Sealing soundproofing system for positioning under floor tiles

Description

[0001] The present invention relates to a waterproof soundproofing system in the form of plates intended to be positioned under a floor covering of the glued tile type. The invention also relates to a method of manufacturing a tiled floor using this system to provide both soundproofing against impact noise and waterproofing.

[0002] Due to current standards in new construction or the renovation of existing housing, it is mandatory to provide soundproofing solutions to reduce the transmission of impact noise through the floor. There are many solutions to meet these standardized requirements.

[0003] On the other hand, it is customary, when it is necessary to protect water-sensitive supports, to provide a waterproofing system that is placed under the tiles. When looking for a system that is both waterproof and meets the sound insulation requirements, the sound insulation systems under screed currently used for laying tiled floors require the presence of a rigid screed between the sound insulation system and the waterproofing system. Thus, in these systems, a thin acoustic layer with a thickness of less than or equal to 10 mm is placed on the support to be covered, then a screed is poured whose thickness varies from 5 to 60 mm depending on the acoustic system chosen. The existence of this screed is essential for the proper functioning of the sound insulation system and provides sufficient conditions in terms of mechanical rigidity and surface condition for laying the tiles.It is therefore necessary to let it dry before continuing with the installation. After the screed has dried, a waterproofing membrane is placed, which can be in the form of a sheet ready to be laid and glued to the support, or in the form of a liquid or paste-like waterproofing product that must be applied to the screed and which, when drying, will ensure the waterproofing function. In the case of a liquid or paste-like waterproofing product for which several successive passes are carried out, it is therefore necessary again to wait for the product to dry between each pass before being able to lay the tiles. In all cases, the tiles are laid by applying tile adhesive to the waterproofing membrane and then directly to the tiles.Regardless of the solution chosen for the waterproofing membrane, with current systems, waiting time for the applicator is unavoidable due to the application and drying of the screed.

[0004] Also known is document CH 692510 describing a combined sound and thermal insulation product combining a layer of compression-resistant synthetic foam and a layer of mineral wool, glass wool or rock wool and serves as sound insulation, intended to insulate a floating screed, a slab or a roof on rafters. Document DE 4441646 describes a method for manufacturing a covering for balconies or terraces. The system comprises a rigid foam panel, coated on both sides with a fabric to ensure waterproofing, then bonded to the support by a layer of mortar. Document DE 8621064 describes a roofing jointing system comprising waterproof strips to prevent flows between the joints of low-viscosity and mobile materials to compensate for possible shrinkage or displacement phenomena. These strips are positioned on top of each other with an overlap.

[0005] We are therefore seeking solutions to reduce the waiting times of tilers as much as possible. This is the context of the present invention, which proposes a system that provides both waterproofing and sound insulation and that can be positioned directly under the tiles, without requiring the installation of any screed. This system saves time and therefore significantly shortens the total duration of construction sites requiring the implementation of acoustic and waterproofing systems with a glued tile finish. The waterproofing and sound insulation properties of this new system are equivalent to those of current sound insulation systems under screed combined with waterproofing solutions, for a lower total thickness since it is no longer necessary to pour screed between the acoustic layer and the waterproofing membrane.For this purpose, the invention is defined by the waterproof soundproofing system according to independent claim 1, as well as by a method of manufacturing a tiled floor according to claim 5 using such a system. Preferred embodiments are defined in the dependent claims.

[0006] One of the objects of the present invention is a waterproof soundproofing system in the form of plates intended to be positioned on a support and directly under floor tiles. This system consists of an insulating plate coupled to a waterproof part, said insulating plate being composed of one or more layers integral with each other.

[0007] Said insulating plate comprises at least one flexible underlay and at least one rigid underlay secured to the flexible underlay and positioned opposite the tiles. The insulating plate is the part of the system providing acoustic insulation. This plate is coupled to a second part which ensures sealing.

[0008] Preferably, the system according to the present invention is prefabricated. Thus, the coupling between the insulating plate and the waterproof part is carried out during the manufacture of the system, in the factory. The tiler therefore does not need to carry out the association between the two parts on site, which also constitutes a time saving for him.

[0009] The waterproof part can come in different forms.

[0010] According to a first embodiment not forming part of the invention, the waterproof part is a sheet of synthetic material, for example polyethylene, preferably with a thickness of less than 2 mm, or even less than 1 mm. It is advantageously coated on each side with a non-woven material, such as a non-woven polypropylene fiber. This coating advantageously improves the adhesion between the different constituent parts of a system, in particular between the waterproof part and the insulating plate and also between the waterproof part and the adhesive mortar which is used to glue the tiles. It is then coupled with the insulating plate by heat-welding or gluing, preferably with an acrylic type adhesive. The coupling takes place in the factory. It is carried out with the adhesives currently used to glue acoustic layers. For example, we can cite the weber.sys acoustic adhesive.

