Fabric for stretched false ceilings or false walls and false partition comprising such a fabric

Abstract

A fabric for a stretched false ceiling or false wall, the fabric being made of thermoplastic rubber, advantageously selected from the group comprising thermoplastic polyurethanes.

Description

[0001] False ceiling or stretched wall fabric and false wall including such a fabric

[0002] The invention relates to the technical field of suspended ceilings and stretched false walls.

[0003] Suspended ceilings and suspended walls made of stretch fabric have been known for a long time. Reference can be made, for example, to documents CA835014 (Barracudavernen, 1970), FR2078579 (Blick, 1971).

[0004] Suspended ceilings and stretched walls are formed by mounting at least one canvas onto a frame.

[0005] The frame is formed by assembling profiles, called smooths, made of polymer material such as polyvinyl chloride, ABS (acrylonitrile butadiene styrene), or of metal alloy, typically aluminum alloy, or of composite material, for example fiber-reinforced polymer material.

[0006] Depending on their constituent material, the smooths are conventionally extruded or pultruded.

[0007] The frame can be fixed directly to the walls of a room, for example by screwing.

[0008] The canvas can then be of large surface area, and be formed by assembling strips.

[0009] We also know of false walls and false ceilings comprising slabs or boxes, each slab comprising at least one canvas mounted on a frame of rails.

[0010] When the false ceiling or false wall is in the form of tiles, the frame can be contained or encased within a fabric envelope. Tiles made of two fabrics attached to a frame are also known; see, for example, FR13191 71 (Isora, 1963), US3460299 (Wilson).

[0011] The vast majority of stretch ceilings are installed with their horizontally stretched fabric in its entirety.

[0012] In some designs, the canvas being stretched over a horizontal frame of slats fixed to the walls of a room, deformations of the stretched sheet are made, as described in documents FR1 51 5260 (Saulnier, 1968) or EP281468 (Scherrer, 1988).

[0013] The fabrics used for suspended ceilings or stretched walls are most often made of deformable polymer, particularly polyvinyl chloride. "Deformable" here refers to the ability to stretch these fabrics manually.

[0014] We also know of stretched false ceilings and stretched false walls comprising a low-deformability fabric, in particular made of fabric, or coated fabric, for example by calendering.

[0015] The methods of mounting the edges of canvases onto a frame of rails are very varied.

[0016] In a first family of means of mounting the edges of the canvas on the frame of rails, the perimeter of the canvas includes a strip of added material, presenting a section in the shape of a hook.

[0017] In this first family and according to one type of embodiment, the rail has a U-shaped groove, and one of the two walls of the U-shaped groove has a lip facing the bottom of the groove. The hook-shaped canvas edge is anchored positively to this lip. See, for example, document FR1303930 (Barracudavernen, 1962).

[0018] In this first family and according to a second type of construction, the rail has a U-shaped groove, and one of the two walls of the rail's groove includes a shoulder, the part of which located towards the bottom of the groove forms a support for the hook-shaped edge of the canvas. See, for example, documents FR 1475446 (Licentia, 1967), FR2002261 (Barracudavernen, 1969), ER 338925 (Scherrer, 1989), FR2843141 (Mphi, 2004).

[0019] In this first family and according to a third type of construction, the rail has a U-shaped groove, and each of the two sides of the rail's groove has a shoulder, while the edge of the canvas is shaped like a double hook. See, for example, documents FR24861 27 (Allemann, 1982) and FR2627207 (Bidini, 1989).

[0020] In this first family and according to a fourth type of construction, the rail has a rigid lip onto which the edge of the canvas is attached. See, for example, document FR278651 5 (Newmat, 2000).

[0021] In a second family of methods for mounting the edges of the canvas onto the frame of rails, the canvas is pinched.

[0022] In this second family and according to a first type of construction, the canvas is pinched by the rail against a wall. See, for example, documents FR2715682 (Hosteing, 1995), FR 2734296 (Ringaud, 1996).

