EP1015709A1

EP1015709A1 - Soundproofing product and method for making same

Info

Publication number: EP1015709A1
Application number: EP98944004A
Authority: EP
Inventors: Laurent Gromier
Original assignee: Onduline SA
Current assignee: Onduline SA
Priority date: 1997-09-18
Filing date: 1998-09-16
Publication date: 2000-07-05
Also published as: TW401475B; NO20001346L; WO1999014447A1; DE1015709T1; HUP0004620A1; ES2152195T1; IL135005A0; HUP0004620A3; AU9169398A; NO20001346D0; SK3732000A3; FR2768448B1; JP2001516829A; TR200000643T2; PL339341A1; FR2768448A1

Abstract

The invention concerns a soundproofing product to be used on a structure vertical wall and a method for making such a product. The product comprises successively: a first synthetic foam layer to be placed on the wall to be soundproofed; a second layer made of a mixture of filler bitumen and at least one polymer, without reinforcement; and a third finish material layer for receiving a wall coating.

Description

SOUND INSULATION PRODUCT AND METHOD FOR MANUFACTURING SUCH A PRODUCT

The invention relates to the field of sound insulation and more particularly to a product intended to reinforce sound insulation, with respect to airborne noise, of walls and in particular of vertical partitions of constructions, as well as a method of manufacturing a such product. In buildings, noise is transmitted through walls and screeds by vibration of these. The purpose of noise insulation is to reduce the transmission of residual noise through the partitions. A new regulation now in force for new constructions aims to fight against noise. Tests are defined in particular to measure the transmission of noise from one room to another. The noise level measured must be below a determined threshold before the construction can be placed on the market.

In practice, when the authorized thresholds are exceeded, additional acoustic insulation must be applied. Furthermore, during the rehabilitation of old dwellings, an improvement in sound insulation is also desired.

There is therefore a need for effective sound insulation products, which are easy to install and have a small footprint, so that the area of the buildings is practically unchanged.

In this regard, it should be noted that certain products can absorb noise and reduce the resonance in a room, without however isolating the room, since the transmission of residual noise through the partition is not reduced. This is particularly the case for a wall carpet or a cork covering. Thus, sound absorption only benefits the occupants of the room concerned.

Relatively thick sound insulation products are already known, for example made of glass wool and plasterboard. The thickness of such products is at least 4 cm. They are therefore very bulky and reduce the living area.

Soundproofing products of smaller thickness are also known, presented in sheets or rolls, generally multilayer.

Mention may in particular be made of a product made of rigid plates, consisting of a layer of cork granules, intended to be bonded to the wall to be insulated, an intermediate layer composed of bitumen and mineral fillers and a bonding layer. , intended to be placed on the outside and on which a wall covering is generally laid.

This product has the drawback of being relatively heavy, the weight per m ² being approximately 10 kg. It takes a long time to install since it is in the form of sheets of approximately 0.25 m ² . In addition, the presence of numerous joints involves a significant work of preparation before the installation of the wall covering. Finally, the plates have a still relatively large thickness, of the order of 8 mm.

The products sold in the form of rolls allow bonding by strips and the exposure time is therefore reduced compared to products in sheets.

A known roll product consists of a layer of sound-absorbing polyurethane foam, covered with a paper support allowing the installation of a wall covering.

This product is also relatively light since its weight is less than 2 kg per m ² and its thickness is around 6 mm.

It is an excellent support for wallpaper or acrylic paint. However, this product in foam has mainly sound absorption qualities and is found to have practically no effect on the passage of noise through a partition.

Document JP-A-09029873 relates to a sheet sound insulation product consisting of a bituminous base layer, a foam layer and a protective layer. These three layers can be placed in the protective layer / base layer / foam layer order. This known product is intended to be placed on a floor, and this so that the foam layer is oriented towards the outside, that is to say towards a source of noise such as a person moving on the floor. .

The protective layer of the product known from document JP-A-09029873 can be made of a woven or nonwoven material. The bituminous layer can comprise between 10 and 35% by weight of an asphalt and between 65 and 90% of filler. The foam layer is made of closed cell foam in order to be able to withstand the stress which it undergoes, for example, by the weight of furniture placed on the floor.

Document JP-A-06087170 relates to the manufacture of a polyurethane foam from a crumbled and agglomerated recycled polyurethane foam. For the manufacture of the foam, the crumbled material and a binder are introduced into a mold.

Document US-A-5, 665, 447 relates to a soundproofing screen comprising a central bituminous layer successively covered on both sides with an insulating layer of mineral fibers, advantageously glass fibers, such as glass wool, and a protective layer.