[0011] The waterproof part in the form of a sheet comprises at least two overflow zones protruding from the insulating plate, these zones being located over the entire length of at least two consecutive sides of the insulating plate. Thus the positioning of these overflow zones ensures continuity of the waterproofing. When laying the different plates on the support to be coated, the overflow zone of the waterproofing sheet is positioned so as to provide a means of joining with the juxtaposed insulating plate. Thus the overflow zone of a plate is positioned above the existing connection between two plates positioned next to each other and is glued to the adjacent plate. It is important that these overflow zones are continuous so as not to create a break in the waterproofing. The overflow zones are glued to the plates with different systems such as sealing mastics or adhesives.The relative dimensions of the insulating board and the waterproofing membrane in sheet form are such that when coupling the two parts it is preferable to provide continuous overhanging areas of the waterproofing membrane beyond the insulating board. For example, the dimensions of the insulating board are of the order of 1 m x 0.5 m, and the overhanging areas protrude from the insulating board by approximately 5 to 10 cm.

[0012] According to the invention, the waterproofing is provided by treating the insulating plate with a liquid or pasty waterproofing product, which after drying will provide the necessary waterproofing. This waterproofing product is applied directly to the rigid underlay of the insulating part during the manufacture of the system. The waterproof part is thus a waterproofing membrane obtained after drying of a liquid or pasty waterproofing product applied directly to the rigid underlay of the insulating part. The thickness of the membrane after drying is less than 2 mm, or even around 1 mm. The thickness of the membrane is adjusted during the manufacture of the insulating system according to the recommendations imposed by the manufacturer. The water-repellent properties of the waterproofing product allow it to act as a waterproofing film after drying.For example, it can be obtained by mixing a two-component product consisting of a mixture of a dispersion resin and a powder based on a hydraulic binder with synthetic additives. An example of a liquid or pasty sealant is the commercial product weber.tec superflex@ D2.

[0013] In this system according to the present invention which comprises a waterproofing membrane obtained from a liquid or pasty waterproofing product, to avoid having to place jointing means between each plate of the system according to the invention, which would constitute an additional step to be carried out by the tiler, the waterproof part further comprises a strip of waterproofing membrane in the form of a sheet coupled by gluing to the insulating plate, these zones being located over the entire length of at least two consecutive sides of the insulating plate. This strip, the total width of which is for example between 5 and 15 cm, is placed at the edge of the plate and in particular makes it possible to provide overflow zones beyond the insulating plate to ensure the jointing between the different plates of the system according to the present invention.The waterproofing membrane strip in sheet form is positioned continuously over the entire length of at least two consecutive sides of the insulating plate. At least part of the strip is superimposed on the waterproof part obtained after drying of the waterproofing product to ensure the continuity of the waterproof part over the entire insulating plate. For example, the part of the strip which is glued to the waterproof part of the insulating plate represents a strip with a width of between 3 and 7 cm.

[0014] Advantageously, to allow easy storage of the plates of the system according to the present invention, the overhanging areas of the sealing sheet are pre-folded, so that the size of the plates to be stored corresponds to the size of the insulating part of the system. The pre-folded part of the overhanging area can easily be unfolded when the plate is installed on site.

[0015] The flexible underlay of the insulating board is made of at least one fibrous material of mineral or synthetic origin, such as glass fibers and / or polyester fibers or of the synthetic cellular layer type such as polyethylene or polyurethane. The underlay is preferably made of a thermo-bonded carded synthetic non-woven fabric, needle-punched or non-needled. It may also be a mineral non-woven fabric obtained by melting. It may also be a cellular material such as a synthetic foam, such as polyurethane foam. For example, the flexible underlay is a needle-punched non-woven fabric made of polyester fibers, or a non-woven fabric made of glass fibers. Its thickness is between 2 and 10 mm.

[0016] The rigid underlay, which is attached to the flexible underlay and positioned opposite the tiles, is based on a mineral binder, such as cement, gypsum, mortar, or bitumen, or agglomerated fibers such as plant fibers such as wood, hemp, mineral fibers such as rock wool, or based on a synthetic composite material such as synthetic fibers or synthetic resin, or based on a mixture of fibers and resin. This rigid underlay has a thickness of between 2 and 10 mm.