[0023] In this second family and according to a second type of implementation, the rail is equipped with means forming a clamp for positioning and tensioning. See, for example, documents FR 269921 1 (Swal, 1994) and FR 25371 1 2 (Bernardy, 1984).

[0024] In a third type of method for mounting canvas edges within the frame of stringers, the canvas edge is fitted with a rod, generally round in cross-section, which fits snugly into a groove in the stringer. See, for example, document FR1 5881 50 (Pecault, 1970).

[0025] While many developments have been proposed since the 1970s for the means of mounting canvases on the tracks, the same cannot be said for stretched ceiling and stretched wall canvases.

[0026] Polyvinyl chloride (PVC) has remained, for decades, the most commonly used material worldwide for the production of stretch ceilings and stretch walls.

[0027] The use of PVC to form suspended ceiling tiles with stretched fabric has been known since the 1950s. One can refer for example to the documents FR1 091 635 (Isolation rationnelle, 1955), FR1203409 (Ternynck, 1960), FR 13191 71 (Isora, 1962), US3460299 (Bertram, 1969).

[0028] For stretch ceilings with a grid of tracks fixed to the walls, the PVC fabric is installed using a hot-air method, a technique employed for decades and described, for example, in document GB1 1 59804 (Bergstrom, 1969), or in documents FR231 0450 (Anthonioz, 1976) and FR2552473 (Chiausa, 1985). The PVC fabric is made more easily stretchable by heating it to a temperature of around 40°C using a hot air gun, and then manually mounted onto a grid of tracks. Once the fabric returns to room temperature, it is tensioned. This installation technique is the only one mentioned in the NF DTU 58.2 standard for stretch ceilings with flexible fabric, i.e., without the use of a coated fabric. Installation tools are commercially available for mounting the canvas to the frame.For such tools, one can refer for example to the documents FR2974827 (Newmat, 2012), FR2935150 (Normalu, 2010), US5413300 (Hosteing, 1995), FR2627207 (Bidini, 1989).

[0029] For 60 years, PVC has remained the most widely used material for stretch ceiling fabrics, and there is a very large body of patent documents consistently and conventionally describing the use of PVC in stretch ceilings. Reference can be made, for example, to documents FR2002261 (Barracudawerken, 1966), GB1 159804 (Bergstrom, 1966), FR1475446 (Licentia, 1967), US3405489 (Frisk, 1968), GB1 1 89849 (Gibson, 1970), FR24861 27 (Allemann, 1982), FR2524922 (Scherrer, 1983), FR2914667 (Scherrer, 2008), EP2900884 (Normalu, 2015), FR31 03837 (Normalu, 2021).

[0030] PVC offers numerous advantages. Available in a wide range of finishes, PVC fabrics can be translucent or opaque, dyed or undyed, matte, lacquered, marbled, or satin, making them suitable for use in industrial settings, hospitals, public facilities, laboratories, and homes. A lacquered finish provides a mirror-like effect, often used in shopping centers, while a matte finish, similar to a plaster-like appearance, is more common in traditional decors. PVC fabrics have a certified fire rating of BS1-d0, BS2-d0, or BS3-d0, depending on the finish.

[0031] PVC stretch ceiling fabric can be perforated for the creation of acoustic ceilings, as has long been known. See, for example, document GB1 189849 (Ekman, 1970).

[0032] For a presentation of the mechanical properties of PVC films for suspended ceilings, one can refer for example to the document Ambroziak, Experimental tests for the determination of mechanical properties of PVC foil, Advances in Mechanics: Theoretical, Computational and Interdisciplinary Issues, pp.67-70, 2016.