The characteristic of reduction of sound transmission through this known sound insulation screen can be varied by adding different quantities of fine charges to the mixture of the bituminous layer. The products used until now to obtain sound insulation are light when they are designed so as to reduce the reverberation time, that is to say when they are intended for acoustic correction. On the contrary, they are heavy when they are designed to reduce the transmission of sound, that is to say when they are intended for acoustic or sound insulation. None of these products is light, thin and designed to effectively reduce the transmission of sound (sound insulation).

The object of the invention is to provide a soundproofing product for a wall which is light and easy to install, while effectively reducing the transmission of noise through the wall, and which has a small footprint.

The object of the invention is achieved with a sound insulation product for a vertical building wall and which successively comprises: - a first layer of open cell foam of synthetic material, intended to be placed on the wall to be insulated and whose thickness is between 1.5 mm and 5 mm,

a second layer of a mixture of bitumen, of fillers in limited quantity and of at least one polymer, without reinforcement, the thickness of which is between 1 and 4 mm and

- a third layer, waterproof to bitumen, in a primer, intended to receive a wall covering.

The first layer is preferably made of polyurethane foam, melamine foam, polyester foam or polyether foam. It can also be produced by mixing these foams, for example from chopped and then agglomerated foam waste, or in a multilayer assembly. The density of the foam is preferably between 15 and 35 kg / m 3, if the

₃ foam is homogeneous, and between 150 and 350 kg / m, if the foam is not homogeneous. For example, a heterogeneous polyurethane foam will be chosen, in particular consisting of relatively large waste (1 to 3 mm), agglomerated and bound, whose density is advantageously of

3

250 kg / m. It is possible in particular to use the polyurethane foam sold by the company RECTICEL under the reference RECFOAM U250 / 2.5, the mass of which

₃ density is 250 kg / m and the thickness of 2.5 mm, or under the reference RECFOAM U250 / 4.5, whose density is 250 kg / m and the thickness of 4.5 mm.

In another example, a polyester foam will be chosen, the density of which is advantageously

₃ of 25 kg / m.

Under these conditions, the layer of synthetic foam is flexible, which is preferable for the product to fulfill its sound insulation function.

The second layer has a density between only 900 kg / m 3 and 1300 kg / m3, these values having been obtained by adding, in a limited quantity, fillers.

The second layer advantageously comprises:

- between approximately 0% and 25% by weight of fillers,

- between approximately 46% and 92% by weight of bitumen and

- between about 8% and 29% by weight of at least one polymer, preferably at least two ho opolymers.

The bitumen used is preferably road bitumen, the penetration of which at 25 ° C., according to standard NFT 66-004, is between 70 and 220 tenths of a mm, advantageously between 120 and 220 tenths of a mm. Alternatively, the bitumen can be deasphalted bitumen, synthetic bitumen or fluxed bitumen. However, the use of oxidized bitumens or natural asphalt is not recommended, as they would cause the bituminous mixture to lose its flexibility. Indeed, the reduction in sound transmission, and therefore the sound insulation, is obtained, for the product according to the invention, by a transformation of the acoustic energy into heat energy exploiting the visco-elastic / visco-plastic nature of the product. according to the invention (visco-elastic / visco-plastic work). The fillers are, for example, made of calcium carbonate or aluminum hydroxide, in the form of powder of small particle size.

The polymer blend advantageously comprises APP (atactic polypropylene), IPP (isotactic polypropylene), with optionally copolymers, or SBS (styrene-butadiene-styrene).

Those skilled in the art know that APP is obtained from IPP manufacturing waste. SBS is a product that can replace other polymers. Furthermore, IPP is used to impart rigidity to the second layer of the insulating product.

When the polymers are in the form of a mixture of IPP, APP and optionally of copolymers, the proportions of each constituent of the mixture of polymers are preferably as follows:

- between around 8 and 24% by weight of APP

- between about 2.5 and 5% by weight of PPI, and between about 0 and 7% by weight of copolymers. The presence of copolymers improves the visco-elastic qualities of the second layer of the product, which also improves the resistance to cracks, as will be explained below.

In the particular case where the mixture does not contain copolymers, the percentage by weight of fillers is preferably between 10 and 15%, while the percentage by weight of APP, respectively of IPP is between 13 and 24%, respectively between 2.5 and 5%.

When the polymer present in the second layer consists of SBS alone, the percentage of SBS is between 8 and 15%.

Preferably, this second layer of the insulation product does not contain added oils.

The third layer is a primer allowing the installation of a wall covering, such as paint or wallpaper.