[0017] The flexible underlay and the rigid underlay are joined together during the manufacturing process of the system according to the present invention, for example by bonding using heat or using an adhesive. The way in which these two underlays are joined together is adapted according to the type of material of each of the layers.

[0018] The present invention also relates to a method of manufacturing a tiled floor on a support to be covered comprising the following steps: a. positioning and gluing several plates of the system according to the invention next to each other without spacing on said support; b. treatment of the jointing means to ensure continuity of the waterproofing; c. direct application of a tile adhesive on the waterproof part of the system and d. laying the tiles.

[0019] Several panels of the system according to the present invention are positioned next to each other, so as to cover the entire surface to be covered. Depending on the size of each panel, the tiler can cut certain panels before installation in order to obtain the desired dimensions.

[0020] The plates are laid so as to leave no space between them to limit any risk of leaks or sound insulation. When the plates include pre-folded overhanging areas, they are laid next to each other, edge to edge, keeping the overhanging areas pre-folded. The overhanging areas will only be unfolded, if necessary, at step b) of the process.

[0021] In order to treat the sealing between the different plates, after step a) of positioning and gluing the system plates, a joining means is positioned at the level of the jointing part of two consecutive plates covering the support.

[0022] A jointing means that is not in accordance with the invention may take several forms. It may be a waterproof strip that the tiler sticks to all the jointing parts. It may also be a liquid or sealing mastic that the tiler applies to the jointing parts of the different panels. In the latter case, it may sometimes be necessary to allow time for the jointing means to dry before the tile adhesive can be applied. The jointing means may comprise both a liquid or sealing mastic applied between the panels and a waterproof strip positioned between the panels.

[0023] According to the invention, the joining means is directly integrated into the system according to the present invention and corresponds to the overflow zones of the waterproofing membrane in the form of a sheet protruding from the insulating plate and preferably pre-folded to facilitate storage. Thus, when installing a plate, the part of the waterproofing membrane which is in the form of a sheet and which protrudes from the insulating plate is unfolded and positioned so as to partially cover the plate positioned consecutively and thus ensures sealing at the joints of the different plates. Advantageously, the overflow zone is glued to the adjacent plate after being unfolded. Here again, the joining means may comprise both a liquid or sealing mastic applied between the plates and on which the overflow zone is then positioned.

[0024] Thus, the overhanging areas are unfolded after the installation of the plate to which they are fixed so as to cover one dimension (width and / or length) of an adjacent plate. If the plate is installed directly along a wall, its overhanging area can be glued directly to the lower part of the wall so as to ensure waterproofing along the wall.

[0025] All the specific points of the surface to be covered are treated, in particular by adding a waterproof strip to ensure that the entire surface to be covered with tiles is waterproof.

[0026] After the step of positioning the plates and the means of joining adjacent plates, the method according to the invention comprises a step of applying a tile adhesive and then laying the tiles. The use of the waterproof soundproofing system which provides sufficient rigidity advantageously makes it possible to avoid having to apply a thick layer of a special mortar acting both as an adhesive mortar for the tiles and as a leveling mortar to reinforce the rigidity. Depending on the acoustic system chosen, the use of certain specific adhesives may be recommended by the manufacturer.

[0027] Step c) of the method according to the invention is the step of laying the tiles, which is carried out in the usual manner by the tiler. After a drying time of approximately 24 hours, a jointing mortar is applied between the tiles.

[0028] Other advantageous details are described below with reference to the figures illustrating the invention: There Figure 1 represents a sectional view of a schematic representation of the sealed soundproofing system not forming part of the present invention. The Figure 2 represents a sectional view of a floor covered with tiles positioned on the waterproof acoustic insulation system not forming part of the present invention. The Figure 3 represents a top view of four plates of the waterproof acoustic insulation system not forming part of the present invention arranged next to each other with a joining means integrated into the system. Figure 4 represents a top view of a waterproof acoustic insulation system according to the invention comprising both a waterproofing membrane obtained from a liquid waterproofing system and a waterproofing strip integrated into the system.

[0029] The sectional view shown on the Figure 1 shows a waterproof sound insulation system (1) not forming part of the present invention which is made up of an insulating plate (2) coupled to a waterproof part (3). The insulating plate (2) comprises at least two sub-layers: the sub-layer (2a) is the flexible sub-layer providing sound insulation and the sub-layer (2b) is the rigid sub-layer providing mechanical resistance to the system. The system (1) is intended to be fixed by gluing to the floor to be covered, for example by means of an acrylic or vinyl glue, as shown in the Figure 2. Several system plates (1) are glued onto the support to be covered (5). The connection between the two plates shown is indicated by the reference (6). According to the embodiment illustrated in this figure, the flexible underlay (2a) is the one positioned on the side of the support (5), the rigid underlay (2b) being the one opposite the floor tiles (4). The tiles (4) are positioned next to each other, leaving a space between each one which will be filled with a jointing mortar during the last stage of the tiled floor manufacturing process. On the Figure 2 , the layer of adhesive mortar applied to the waterproof part (3) and under the tiles (4) is not shown.