[0033] Cold-stretched fabrics are also known, for example, polyester fabric coated with polyurethane. See, for example, document EP 1341975B1 (Clipso, 2006). Document FR2738847 (ADP, 1997) describes a fabric stretched at room temperature for suspended ceilings, the fabric comprising 18% to 24% by weight of a polyester fabric substrate and 76% to 82% by weight of a PVC coating. Document WO2017 / 01 7328 (Normalu, 2017) describes a suspended ceiling fabric made of fiberglass fabric coated with polyurethane or PVC, with a softening agent containing starch being sprayed on during or after the coating of the woven fabric. We also know of non-stretch fabrics, stretched using elastic cords, with the edge of the tablecloths including a deformable rubber band. See, for example, document FR2921947 (Normalu, 2009).

[0034] The use of materials other than PVC for the production of stretchable fabrics for false ceilings or stretched walls has rarely been proposed in the prior art.

[0035] The document FR2799222 (Newmat, 2001) proposes, in addition to PVC, derived polymers such as super-chlorinated vinyl chloride, polyvinylidene chloride and vinyl chloride / vinylidene chloride copolymers.

[0036] Document FR21 60064 (Ljungbo, 1973) proposes a plastic or rubber fireproof sheet, comprising a fire-retardant material.

[0037] Document FR2814758 (Comm et Tech, 2002) describes the manufacture of a mirror formed by a thin film stretched over a support. The film is made of polyester or polystyrene, with a thickness of 12 to 50 microns, and is vacuum-metallized with aluminum. The film is stretched over the support and then passed through a heating tunnel. The tunnel is heated to a temperature between 170°C and 210°C, causing the film to shrink. Document FR2844692 (Like Mirror, 2004) describes the manufacture of a mirror formed by a thin film stretched over a support. The film is made of polyester or polystyrene, with a thickness of 23 to 50 microns, and is vacuum-metallized with aluminum. The film is stretched over the support by mechanical means.

[0038] Document EP261 0018 (Normalu, 2013) mentions the use of ethylene tetrafluoroethylene ETFE, which is a thermoplastic fluoropolymer (CAS 25038-71-5).

[0039] The document WO201 9 / 1 58874 (Normalu , 201 9) proposes the use of a thermoplastic polymer fabric, in particular ethylene tetrafluoroethylene ETFE, treated by ionization to eliminate the electrostatic charges present on the surface of the fabric, with air being blown during ionization.

[0040] The document CN213233961 (Shenzhen Senmo Membrane Structure, 2021) mentions the use of films made of PVDF (polyvinylidene fluoride, CAS 24937-79-9) or ETFE.

[0041] The document FR2976307 (Dom Innov, 2012) describes a device for mounting a canvas in a rail, the device being a harpoon including a clamp, the document alluding to a possibility of using non-weldable fabrics or canvases or polyurethane, without further details.

[0042] Most of the materials other than PVC offered in the prior art have not been commercially implemented. To the applicant's knowledge, for stretch ceiling or wall coverings not incorporating coated textiles, only ETFE is still available (for products marketed under the Mircosorber® brand), and aluminized heat-shrink polyester (marketed under the Mirolège® brand) for stretch mirrors.

[0043] PVC has sometimes been the subject of debate, particularly concerning certain plasticizers, the presence of heavy metals, its life cycle (especially recycling), and its carbon footprint. See, for example, the document by Joe Thornton, *Environmental Impacts of Polyvinyl Chloride Building Materials*, ISBN 0-9724632-0-8, 2002.

[0044] In a report published on November 29, 2023, the European Chemicals Agency (ECHA) estimates that the European Union (EU) should better regulate the production of polyvinyl chloride (PVC), as some PVC additives may pose risks to human health and the environment.

[0045] Criticisms of PVC use in construction do not affect the field of stretch ceilings and suspended walls, for several reasons. Firstly, the weight of material used for stretch ceilings is low (approximately 0.3 kg per square meter of suspended ceiling).

[0046] Secondly, PVC is presented as recyclable, with some manufacturers recovering old stretch ceiling fabrics and marketing recycled PVC fabrics made from these old fabrics.

[0047] Thirdly, the lifespan of PVC fabrics is over 20 years.

