FLOATING SCREED FLOOR SYSTEM WITH SEPARATES

Abstract

The present invention relates to a floor system comprising a floating screed and separators arranged beneath said floating screed. The floor system comprises a floating screed and separators arranged beneath said floating screed. The separators are in point and / or line contact with the surface of an underlying element capable of supporting the floor system and with the surface of an overlying layer disposed between said floating screed and said separators.

Description

Floating screed floor system with spacers

[0001] The present invention relates to a floor system comprising a floating screed and separators arranged under said floating screed.

[0002] The acoustic properties of floors play an important role in the acoustic comfort of buildings. The dropping of an object, the footsteps of people moving about, or the movement of an object on a floor with poor acoustic properties in a room adjacent to another can be significant sources of noise pollution for the activities taking place there. Such a floor can also reflect the sound waves emitted during these activities and cause a reverberation effect that degrades the acoustic comfort necessary for their smooth operation. Libraries, museums, schools, train station concourses, restaurant dining rooms, and event venues are all examples of places where a reduction in noise pollution is often sought. Similarly, in residential premises and buildings, a reduction in impact noise on floors is generally desired to ensure the peace and quiet of residents.

[0003] To this end, floor systems comprising functional elements that attenuate the propagation of sound or acoustic waves are used as floor coverings. These functional elements are generally in the form of an insulating layer that reduces the intensity of the mechanical coupling between the structural element supporting the floor and the upper part of the floor on which it is possible to walk.

[0004] By way of example, patent KR101704909 B1 discloses an insulation layer comprising cells into which hollow capsules can be inserted to absorb shock waves. Utility model CN201486105 U and application JPH04293857 disclose insulation layers formed by separator pads arranged between a structural element and the upper part of a floor.

[0005] The present invention improves the acoustic performance of existing floating screed floor systems.

[0006] It relates to a floor system comprising a floating screed and separators arranged under said floating screed, characterized in that the separators are in point and / or line contact with the surface of an underlying element capable of supporting the floor system and with the surface of an overlying layer arranged between said floating screed and said separators, and in that the overlying layer and / or the separators are based on resilient material.

[0007] In the context of the invention, the function of the separators is to separate the underlying element and the overlying layer so that they are not in contact with each other. In particular, the separators can help to form a hollow cavity and / or a network of hollow cavities between the underlying element and the overlying layer. The separators can be solid or hollow.

[0008] For the purposes of this invention, the term "screed" has a broader definition than that of standard EN 13318:2000. It is defined as a layer or set of layers of material placed on a substrate or on a set of intermediate layers, possibly insulating, in order, for example, to achieve a specific level, to receive another floor covering and / or to serve as a finished floor. It covers so-called "wet" screeds and so-called "dry" screeds.

[0009] Wet screeds generally refer to screeds that are in a liquid or pasty state when applied to the substrate and then harden after setting and drying. Examples of wet screeds include cement-based screeds, synthetic resin screeds, calcium sulfate screeds, magnesium screeds, and / or bitumen emulsion screeds. The most common type of wet screed is cement mortar screed.

[0010] Dry screeds generally refer to slabs in the general sense, made of rigid planks or panels that can be placed side by side. Examples include plaster-based or cement-based boards. They may optionally be reinforced with cellulose fibers or glass fibers.

[0011] In the context of the invention, the term "floating screed", also called a bonded screed or unbonded screed, refers, in accordance with common usage in the construction industry, to a screed with little or no It adheres well to the surface on which it is placed. It is also weakly or not at all connected to other structural elements.

[0012] The underlying element capable of supporting the floor system can be any structural element suitable for the installation of a floor system. Generally, it is a flat structure or a horizontal surface. For example, it can be a concrete or mortar slab, bare or optionally covered with one or more surface coverings made of interlocking manufactured elements such as ceramic, stone, resin, thermoplastic, or wood tiles or slabs. It can also be a concrete, wood, or metal floor. It may also include a sound and / or thermal insulation covering.