[0030] There Figure 3represents a top view of four plates of the waterproof system not forming part of the present invention, positioned next to each other. The waterproofing membrane (3a) is in the form of a sheet glued to the rigid underlayer (2b) of the insulating plate. The overflow zone (7) of the waterproof sheet (3a) is not shown on the Figure 3 only for a single plate. The overflow zone (7) is present in this case only on two consecutive sides of the plate. It thus makes it possible to cover the connection (6) and therefore to ensure sealing between two consecutive plates. It is glued to the connection and to the adjacent plate.

[0031] There Figure 4represents a top view of a plate of the system according to the present invention in which the waterproofing membrane (3b) has been obtained from a liquid or pasty component. It is intended to associate this type of membrane (3b) with a strip (8) of waterproofing membrane in the form of a sheet, so as to provide an overflow zone identical to that shown in the figure which at the time of installation is glued to the connection and to a part of the adjacent plate to ensure continuity of the waterproofing

[0032] The acoustic performances of the acoustic and waterproof system according to the present invention are at least equivalent to the performances of the acoustic system alone without the waterproofing layer. These performances are notably similar to those of the acoustic systems currently used on the market for the traditional construction of this type of structure with acoustic and waterproof properties. The value of the impact sound reduction index ΔLw makes it possible in particular to characterize the impact sound insulation performances of the floor systems (EN ISO 10140-3 and 717-2). Thus, the under-screed systems traditionally installed in this type of structure have a ΔLw index of between 15 and 20 dB, or even up to 22 dB in the case of a high thickness of the poured screed. Examples of commercial systems include the following systems: weber.floor 4955 underlay under 40 mm of screed for which the ΔLw index is 20 dB; Siplast Assour screed 19 underlay under 40 mm of screed for which the ΔLw index is 19 dB, Siplast Assour screed PLUS underlay under 40 mm of screed for which ΔLw is 21 dB. Carrying out the standardized measurement for characterizing the attenuation index ΔLw is cumbersome and expensive. As a result, it is reserved for limited use, mainly during the marketing of an acoustic system. Consequently, techniques for calibrating acoustic performance that are more suited to a screening process on a large number of systems have been implemented and validated by the acoustic community. The coupling of a calibration technique and a few corresponding standardized measurements allows for a rigorous and low-cost relative classification of the performance of a large number of systems while informing oneself of their absolute performance levels.

[0033] One of these comparative calibration techniques consists of characterizing the energy radiation of concrete support slabs treated by the floor systems to be characterized. Comparing the treated slab with the reference concrete support slab allows the relative assessment of the impact sound insulation gain ∂L in dB and therefore the classification of the systems studied according to their performance. In practice, samples with dimensions of around 500 x 500 mm are suspended in a free-free condition (i.e. suspended with tensioners) and instrumented on the back face with a sufficient number of accelerometers. Impact hammer strikes are carried out on the front face of the sample. The radiated powers are collected by the accelerometers.Post-processing of the measurements consisting of performing the energy sum on the third octave bands of frequency 100 Hz to 3150 Hz makes it possible to calculate the relative insulation gain ∂L in dB of the treated slabs compared to the support slab and consequently the classification of the different systems. Tests carried out according to the comparative calibration method described above on reference systems for which the insulation values ​​according to the standardized method (carried out by an external certification body) are available, made it possible to establish a clear link between the classification of the said systems according to the relative scale in ∂L and the absolute scale in ΔLw.

[0034] Comparative calibration tests were also carried out on systems once covered with tiles. Three different systems were tested: The first system tested (system 1) comprises an insulating part whose 5 mm flexible layer is made from needle-punched polyester fibres and the 3 mm rigid underlay is a needle-punched synthetic fibre impregnated with resin. The waterproof part is a waterproofing membrane in the form of a sheet glued onto the rigid part, marketed under the name weber.sys waterproof. The waterproofing sheet is pre-glued with an acrylic adhesive marketed under the name weber.sys acoustic. The second system tested (system 2) is identical to the first system in terms of the insulating part but comprises a waterproofing membrane obtained from a liquid component, marketed under the name weber.tec superflex D2. The third system tested (system 3) is identical to the first except that the flexible layer of the insulating part has been replaced by a non-woven glass fleece of approximately 3.5 mm and 300 g / m 2 < .The sealing sheet, identical to that of system 1, is pre-glued with an acrylic glue marketed under the name weber.sys acoustic.