[0048] Some manufacturers also offer PVC stretch ceilings made with phthalate-free plasticizers, or bio-based plasticizers, such as epoxidized sunflower oil or epoxidized soybean oil. Some manufacturers of stretch ceilings highlight the use of such plasticizers, emphasizing their plant-based origin in the PVC fabrics.

[0049] The PVC fabrics sold are also labeled A+, with regard to the level of emission of volatile organic compounds (VOCs) and indoor air quality.

[0050] The invention aims to provide fabrics for the construction of false ceilings or stretched false walls, these fabrics not containing PVC.

[0051] For these purposes, it is proposed, according to a first aspect, a fabric for false ceiling or false stretched wall, the fabric being made of thermoplastic rubber, advantageously chosen from the group including thermoplastic polyurethanes.

[0052] By canvas, we mean here a strip, a film, a sheet of material, the terms "film", "sheet", "strip" being used because of the thinness of the canvas, for example on the order of 0.1 mm.

[0053] Thermoplastic rubber refers to a polymer or polymer blend that does not require vulcanization or crosslinking during processing and exhibits properties at service temperature similar to those of vulcanized rubbers. Thermoplastic rubbers consist of a rigid phase at room temperature with a glass transition temperature above room temperature and a flexible elastomeric phase with a glass transition temperature below room temperature.

[0054] Polyurethane refers specifically to products resulting from the polyaddition reaction of isocyanates and polyisocyanates with polyols. Isocyanates and polyisocyanates can be aromatic or aliphatic.

[0055] Thermoplastic polyurethane refers here to a polyurethane elastomer, in particular a linear thermoplastic polymer resulting from the reaction of a diisocyanate with a dialcohol, or from the condensation of a high molecular weight diol, a short diol, and a diisocyanate. Thermoplastic polyurethane also refers to a polyurethane comprising long linear molecules obtained by the condensation of bifunctional constituents. Finally, thermoplastic polyurethane also refers to a thermoplastic elastomer having a flexible phase comprising a long diol and a rigid phase comprising a polyurethane resulting from the reaction of a short diol with a diisocyanate.

[0056] For a general presentation of polyurethane elastomers, one can refer for example to the document Prisacariu, Polyurethane Elastomers, From morphology to mechanical aspects, ISBN 978-3-7091 - 0513-9, 2011.

[0057] In some implementations, thermoplastic polyurethane is a thermoplastic ester polyurethane, the long diol used during the synthesis of thermoplastic polyurethane being a polyester.

[0058] In other applications, the thermoplastic polyurethane is a thermoplastic polyurethane ether, the long diol used in the synthesis of the thermoplastic polyurethane being a polyether. Depending on the application, the perimeter of the fabric includes a strip of added material, for example with a hook or harpoon-shaped cross-section, or comprising a bead.

[0059] The applied material strip or bead can be made of PVC. Advantageously, the applied material strip or bead is made of polyurethane.

[0060] The thickness of the fabric is advantageously between 100 microns and 500 microns, and preferably between 100 microns and 200 microns. For thicknesses greater than 500 microns, manually tensioning the fabric becomes difficult.

[0061] A second option is proposed: a false ceiling or false wall made of stretched material such as that shown above, mounted stretched over a frame of rails.

[0062] A third option is proposed: a false ceiling or false wall panel, comprising a canvas as shown above, mounted stretched or bagged on a panel frame.

[0063] Other objects and advantages of the invention will become apparent from the description of embodiments, given below with reference to examples of implementation, a description which will be made with reference to the accompanying drawings, in which:

[0064] - Figures 1 to 3 are photographs showing a suspended ceiling, comprising a polyurethane elastomer fabric, mounted stretched in a rail frame, the rail being for example of the type shown in Figure 4;

[0065] - Figure 4 is an example of mounting a polyurethane elastomer fabric on a rail profile.