[0013] For the purposes of this invention, the term "resilient," used to describe a material, refers to a material capable of absorbing energy when elastically deformed and releasing all or part of that energy when the deformation stress is removed. Examples of resilient materials include elastic materials such as rubber, cork, and expanded polystyrene; viscoelastic materials such as polyurethane, silicone, and polyacrylate; and mineral wools such as rock wool or glass wool.

[0014] The floor system according to the invention has as its main advantage a gain of 25 to 110% on the reduction of the impact-weighted noise level compared to a floor system according to the prior art.

[0015] The reduction in the weighted impact noise level, ALW, of a floor system according to the invention compared to a reference floor is generally between 18 and 30 dB. The reference floor is defined by the same standards NF EN ISO 10140:2013 and NF EN ISO 717-2:2013. It is a concrete slab with a thickness of 140 mm.

[0016] A second advantage is that it can be used on existing floors and / or subfloors, for example in the case of renovation, provided that these floors and subfloors are suitable to support another floor covering.

[0017] A third advantage is that, in the case where the floating screed is a wet screed, the screed in liquid or pasty form can be poured directly onto the layer above.

[0018] In one embodiment of the invention, the separators are convex-shaped particles. A convex shape ensures point and / or line contact of the separators with the surface of the underlying element that can serve as a support for the flooring system and with the surface of the overlying layer. The greater the degree of convexity of the external surface of the particles, the smaller the contact area and the higher the level of noise reduction of the flooring system.

[0019] The separators may have a regular or irregular geometry. Preferably, they are spherical or cylindrical particles. These types of shapes generally minimize the area of ​​the point and / or line contact surfaces of the separators with the underlying element and the overlying layer.

[0020] To define the size of a separator, the Féret diameter can be used. The Féret diameter is the maximum distance between two parallel lines between which the separator can geometrically be inscribed.

[0021] According to one embodiment of the invention, the diameter of the separators is between 1 and 100 mm, preferably between 3 and 70 mm. These particle sizes prevent an excessive elevation of the upper surface level of the flooring system relative to the surrounding structure in which it is installed.

[0022] The distribution density of the separators between the underlying element and the overlying layer can vary, particularly depending on the size of the separators and the surface condition of the underlying element that may serve as a support for the floor system. In particular, the distribution density of the separators is between 10 and 2500 separators per square meter, preferably between 100 and 2500 separators per square meter. This density range is optimal for a homogeneous distribution of the separators on the surface of the underlying element and the formation of a hollow cavity and / or a network of hollow cavities.

[0023] It is also possible to distribute the separators regularly across the surface of the underlying element so as to form regularly spaced point and / or line contact points between the separators and the surfaces of the overlying layer and the underlying element. This promotes better distribution of mechanical stresses when the floor system is under load and homogeneous acoustic performance. In this particular embodiment of the invention, the separators are distributed across the underlying element according to a regular geometric pattern. A regular geometric pattern corresponds to any type of pattern formed by periodically tiling a symmetrical or asymmetrical regular sub-pattern. Examples of patterns are squares, rectangles, pentagons, and hexagons, alone or in combination.

[0024] In an alternative embodiment of the flooring system of the invention, the separators are cords forming a mesh. The cords may be in the form of a grid with a woven or non-woven mesh. The cords may be solid or hollow. The distance between two cords of the mesh may be between 1 mm and 30 cm.

[0025] In addition to the effect of point and / or line contact of the separators with the surface of an underlying element and the surface of an overlying layer, a further synergistic effect has been observed between the separators and the overlying layer. Depending on whether the overlying layer is made of resilient or non-resilient material, the use of separators made of resilient or non-resilient material can yield unexpected acoustic and mechanical performance. The thickness or density of the overlying layer can also influence this performance.

[0026] In a first preferred embodiment of the invention, the overlying layer is made of a resilient material. Preferably, the Young's modulus of the overlying layer is less than or equal to 1 GPa at 20°C. In this embodiment, the separators are made of a resilient material. The Young's modulus of the separators is less than or equal to 1 GPa at 20°C.

[0027] In a second preferred embodiment of the invention, the overlying layer is based on a resilient material. Preferably, the Young's modulus of the overlying layer is less than or equal to 1 GPa at 20°C. In In this embodiment, the separators are not made of resilient material. The Young's modulus of the separators is preferably greater than 20 GPa at 20°C.