The thickness of this third layer is preferably less than 0.5 mm.

It can in particular be made of a non-woven material such as a glass or polyester veil, or also of paper, cardboard or metal sheets.

This third layer will preferably be produced in a glass veil whose surface mass is 60 g / m ² . This glass veil is advantageously subjected to a coating treatment. The coating layer obtained has a surface mass preferably of the order of 40 g / m ² . It makes it possible to seal the porosities of the glass veil and therefore both to avoid the rise of the bitumen through the glass veil and the penetration into the glass veil of the finishing layer, such as paint.

This coating treatment can also be used for other priming layers, such as those in polyester fleece, cardboard or paper. In the latter case, greaseproof paper will be used in particular.

An example of a sound insulation product according to the invention comprises:

- a first layer of foam of the RECFOAM U250 / 2.5 type, the density of which is 250 kg / m ³ and the thickness of 2.5 mm, a second layer 1.5 mm thick, comprising 65% by weight of road bitumen whose penetration at 25 ° C is 150 tenths of mm, 18% by weight of APP, 4.5% by weight of PPI and 12.5% by weight of fillers,

- a third layer with a thickness of 0.4 mm, produced in a glass veil whose surface mass is 60 g / m ² and coated with a coating layer whose surface mass is 40 g / m ² . The soundproofing product according to the invention is placed on a wall using an appropriate adhesive, using a notched trowel. This glue must not contain organic solvents.

The glue sold by the company HENKEL, under the name THOMSIT K188, is compatible with this product.

The product of the invention was subject to tests of sound reduction index R, the product according to the invention being placed on two different partitions: a prefabricated partition of the type

PLACOPAN and a plaster tile partition.

It will be recalled here that a prefabricated partition consists of two thin plaster walls, between which a cardboard structure is arranged. These tests have demonstrated that the product according to the invention allows an improvement in sound insulation ranging from 2 dB to 9 dB, depending on its composition and the support.

The results of these tests are shown graphically in the attached single Figure 1.

The single Figure 1 shows in a graphic design two curves of sound reduction index R, referenced (a) and (b). Curve (a) is that of the acoustic attenuation as a function of the frequency of the transmitted sound, measured for a drywall 72 mm thick, consisting of two facings made of 12.5mm BA13 gypsum board. thick bonded to a core in a cardboard honeycomb network. Curve (b) corresponds to the acoustic reduction as a function of the frequency of the sound transmitted through a drywall specified above and provided on one of its faces with an insulation product according to the invention applied by gluing.

These tests also showed that, when a thick insulating product, the thickness of which is at least 4 cm, is covered with an insulating product according to the invention, the latter makes it possible to improve the sound insulation of the product. thick insulation, especially at low frequencies.

To explain the improvement in the sound insulation obtained with the product according to the invention, without this explanation being definitive or limiting, it can be argued that the second layer of bitumen / modified makes it possible to distribute the sound energy over a greater surface of the first layer of synthetic foam, the sound energy absorption function of which is even better used.

This results in an improvement in sound insulation with an insulating product which remains relatively fine.

It has also been found that the soundproofing product according to the invention improves the resistance to cracking of wall coverings, for example paper or paints, to which the insulating product serves as a support.

Indeed, the wall on which the insulating product is stuck can have instabilities. These are likely to generate ruptures and / or cracks in the insulating product and therefore also in the wall covering.

It appears that each of the three constituent layers of the insulation product according to the invention makes it possible to absorb, at least in part, the stresses due to the instability of the wall. As a result, the insulating product according to the invention makes it possible to improve the resistance to cracking and to rupture, of the wall coverings fixed to it.

It has thus been observed that cracks up to 3 mm in width do not cause any deterioration of the wall coverings, when the sound insulation product according to the invention comprises a layer of synthetic foam with a thickness of approximately 2, 5 mm and a layer of modified bitumen about 1.5 mm thick.

A layer of glass veil facilitates the holding of wall coverings, thanks to its “hanging” qualities.

As regards fire resistance, a special coating can be applied to the product according to the invention, during its manufacture or after it has been placed on a wall.

It can be noted that the presence of a glass veil gives the sound insulation product better fire resistance, compared to other priming layers. Furthermore, a plasterboard can be placed on the soundproofing product according to the invention, without its soundproofing qualities being degraded. The object of the invention is also achieved by a process for manufacturing the soundproofing product described above in principle and according to its various embodiments.