[0066] In the first series of implementation tests, the fabric was made of polyurethane ether, marketed by Pascon under the references Platilon® 4201 NU, Platilon® 4201 AU, and Platilon® 4281 AU. The elongation at break of these fabrics, measured according to ISO 527, is 550%. The tear resistance, measured according to ISO 34-1, is 60 kN / m for the Platilon® 4201 NU reference.

[0067] The Platilon® 4201 AU fabric is 100 microns thick and has good transparency, which makes it unsuitable for the technical field of false ceilings or false walls, as the elements in the plenum are not hidden or masked from view by the presence of the fabric for a person observing the false ceiling.

[0068] The Platilon® 4281 AU fabric is 150 microns thick, opaque, and black. The fabric has surface irregularities, making it unsuitable for the technical applications of suspended ceilings or false walls.

[0069] Advantageously, the transparent Platilon® 4201 AI fabric was combined with a black Platilon® 4281 AU fabric to form a two-layer system. The transparent layer conceals any imperfections in the appearance of the Platilon® 4281 AU fabric. For mounting on a frame of battens, the two-layer fabric was edged with a harpoon-shaped border made of PVC or polyurethane, either welded to the fabric or held under tension by pinching it within a batten frame profile.

[0070] In a second series of tests, the canvas is a canvas marketed under the reference XG3F85-02, by the company Shanghai Functech Co.

[0071] Figures 1 to 3 are photographs showing a suspended ceiling, comprising an XG3F85-02 fabric, mounted stretched in a rail frame, according to an assembly as shown in Figure 4.

[0072] The plaintiff was able to mount the polyurethane elastomer fabric on different rails.

[0073] Figure 4 shows an example of a mounting rail, which is advantageously a conventional rail, marketed by the applicant under the name Elégance. This rail is included in standard NF DTU 58.2 relating to stretch ceilings, this DTU applying to the conditions of execution, inside buildings, of stretch ceilings fixed by an anchoring device conforming to standard NF EN 1471 6.

[0074] The applicant has identified, surprisingly, that the use of a polyurethane elastomer for the canvases did not require modification of the mounting rails, even though the mechanical properties of polyurethane elastomers are very different from those of PVC used in the field of stretch ceilings and stretch walls.

[0075] Polyurethane elastomers in particular exhibit hyper-elastic properties, and may also exhibit stress relaxation after stretching, these characteristics not being favorable for use in suspended ceilings or suspended walls.

[0076] The table below presents the tensile properties at 20°C of XG3F85-02 polyurethane. Five tests were performed. The thickness of the polyurethane fabric is 0.1 mm. For these tests and the tensile tests mentioned later in this description, the testing machine used is a DY series machine manufactured and marketed by the French company Adamel-Lhomargy. The crossbar travel speed is 100 mm / min.

[0077] The comparative table below shows the tensile properties at 20°C of a PVC fabric commonly used for stretch ceilings or suspended walls (matte white fabric from CTN, reference 5091 201). Five tests were carried out. The fabric thickness is 0.2 mm.

[0078] The elongation at break at 20°C for polyurethane is three times higher than for PVC. The tensile strength for polyurethane is half that of PVC.

[0079] The applicant has successfully managed to install the polyurethane fabrics at room temperature, it being recalled that conventional stretch ceiling fabrics, made of PVC, are installed hot, with a hot air gun ensuring that the PVC fabrics are heated to a temperature of around 45°C.

[0080] The table below shows the tensile properties of PVC at 45°C, the PVC fabric being the same as that in the table above (matte white fabric from CTN, reference 5091 201, thickness 0.2 mm). Five tests were carried out.

[0081] The elongation at break at 20°C for polyurethane is three times greater than that of PVC at 45°C. The tensile strength of polyurethane at 20°C is 25% lower than that of PVC at 45°C. Tensile tests were performed on polyurethane fabrics after welding and compared to tensile tests after welding for prior art PVC fabrics.