[0028] For example, the overlying layer may be based on a material chosen from expanded polystyrene, rubber, silicone, polyurethane, mineral wool, woven or non-woven glass fibers or a combination thereof.

[0029] The thickness of the overlying layer can advantageously be between 10 and 200mm, preferably between 20 and 80mm.

[0030] The separators may be wood-based, thermosetting resin-based, mineral-based, or organic-based. Examples of mineral-based materials include glass, ceramics, concrete, mortar, and granular composites.

[0031] In a third preferred embodiment of the invention, the overlying layer is not made of a resilient material. The Young's modulus of the overlying layer may, in particular, be greater than 1 GPa at 20°C. In this embodiment, the separators are made of a resilient material. The Young's modulus of the separators is preferably less than or equal to 1 GPa at 20°C.

[0032] The overlying layer may be based on a material chosen from plaster, cork, wood or their combination and / or the separators may be based on a material chosen from expanded polystyrene, latex, silicone elastomer, polyurethane, rubber, mineral fibers, organic fibers, or their combination.

[0033] The thickness of the overlying layer can advantageously be between 0.5 and 50mm, preferably between 2 and 30mm.

[0034] In these first and third preferred embodiments, the viscoelastic damping ratio of the separators can advantageously be equal to or greater than 5% at 20°C. This damping ratio can be measured by dynamic mechanical analysis, also known as dynamic mechanical spectrometry, in which the separator material is subjected to oscillatory mechanical stress. It generally corresponds to the ratio of the loss modulus to the storage modulus.

[0035] The invention also relates to a method for manufacturing a floor system according to any one of the embodiments described below. The method comprises the following steps: a. the dispersion of separators on an underlying element capable of serving as a support for the floor system, b. the laying of an overlying layer on top of the separators so that the separators are in point and / or line contact with the surface of said overlying layer, c. the installation of a floating screed on top of said overlying layer.

[0036] To facilitate the on-site manufacture of a flooring system according to the invention, it may be advantageous to have a manufacturing kit available. Such a kit includes a preparation for a floating screed, an underlying layer, and a set of separators.

[0037] The features and advantages of the invention are illustrated by the figures and examples described below.

[0038] Figure 1 is a schematic representation of the cross-section of a floor system according to a first embodiment of the invention.

[0039] Figure 2 is a schematic perspective representation of a floor system according to a second embodiment of the invention.

[0040] Figure 3 is a graphical representation of the evolution of the reduction of the impact noise level as a function of frequency for examples 1 to 3 and 6, and counterexamples 1 and 2.

[0041] Figure 4 is a graphical representation of the evolution of the reduction of the impact noise level as a function of frequency for examples 4 and 5, and for counterexamples 3.

[0042] Figure 1 schematically represents a first embodiment of a floor system 1000 according to the invention. It comprises a floating screed 1001 and separators 1003 arranged under said floating screed 1001. The separators 1003 are in point and / or line contact with the surface of an underlying element 1004 capable of supporting the floor system and with the surface of an overlying layer 1002 arranged between said floating screed 1001 and said separators 1003. On In the present figure, the separators 1003 separate the underlying element 1004 and the overlying layer 1002 so that they are not in contact with each other and to form a hollow cavity network 1005 between the underlying element 1004 and the overlying layer 1002.

[0043] Figure 2 schematically represents a second embodiment of a floor system 2000 according to the invention. It comprises a floating screed 1001 and separators 2001 arranged under said floating screed, characterized in that the separators 2001 are in point and / or line contact with the surface of an underlying element 1004 capable of supporting the floor system and with the surface of an overlying layer 1002 arranged between said floating screed 1001 and said separators 2001. In the present figure, the separators 2001 are cords forming a mesh. They separate the underlying element 1004 and the overlying layer 1002 so that they are not in contact with each other and to form a hollow cavity network 1005 between the underlying element 1004 and the overlying layer 1002.For clarity of illustration and to illustrate the mesh of the separators, the separators of the floor system 2000 in Figure 2 are not shown in contact with the overlying layer 1002.