More particularly, the invention relates to a method of manufacturing a sound insulation product for a vertical building wall, the insulation product successively comprising:

- a first layer of open cell foam, made of synthetic material, intended to be placed on the wall to be insulated and whose thickness is between 1.5 mm and 5 mm, - a second layer of a mixture of bitumen, of fillers in limited quantity and of at least one polymer, without reinforcement, the thickness of which is between 1 and 4 mm and - a third layer, impermeable to bitumen in a material d primer, intended to receive a wall covering.

According to an advantageous embodiment of the process of the invention, the insulating product according to the invention is produced as follows.

The first layer of synthetic foam is preferably purchased directly from a supplier in a roll presentation.

The third layer of primer, especially in glass veil, is also purchased directly from a supplier in a roll presentation.

The second layer or intermediate layer of modified bitumen is produced by first preparing an appropriate mixture, then by pouring this mixture in the liquid state onto the layer of synthetic foam or onto the layer of primer. The casting temperature is between 150 ° C and 190 ° C and is advantageously located at around 170 ° C.

According to a first variant, before the layer of modified bitumen obtained is completely cooled, the other layer is applied to its free side, that is to say the layer of synthetic foam or the primer layer.

The second layer has a tackiness, as long as it is not completely cooled.

This first variant therefore makes it possible to bond the first and third layers to the intermediate layer, without an adhesive or an additional operation being necessary. It is therefore a simple and economical variant.

According to a second variant, the second layer is allowed to cool until it solidifies. We can then glue the other layer (synthetic foam layer or primer layer) on the other side of the second layer, using an appropriate glue. The second layer can also be superficially reheated on its free side so that the bitumen becomes liquid on the surface.

Then applied on the free side of the second layer, the other layer of the insulation product according to the invention (the layer of synthetic foam or the primer layer), to obtain the sound insulation product.

Claims

1. Sound insulation product for a vertical building wall, successively comprising: - a first layer of open cell foam, made of synthetic material, intended to be placed on the wall to be insulated and whose thickness is between 1 , 5 mm and 5 mm,

2. Sound insulation product according to claim 1, characterized in that the density of the foam is between 15 and 35 kg / m, for a homogeneous foam and between 150 and 350 kg / m, for a heterogeneous foam.

3. Sound insulation product according to one of claims 1 or 2, characterized in that the first layer is made of polyurethane foam, melamine foam or polyester foam.

4. Soundproofing product according to one of claims 1 to 3, characterized in that the first layer is produced from waste polyurethane foam chopped and then agglomerated.

5. Sound insulation product according to one of claims 1 to 4, characterized in that the second layer has a density between 900 kg / m ³ and 1300 kg / m ³ .

6. Sound insulation product according to one of claims 1 to 5, characterized in that the second layer comprises:

- between about 0 and 25% by weight of fillers, - between about 46% and 92% by weight of bitumen

- And between about 8% and 29% by weight of at least one polymer.

7. Sound insulation product according to one of claims 1 to 6, characterized in that the bitumen used in the second layer is road bitumen whose penetration at 25 ° C, according to standard NFT 66-004, is included between 70 and 220 tenths of a mm.

8. Soundproofing product according to one of claims 1 to 7, characterized in that the second layer comprises a mixture of APP, IPP and copolymers in the following proportions:

- between around 8% and 24% of APP,

- between approximately 2.5% and 5% of PPI, - and approximately 0% and 7% of copolymers.

9. sound insulation product according to claim 8, characterized in that when the mixture does not contain copolymers, the percentage by weight of fillers is between 10 and 15%, the percentage by weight of APP being between 13 and 24%.

10. Sound insulation product according to one of claims 1 to 7, characterized in that the second layer comprises a single polymer which is SBS in a percentage between 8 and 15%.

11. Soundproofing product according to one of claims 1 to 10, characterized in that the third layer is produced in glass or polyester fleece, in paper, in cardboard or in metallic sheets.

12. Sound insulation product according to one of claims 1 to 11, characterized in that the third layer is subjected to a coating treatment.

13. Method for manufacturing a sound insulation product for a vertical wall of construction, the sound insulation product successively comprising:

- a first layer of open cell foam, made of synthetic material, intended to be placed on the wall to be insulated and whose thickness is between 1.5 mm and 5 mm, a second layer of a mixture of bitumen, fillers in limited quantity and of at least one polymer, without reinforcement, the thickness of which is between 1 and 4 mm and

- a third layer, impermeable to bitumen in a primer, intended to receive a wall covering, characterized in that the method consists: - in pouring a mixture of bitumen with fillers and at least one polymer on the first or the third layer of the insulation product, so as to obtain a second layer whose thickness is between 1 and 4 mm, and - to be bonded to the free side of said second layer, the other layer of the insulating product.