2100 kg/m.sup.3.

[0067] Without moving away from the scope of the invention, the first rigid layer (3) and/or the second rigid layer (4) can each be constituted of two layers of different densities in the range of values specified above.

[0068] The first rigid layer (3) and/or the second rigid layer (4) preferably comprises a flex resistance of between 15 MPA and 30 MPa, preferably between 20 and 25 MPa, measured according to standard ISO 178:2011.

[0069] As an example, the first PVC foam damping layer (2) and/or the second PVC foam damping layer (5a) has between 50 and 60%, and preferably 55% of PVC, and between 35 and 40%, preferably 37% of plasticizers in total weight of the layer.

[0070] According to an example of a construction called example no. 1, the first PVC rigid layer (3) has a thickness of 3 mm and a density of 1926 kg/m.sup.3. The first PVC rigid layer (3) also has a flex resistance of 22.22 Mpa, measured according to standard ISO 178:2011, an elasticity modulus (deformation of 0.05 to 0.25%) of 7.77 GPa, measured according to standard ISO 178:2011, and a storage modulus of 9.37 GPa, measured according to a test method based on standard EN 29-052-1.

[0071] The first damping layer (2) is made of PVC foam having a thickness of 1 mm and a density of 450 kg/m.sup.3. The storage modulus of the first damping layer (2) is 0.458 MPa, measured according to the test method based on standard EN 29-052-1.

[0072] The second PVC rigid layer (4) has a thickness of 2 mm and has parameters which are identical to those of the first PVC rigid layer (3), in particular in terms of density, flex resistance, elasticity modulus and storage modulus.

[0073] In this example no. 1, the second damping layer (5) is presented in the form of a non-woven glass fiber sheet (5b) of a thickness of 0.8 mm and of a density of 121.75 kg/m.sup.3.

[0074] The non-woven glass fibers are bonded together by a binder, which is for example a phenolic resin which represents, for example, between 11 and 29% of the mass of the glass fiber sheet (5b), for example 18%.

[0075] The compression resistance of the non-woven glass fiber sheet (5b), to 10% deformation is:

[0076] greater than or equal to 1000 Pa, preferably greater than or equal to 3900 Pa for a 5×5 cm sample;

[0077] greater than or equal to 500 Pa, preferably greater than or equal to 1700 Pa, for a 10×10 cm sample;

[0078] greater than or equal to 500 Pa, preferably greater than or equal to 1600 Pa, for a 20×20 cm sample.

[0079] The compression resistance of the non-woven glass fiber sheet (5b), for a 0.5 mm deformation, is:

[0080] greater than or equal to 7000 Pa, preferably greater than or equal to 15000 Pa, for a 5×5 cm sample;

[0081] greater than or equal to 1000 Pa, preferably greater than or equal to 5000 Pa, for a 10×10 cm sample;

[0082] greater than or equal to 10200 Pa, preferably greater than or equal to 19100 Pa, for a 20×20 cm sample.

[0083] A lower compression resistance degrades the punching resistance of the multi-layer structure (1).

[0084] The compression resistance of the second damping layer (5) makes it possible to preserve a good acoustic insulation over time, while contributing to the traffic resistance of the assembly means (if they exist). The compression resistance is connected to the fiber surface mass, to a binder surface mass, to the nature and the resilience of the fibers. A person skilled in the art knows how to adapt these parameters to obtain the desired compression resistance values.

[0085] The compression resistance is measured according to standard CEN/TS 16354:2012 which itself makes reference to standard NF EN 826 of May 2013. This method corresponds to a compression measurement for a 0.5 mm deformation.

[0086] Tests carried out on the example no. 1 according to standard NF EN ISO 717-2 have made it possible to satisfactorily observe an acoustic attenuation of 19 dB, acoustics when walking of 75 dB, a 2.5-hour punching of 0.29 mm and a 24-hour punching of 0.22 mm.

[0087] Tests have also been carried out on an example no. 2 according to standard NF EN ISO 717-2.

[0088] According to this example no. 2, the nature of the layers is identical to that of example no. 1, except for:

[0089] the first PVC rigid layer (3) having a thickness of 2 mm instead of 3 mm;

[0090] the first PVC form damping layer (2) having a density of 300 kg/m.sup.3 instead of 450 kg/m.sup.3.

[0091] These tests have made it possible to satisfactorily observe an acoustic attenuation of 19.7 dB, acoustics when walking of 71 dB, a 2.5-hour punching of 0.38 mm and a 24-hour punching of 0.30 mm.

[0092] According to a second method for constructing the multi-layer structure (1) according to the invention, the second damping layer (5) is a PVC foam (5a).

[0093] Tests have also been carried out on an example no. 3, according to the second embodiment, and according to standard NF EN ISO 717-2.

[0094] According to this example no. 3, the nature of the layers is identical to that of example no. 1, except for:

[0095] the first PVC foam damping layer (2) having a density of 200 kg/m.sup.3 instead of 450 kg/m.sup.3;

[0096] the second damping layer (5) being a PVC form (5a) having a density of 450 kg/m.sup.3 and a thickness of 1 mm.