[0044] Figure 3 shows the evolution of the impact noise reduction level as a function of frequency for examples 1 to 3 and 6, and counterexamples 1 and 2, described below. The impact noise reduction level, AL, expressed in dB, is shown on the y-axis. The frequency, F, expressed in Hz, is shown on the x-axis.

[0045] Figure 4 shows the evolution of the impact noise reduction as a function of frequency for Examples 5 and 4, and Counterexample 3, described below. The impact noise reduction, AL, expressed in dB, is shown on the y-axis. The frequency, F, expressed in Hz, is shown on the x-axis.

[0046] Six examples of floor systems according to the invention are described in Table 1 below. In all six examples, the floating screed is a 30mm thick cement mortar screed. The underlying element supporting the floor system is a concrete slab.

[0047] In Examples 1 to 3, the overlying layer is made of a non-resilient material and the separators are made of a resilient material. In Examples 1 and 2, the overlying layer is a plasterboard or a set of plasterboards placed side by side with a thickness of 10 mm. The Young's modulus of the plasterboard(s) is 2 GPa at 20°C. In Example 3, it is a woodboard or a set of woodboards placed side by side with a thickness of 3 mm. The Young's modulus of the woodboard(s) is 2.7 GPa at 20°C. In Example 1, the separators are polyurethane granules with a diameter of 1 mm. The Young's modulus of the polyurethane granules is 19 MPa at 20°C. In examples 2 and 3, they are silicone granules with diameters of 2 mm and 6 mm respectively. The Young's modulus of the silicone granules is 4 MPa at 20°C.

[0048] In Examples 4 and 5, the overlying layer is made of a resilient material and the separators are made of a non-resilient material. In Examples 4 and 5, the overlying layer is a sheet or a set of sheets of juxtaposed expanded polystyrene with a thickness of 30 mm. The Young's modulus of the expanded polystyrene sheet(s) is 3.5 MPa at 20°C. In Example 4, the separators are glass beads with a diameter of 6 mm. The Young's modulus of the glass beads is 69 GPa at 20°C. In Example 5, they are polyurethane granules with a diameter of 1 mm. The Young's modulus of the polyurethane granules is 19 MPa at 20°C.

[0049] In Example 6, the overlying layer is silicone-based. It is a plate or a set of juxtaposed silicone-based plates with a thickness of 3 mm. The Young's modulus of the silicone plate(s) is 4 MPa at 20°C. The separators are rubber cords forming a mesh. The cords are solid cords with a diameter of 2 mm. The mesh is a woven grid in which the cords are regularly spaced 5 cm apart. The Young's modulus of the rubber used to form the cords is 5 MPa at 20°C.

[0050] Table 1 Table 1 Ex. 1 Ex. 2 Ex. 3 Ex. 4 Ex. 5 Ex. 6 Floating screed 30mm mortar 30mm mortar 30mm mortar 30mm mortar 30mm mortar 30mm mortar Overlying layer 10mm plasterboard 10mm plasterboard 3mm wood board 30mm EPS board 30mm EPS board 30mm silicone board 3mm separator 0.1mm PU granules 0.2mm silicone granules 0.6mm silicone granules 0.6mm glass beads 0.1mm PU granules UC woven rubber grid Underlying element Concrete slab Concrete slab Concrete slab Concrete slab Concrete slab Concrete slab Concrete slab

[0051] Four counter-examples of a floor system according to the prior art are described in Table 2. For comparison purposes, in all four counter-examples the floating screed is also a 30mm thick cement mortar screed, and the underlying element supporting the floor system is a concrete slab.

[0052] In counterexamples 1 to 2, the overlying layer and the separators are made of a non-resilient material. In counterexamples 1 and 2, the overlying layer is a plasterboard or a set of plasterboards placed side by side, 10 mm thick. The Young's modulus of the plasterboard(s) is 2 GPa at 20°C. In counterexample 1, the separators are glass beads with a diameter of 6 mm. The Young's modulus of the glass beads is 69 GPa at 20°C. In counterexample 2, they are glass fiber-based granules with a diameter of 8 mm.