[0035] The reference system (Ref system) comprises an insulating layer, the flexible part of which is made from polyester fibres and the rigid part is a needle-punched synthetic fibre impregnated with resin, the system being marketed under the reference weber.sys impact.

[0036] The results recorded in Table 1 below clearly show that the acoustic performances of system 1, 2 or 3 are at least equivalent to the performances of the acoustic system alone without the sealing layer and similar to those of the acoustic systems currently used on the market for the traditional construction of this type of work with acoustic and sealing properties. Table 1 Relative improvement in impact noise insulation according to comparative calibration method in dB Reference ∂L ref System 1 ∂L ref +1 System 2 ∂L ref +3 System 3 ∂L ref +10

[0037] The system according to the present invention advantageously reduces the tiler's waiting time. The example below compares the working time required to lay tiles on an acoustic insulation system according to the first embodiment (not part of the invention) and according to the methods currently used which require the application of a screed. The working time for the operator in the two systems studied remains equivalent.

[0038] The installation time for a tile-type covering on a soundproofing system is estimated for a wet room of approximately 5 m 2 < . The different stages are detailed in Table 2 below and the time for each stage is estimated in hours. The reference system is a soundproofing system under screed on which a screed is poured, then two successive layers of a liquid waterproofing system are applied before applying the tiles. Table 2 Reference system Time in hours System according to Time in hours the first embodiment Installation of a peripheral strip 0.25 Installation of a peripheral strip 0.25 Laying the acoustic underlay 0.33 Cutting and laying the plates 2.5 Application of the screed 1 Treatment of the waterproofing between strips 0.5 Screed drying time 48 Treatment of the sealing of peripheral singular points 1 Treatment of the sealing of peripheral singular points 1 Application of the first layer of the liquid waterproofing system 0.75 Drying time 4 Application of the second layer of waterproofing 0.75 Drying time 6 Application of adhesive mortar and laying of tiles 2 Application of adhesive mortar and laying of tiles 2 Drying time 24 Drying time 24 Application of joint mortar and cleaning 1 Application of joint mortar and cleaning 1 Estimated working time 7.08 7.25 Waiting times 82 24 Total time 89.08 31.25

Claims

1. A sealing soundproofing system (1) in the form of boards intended to be positioned on a substrate and directly under floor tiles, said system consists of an insulating board (2) coupled to a sealing part (3), said insulating board (2) consisting of one or more layers fastened to one another, and in that said insulating board (2) comprises at least one flexible sub-layer (2a) and at least one rigid sub-layer (2b) attached to the flexible sub-layer (2a) and positioned facing the tiles (4), the sealing part (3) being a sealing membrane (3b) obtained after drying of a liquid or paste sealing product applied directly to the rigid sub-layer (2b) of the insulating part (2), characterized in that the sealing part (3) further comprises a sealing membrane tape (8) in the form of a film coupled by gluing to the insulating board (2), said tape having at least two overlap zones (7) extending beyond the insulating board (2), those zones being situated on the entirety of the length of at least two consecutive sides of the insulating plate (2).

2. The system (1) as claimed in claim 1, characterized in that it is prefabricated.

3. The system (1) as claimed in claim 1, characterized in that the sealing product is obtained by mixing a two-component product consisting of a mixture of a dispersed resin and a powder based on hydraulic binder with synthetic material additives.

4. The system (1) as claimed in claim 1, characterized in that the overlap zones (7) are pre-folded so that the dimensions of the system are those of the insulating board (2).

5. A method of fabricating a tile floor on a substrate (5) to be coated, characterized in that it comprises the following steps: a. positioning and gluing a plurality of boards of the system (1) as claimed in any one of claims 1 to 4 alongside one another without gaps on said substrate (5); b. treating the sealing means (6) to provide a continuous seal; c. direct application of a tile adhesive to the sealing part of the system; and d. laying the flooring tiles (4).

6. The method as claimed in claim 5, characterized in that the jointing means (6) are directly integrated into the system as claimed in either one of claims 3 or 4 and correspond to the overlap zones (7) of the sealing membrane in the form of a film extending beyond the insulating board (2) and pre-folded that are stuck to the adjacent boards after unfolding them.