[0097] These tests have made it possible to satisfactorily observe an acoustic attenuation of 19 dB, acoustics when walking of 77 dB, a 2.5-hour punching of 0.32 mm and a 24-hour punching of 0.27 mm.

[0098] Tests have also been carried out on an example no. 4, according to the second embodiment, and according to standard NF EN ISO 717-2.

[0099] According to this example no. 4, the nature of the layers is identical to that of example no. 3, except for:

[0100] the first rigid layer (3) having a thickness of 2 mm instead of 3 mm;

[0101] the first PVC foam damping layer (2) having a density of 300 kg/m3 instead of 200 kg/m3.

[0102] These tests have made it possible to satisfactorily observe an acoustic attenuation of 17 dB, acoustics when walking of 72 dB, a 2.5-hour punching of 0.30 mm and a 24-hour punching of 0.24 mm.

[0103] As a summary of the examples tested of multi-layer structures:

Example No. 1

[0104] Decorative layer (6): PVC wear layer (6a), thickness: 0.5 mm+printed decorative film (6b),

[0105] 1.sup.st rigid layer (3): PVC, thickness: 3 mm, density: 1926 kg/m.sup.3, flex resistance: 22.22 Mpa, flex modulus: 7.77 GPa, storage modulus: 9.37 GPa,

[0106] 1.sup.st damping layer (2): closed cell PVC foam, thickness: 1 mm, density: 450 kg/m.sup.3, storage modulus: 0.458 Mpa,

[0107] 2.sup.nd rigid layer (4): PVC, thickness: 2 mm, density: 1926 kg/m.sup.3, flex resistance: 22.22 Mpa, flex modulus: 7.77 GPa, storage modulus: 9.37 GPa,

[0108] 2.sup.nd damping layer (5): Non-woven glass fiber sheet (5b), thickness: 0.8 mm, density: 121.75 kg/m.sup.3, compression resistance to 10% deformation equal to 3900 Pa for a 5×5 cm sample.

Example No. 2

[0109] Decorative layer (6): PVC wear layer (6a) thickness: 0.5 mm+printed decorative film (6b),

[0110] 1st rigid layer (3): PVC, thickness: 2 mm, density: 1926 kg/m.sup.3, flex resistance: 22.22 Mpa, flex modulus: 7.77 GPa, storage modulus: 9.37 GPa,

[0111] 1st damping layer (2): closed cell PVC foam, thickness: 1 mm, density: 300 kg/m.sup.3, storage modulus: 0.458 Mpa,

[0112] 2.sup.nd rigid layer (4): PVC, thickness: 2 mm, density: 1926 kg/m.sup.3, flex resistance: 22.22 Mpa, flex modulus: 7.77 GPa, storage modulus: 9.37 GPa,

[0113] 2.sup.nd damping layer (5): Non-woven glass fiber sheet (5b), thickness: 0.8 mm, density: 121.75 kg/m.sup.3, compression resistance to 10% deformation equal to 3900 Pa for a 5×5 cm sample.

Example No. 3

[0114] Decorative layer (6): PVC wear layer (6a), thickness: 0.5 mm+printed decorative film (6b),

[0115] 1.sup.st rigid layer (3): PVC, thickness: 3 mm, density: 1926 kg/m.sup.3, flex resistance: 22.22 Mpa, flex modulus: 7.77 GPa, storage modulus: 9.37 GPa,

[0116] 1.sup.st damping layer (2): closed cell PVC foam, thickness: 1 mm, density: 200 kg/m.sup.3, storage modulus: 0.458 Mpa,

[0117] 2.sup.nd rigid layer (4): PVC, thickness: 2 mm, density: 1926 kg/m.sup.3, flex resistance: 22.22 Mpa, flex modulus: 7.77 GPa, storage modulus: 9.37 GPa,

[0118] 2.sup.nd damping layer (5): closed cell PVC foam (5a), thickness: 1 mm, density: 450 kg/m.sup.3, storage modulus: 0.458 Mpa.

Example No. 4

[0119] Decorative layer (6): PVC wear layer (6a), thickness: 0.5 mm+printed decorative film (6b),

[0120] 1.sup.st rigid layer (3): PVC, thickness: 2 mm, density: 1926 kg/m.sup.3, flex resistance: 22.22 Mpa, flex modulus: 7.77 GPa, storage modulus: 9.37 GPa,

[0121] 1.sup.st damping layer (2): closed cell PVC foam, thickness: 1 mm, density: 300 kg/m.sup.3, storage modulus: 0.458 Mpa,

[0122] 2.sup.nd rigidity layer (4): PVC, thickness: 2 mm, density: 1926 kg/m.sup.3, flex resistance: 22.22 Mpa, flex modulus: 7.77 GPa, storage modulus: 9.37 GPa,

[0123] 2.sup.nd damping layer (5): closed cell PVC foam (5a), thickness: 1 mm, density: 450 kg/m.sup.3, storage modulus: 0.458 Mpa.