[0053] In counterexamples 3 and 4, the floor system does not include separators. In counterexample 3, the overlying layer is made of a resilient material. It is formed by a sheet or a set of juxtaposed expanded polystyrene sheets with a thickness of 30 mm. The Young's modulus of the expanded polystyrene sheet(s) is 3.5 MPa at 20°C. In counterexample 4, the overlying layer is a 5mm thick fiberglass mat. In these two counter-examples, the overlying layer is in direct contact with the concrete slab.

[0054] For comparison purposes, the overlying layer in the floor systems of Examples 1 and 2 and Counterexamples 1 and 2 is identical. It is a plasterboard or a set of plasterboards placed side by side with a thickness of 10 mm. It is also identical in the floor systems of Examples 4 and 5 and Counterexample 3. It is a plasterboard or a set of expanded polystyrene boards placed side by side with a thickness of 30 mm. Counterexample 4 is an illustrative counterexample.

[0055] Table 2 Table 2 CEx. 1 CEx. 2 CEx. 3 CEx. 4 Floating screed 30mm mortar 30mm mortar 30mm mortar 30mm mortar Overlying layer 10mm plasterboard 10mm plasterboard 30mm EPS board 5mm fiberglass mat Separator 0-6mm glass beads 0-8mm fiberglass granules - - Underlying element Concrete slab Concrete slab Concrete slab Concrete slab

[0056] The floor system of each of the examples and counter-examples was subjected to a measurement of the normalized impact noise level reduction, AL, as a function of frequency according to standards NF EN ISO 10140:2013 and NF EN ISO 717-2:2013 for floor coverings. The reference floor is a concrete slab with a thickness of 140 mm.

[0057] The results are shown in Figure 3 for examples 1 to 3 and 6, and counterexamples 1 and 2, Figure 4 for examples 4 and 5 and for counterexample 3.

[0058] Figure 3 shows that from 200Hz the floor systems according to the invention, examples 1 to 3 and 6, exhibit a higher impact noise level reduction than the floor systems according to the prior art, counterexamples 1 and 2. On average, the reduction is approximately 5 to 20dB greater between examples 1 to 3, on the one hand, and counterexamples 1 and 2, on the other hand.

[0059] Figure 3 shows the impact noise reduction for the floor system of Example 6 for comparison with the floor systems of Examples 1 to 3. In this example, the overlying layer is silicone-based and the separators are rubber cords forming a mesh. Such a floor system achieves an impact noise reduction equivalent to that of the floor systems of Examples 1 and 2.

[0060] Figure 4 shows that, over the entire frequency range, the floor systems according to the invention, examples 4 and 5, exhibit a higher impact noise level reduction than the floor systems according to the prior art, counterexample 3. On average, the reduction is approximately 5dB greater between examples 4 and 5, on the one hand, and counterexample 3, on the other.

[0061] The level of reduction of the weighted impact noise level, ALW, relative to a reference floor, was also determined for each of the floor systems in the examples and counter-examples according to the same standards NF EN ISO 10140:2013 and NF EN ISO 717-2:2013 for floor coverings. The reference floor is a concrete slab with a thickness of 140 mm.

[0062] The results of examples 1 to 3 and counterexamples 1, 2 and 4, in which the overlying layer of the floor system is rigid, are compared in Table 3. The result of example 6 is also shown in Table 3.

[0063] The results of examples 4 and 5, and of counter-examples 3 and 4, in which the overlying layer of the floor system is based on a resilient material, are compared in Table 3.

[0064] Comparison of the data in Table 3 shows that a floor system according to the invention comprising an overlying layer based on a non-resilient material and elastic separators based on a resilient material, examples 1 to 3, allows a gain of about 40 to 110% on the reduction of the weighted impact noise level compared to a floor system according to the prior art comprising separators based on a non-resilient material, counterexamples 1 and 2.

[0065] Table 3 Table 3 Ex. 1 Ex. 2 Ex. 3 Ex. 6 CEx. 1 CEx. 2 △Lw (dB) 20 20 25 19 12 14

[0066] Comparison of the data in Table 4 shows that a floor system according to the invention comprising an overlying layer based on a resilient material and separators based on a resilient or non-resilient material, examples 4 and 5, allows a gain of about 25 to 35% on the reduction of the weighted impact noise level compared to a floor system according to the prior art not comprising separators, counterexamples 3 and 4.