[0082] The weldability of fabrics assembled by high-frequency welding was evaluated in relation to the NF EN 1471 6 standard.

[0083] The service constraint is 5 daN.

[0084] In one example, the welds were carried out under the following conditions, for XG3F85-02 polyurethane fabrics, with a thickness of 0.1 mm:

[0085] After welding, for the polyurethane fabric, the elongation at break was 282%, and the breaking strength was 7.7 daN.

[0086] The table below presents the welding conditions, for the comparative example of welding a commercially available PVC fabric (matte white fabric from the company CTN, 0.2 mm thick, reference 5091201):

[0087] After welding, two tests were carried out on the PVC fabric, one at room temperature and the other at 45°C, with the following results:

[0088] The elongation at break, after welding, for polyurethane fabric is approximately three times greater than for conventional PVC fabric. The tensile strength, after welding, for polyurethane fabric is half that of PVC fabric measured at 45°C.

[0089] We now refer to figure 4.

[0090] The polyurethane fabric 1, for example a 0.1 mm fabric referenced XG3F85-02 marketed by the company Shanghai Fu nctech, is provided on its peripheral edge with a harpoon 2, for example made of PVC, mounted on a rail 3 marketed by the applicant under the name Elegance.

[0091] This track is included in the NF DTU 58.2 standard relating to stretch ceilings. This track 3 includes a vertical flange 4, for fixing to a surface 5 such as a wall, this vertical flange 4 being provided with a C-shaped opening 6, for the mounting of a splice or an assembly bracket.

[0092] The mounting of the canvas 1 onto the rail 3 is done manually, using a tool such as a spatula.

[0093] The invention has many advantages.

[0094] The false ceiling or false wall fabric does not contain PVC, and thus responds to criticisms of this polymer, which has been widely and constantly used for decades.

[0095] The canvas proves to be less fragile than a PVC canvas, which should facilitate its packaging and shipping.

[0096] The canvas can be installed cold, eliminating the need for a hot air gun. This makes the installation process more economical and pleasant.

[0097] The canvas can be fitted with mounting means such as hook or harpoon, single or double, in PVC or polyurethane, or even a rod.

[0098] Although the mechanical properties of polyurethane elastomer fabrics are very different from those of the PVC used for decades, polyurethane elastomer fabrics, or thermoplastic rubber, prove to be compatible with currently available rails.

[0099] The fabric is weldable, allowing the creation of large-scale false ceilings or false walls.

Claims

Demands 1. Fabric for false ceiling or false wall stretched, characterized in that the fabric is made of thermoplastic rubber, advantageously chosen from the group comprising thermoplastic polyurethanes.

2. Stretched fabric for false ceiling or false wall according to claim 1, characterized in that the thermoplastic polyurethane is a thermoplastic polyurethane ester.

3. Stretched fabric for false ceiling or false wall according to claim 1, characterized in that the thermoplastic polyurethane is a thermoplastic polyurethane ether.

4. Fabric for false ceiling or false wall stretched according to any one of claims 1 to 3, characterized in that the perimeter of the fabric comprises a strip of added material, having a cross-section in the shape of a hook or harpoon, or comprises a rod.

5. Stretched fabric for false ceiling or false wall according to claim 4, characterized in that the added material strip or bead is made of PVC or polyurethane.

6. Fabric for false ceiling or false wall stretched according to any one of the preceding claims, characterized in that the thickness of the fabric is between 100 microns and 500 microns, advantageously between 100 microns and 200 microns.

7. Suspended ceiling comprising a fabric according to any one of claims 1 to 6, mounted stretched over a frame of rails.

8. False stretched wall comprising a canvas according to any one of claims 1 to 6, mounted stretched over a rail frame.

9. False ceiling tile comprising a fabric according to any one of claims 1 to 6, mounted stretched or bagged on a tile frame.

10. False wall slab, comprising a canvas according to any one of claims 1 to 6, mounted stretched or bagged on a slab frame.

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