[0124] Examples 5 to 8 describe other possible variants according to the invention also tested according to standard NF EN ISO 717-2.

Example No. 5

[0125] Decorative layer (6): PVC wear layer (6a), thickness: 0.5 mm+printed decorative film (6b),

[0126] 1.sup.st rigid layer (3): PVC, thickness: 2 mm, density: 1926 kg/m.sup.3, flex resistance: 22.22 Mpa, flex modulus: 7.77 GPa, storage modulus: 9.37 GPa,

[0127] 1.sup.st damping layer (2): Plasticized and expanded PVC calendered layer, thickness: 0.6 mm, Young's modulus 121 MPa, density: 1926 kg/m.sup.3,

[0128] 2.sup.nd rigid layer (4): PVC, thickness: 2 mm, density: 1926 kg/m.sup.3, flex resistance: 22.22 Mpa, flex modulus: 7.77 GPa, storage modulus: 9.37 GPa.

Example No. 6

[0129] Decorative layer (6): PVC wear layer (6a), thickness 0.5 mm+printed decorative film (6b),

[0130] 1.sup.st rigid layer (3): PVC, thickness: 2 mm, density: 1926 kg/m.sup.3, flex resistance: 22.22 Mpa, flex modulus: 7.77 GPa, storage modulus: 9.37 GPa,

[0131] 1.sup.st damping layer (2): closed cell PVC foam, thickness: 1 mm, density: 300 kg/m.sup.3, storage modulus: 0.458 Mpa,

[0132] 2.sup.nd rigid layer (4): PVC, thickness: 2 mm, density: 1926 kg/m.sup.3, flex resistance: 22.22 Mpa, flex modulus: 7.77 GPa, storage modulus: 9.37 GPa.

Example No. 7

[0133] Decorative layer (6): PVC wear layer (6a), thickness 0.5 mm+printed decorative film (6b),

[0134] 1.sup.st rigid layer (3): PVC, thickness: 2 mm, density: 1926 kg/m.sup.3, flex resistance: 22.22 Mpa, flex modulus: 7.77 GPa, storage modulus: 9.37 GPa,

[0135] 1.sup.st damping layer (2): closed cell PVC foam (5a), thickness: 1 mm, density: 450 kg/m.sup.3, storage modulus: 0.458 Mpa,

[0136] 2.sup.nd rigid layer (4): PVC, thickness: 2 mm, density: 1926 kg/m.sup.3, flex resistance: 22.22 Mpa, flex modulus: 7.77 GPa, storage modulus: 9.37 GPa,

[0137] 2.sup.nd damping layer (2): non-woven glass fiber sheet (5b), thickness 1 mm, compression resistance to 10% deformation equal to 3900 Pa for a 5×5 cm sample.

Example No. 8

[0138] Decorative layer (6): PVC wear layer (6a), thickness 0.5 mm+printed decorative film (6b),

[0139] 1.sup.st rigid layer (3): PVC, thickness: 2 mm, density: 1926 kg/m.sup.3, flex resistance: 22.22 Mpa, flex modulus: 7.77 GPa, storage modulus: 9.37 GPa,

[0140] 1.sup.st damping layer (2): Plasticized and expanded PVC calendered layer, thickness: 0.6 mm, Young's modulus 121 MPa, density: 1926 kg/m.sup.3,

[0141] 2.sup.nd rigid layer (4): PVC, thickness: 2 mm, density: 1926 kg/m.sup.3, flex resistance: 22.22 MPa, flex modulus: 7.77 GPa, storage modulus: 9.37 GPa

[0142] 2.sup.nd damping layer (2): non-woven glass fiber sheet (5b), thickness: 1.3 mm, compression resistance to 10% deformation greater than or equal to 3900 Pa for a 5×5 cm sample.

[0143] The results from the test are compiled in the table below:

TABLE-US-00001 TABLE 1 Acoustics Acoustic when 2.5-hour 24-hour attenuation walking punching punching (dB) (dB) (mm) (mm) Example 19 75 0.29 0.22 no. 1 Example 19.7 71 0.38 0.30 no. 2 Example 19 77 0.32 0.27 no. 3 Example 17 72 0.30 0.24 no. 4 Example 6 80 <0.40 <0.30 no. 5 Example 16 76 <0.40 <0.30 no. 6 Example 17 75 0.28 0.23 no. 7 Example 19 75 0.24 0.18 no. 8

[0144] It results from the above that the invention does provide a multi-layer structure making it possible to have a good acoustic attenuation, as the acoustic attenuation values reach 19 dB according to standards NF S31-074-717-2 and NF EN ISO 717-2 and good acoustics when walking with values always less than 80, even 75 dB according to standard NF EN ISO 10140-3 and NF EN ISO 717-2. In addition, the 2.5-hour and 24-hour punching resistance according to standard NF EN ISO 24343-1 remains respectively less than 0.40 and 0.30, which is satisfactory.