[0067] Table 4 Table 4 Ex. 4 Ex. 5 CEx. 3 CEX. 4 △Lw (dB) 27 25 20 20

[0068] These examples clearly illustrate the advantages of a flooring system according to the invention compared to a prior art flooring system. The gain in reducing impact-weighted noise levels is at least 25% and can reach more than 100%.

Claims

Claims Claim 1. Floor system (1000, 2000) comprising a floating screed (1001) and separators (1003; 2001) arranged under said floating screed (1001), characterized in that the separators (1003; 2001) are in point and / or linear contact with the surface of an underlying element (1004) capable of serving as a support for the floor system (1000, 2000) and with the surface of an overlying layer (1002) arranged between said floating screed (1001) and said separators (1003, 2001), and in that the overlying layer (1004) and / or the separators (1003, 2001) are based on resilient material. Claim 2. A floor system (1000, 2000) according to claim 1, such that the separators (1003) are convex-shaped particles. Claim 3. A floor system (1000, 2000) according to claim 2, such that the particles are spherical or cylindrical in shape. Claim 4. Floor system (1000, 2000) according to any one of claims 1 to 3, such that the Feret diameter of the separators (1003) is between 1 and 100mm, preferably between 3 and 70mm. Claim 5. Floor system (1000, 2000) according to any one of claims 1 to 4, such that the distribution density of the separators (1003) is between 10 and 2500 separators per square meter. Claim 6. A floor system (1000, 2000) according to any one of claims 1 to 5, such that the separators (1003) are distributed on the underlying element (1004) in a regular geometric pattern. Claim 7. A floor system (1000, 2000) according to claim 1, such that the separators (2000) are cords forming a mesh. Claim 8. A floor system (1000, 2000) according to claim 1 to 7, such that the Young's modulus of the overlying layer (1002) is less than or equal to 1 GPa at 20°C. Claim 9. A flooring system (1000, 2000) according to claim 8, such that the overlying layer (1002) is based on a resilient material. Claim 10. A flooring system (1000, 2000) according to claim 9, such that the overlying layer (1002) is based on a material selected from expanded polystyrene, rubber, silicone, polyurethane or a combination thereof. Claim 11. A floor system (1000, 2000) according to claim 1 to 7, such that the Young's modulus of the overlying layer (1002) is greater than 1 GPa at 20°C. Claim 12. A flooring system (1000, 2000) according to claim 11, such that the overlying layer (1002) is based on a material selected from plaster, cork, wood or a combination thereof. Claim 13. A floor system (1000, 2000) according to any one of claims 8 to 10, such that the Young's modulus of the separators (1003, 2001) is greater than 20GPa at 20°C. Claim 14. Floor system (1000, 2000) according to claim 13, such that the separators (1003, 2001) are based on wood, thermosetting resin, material of mineral nature or material of organic nature. Claim 15. A floor system (1000, 2000) according to any one of claims 1 to 12, such that the Young's modulus of the separators (1003, 2001) is less than or equal to 1 GPa at 20°C. Claim 16. A floor system (1000, 2000) according to claim 15, such that the viscoelastic damping rate of the separators (1003, 2001) is equal to or greater than 5% at 20°C. Claim 17. A floor system (1000, 2000) according to any one of claims 15 to 16, such that the separators (1003, 2001) are based on a material selected from expanded polystyrene, latex, silicone elastomer, polyurethane, rubber, mineral fibers, organic fibers, or a combination thereof. Claim 18. A kit for manufacturing a floor system (1000, 2000) according to any one of claims 1 to 17 comprising a floating screed preparation (1001), an overlying layer (1002) and a set of separators (1003, 2001). Claim 19. A method of manufacturing a floor system (1000, 2000) according to any one of claims 1 to 17 comprising the following steps: a. the dispersion of separators (1003, 2001) on an underlying element (1004) capable of serving as support for the floor system, b. laying an overlying layer (1002) above the separators (1003, 2001) so that the separators (1003, 2001) are in point and / or linear contact with the surface of said overlying layer (1002), c. implementing a floating screed (1001) above said overlying layer (1002).

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