U.S. patent application number 11/155111 was filed with the patent office on 2005-12-22 for sound-absorbing device for a wall covering, ceiling covering, or floor covering.
Invention is credited to Halterbeck, Walter, Huser, Martin.
Application Number | 20050279574 11/155111 |
Document ID | / |
Family ID | 34925386 |
Filed Date | 2005-12-22 |
United States Patent
Application |
20050279574 |
Kind Code |
A1 |
Halterbeck, Walter ; et
al. |
December 22, 2005 |
Sound-absorbing device for a wall covering, ceiling covering, or
floor covering
Abstract
A sound-absorbing device for a wall covering, ceiling covering,
or floor covering has a support that comprises at least one
sound-absorbing layer made of polymer foam. The layer constitutes a
plurality of protrusions. The protrusions are arranged with a
distribution such that a straight line that is continuous over the
surface of the support is not projectable through the
interstices.
Inventors: |
Halterbeck, Walter; (Duren,
DE) ; Huser, Martin; (Duren, DE) |
Correspondence
Address: |
BERENATO, WHITE & STAVISH, LLC
6550 ROCK SPRING DRIVE
SUITE 240
BETHESDA
MD
20817
US
|
Family ID: |
34925386 |
Appl. No.: |
11/155111 |
Filed: |
June 17, 2005 |
Current U.S.
Class: |
181/293 ;
181/290 |
Current CPC
Class: |
E04B 2001/8466 20130101;
B32B 2307/7246 20130101; E04F 15/20 20130101; E04F 15/206 20130101;
E04F 13/00 20130101; B32B 5/18 20130101; B32B 2307/10 20130101;
B32B 2307/7265 20130101; B32B 2471/00 20130101; B32B 3/26 20130101;
E04F 15/185 20130101 |
Class at
Publication: |
181/293 ;
181/290 |
International
Class: |
E04B 001/82; E04B
002/02 |
Foreign Application Data
Date |
Code |
Application Number |
Jun 17, 2004 |
EP |
04 014 185.5 |
Claims
1. A sound-absorbing device (1, 6, 10, 33) for a wall covering,
ceiling covering, or floor covering (31), having a support (2, 7,
11, 15, 34, 37) that comprises at least one sound-absorbing layer
(3, 8, 12, 17, 36) made of polymer foam, which layer constitutes a
plurality of protrusions (4, 9, 13, 18-21, 35), wherein the
protrusions (4, 9, 13, 18-21, 35) are arranged with a distribution
such that a straight line that is continuous over the surface of
the support (2, 7, 11, 15, 34, 37) is not projectable through the
interstices.
2. The sound-absorbing device as defined in claim 1, wherein the
protrusions are embodied in point-like fashion.
3. The sound-absorbing device as defined in claim 2, wherein the
protrusions constitute circular or polygonal surfaces.
4. The sound-absorbing device as defined in claim 1, wherein the
protrusions are embodied as ridges (4, 9, 13, 18-21, 35).
5. The sound-absorbing device as defined in claim 4, wherein ridges
(4, 9, 13, 18-21, 35) proceed in a direction-changing fashion.
6. The sound-absorbing device as defined in claim 5, wherein ridges
(4, 9, 13, 18-21, 35) are continuous.
7. The sound-absorbing device as defined in claim 5, wherein all
the ridges (4, 9, 13, 18-21, 35) proceed in a direction-changing
fashion.
8. The sound-absorbing device as defined in claim 5, wherein ridges
are present that proceed in different direction-changing
fashions.
9. The sound-absorbing device as defined in claim 5, wherein ridges
(4, 9, 13, 18-21, 35) are present that proceed parallel to one
another in a direction-changing fashion.
10. The sound-absorbing device as defined in claim 5, wherein
ridges (4, 9, 13, 18-21, 35) proceed in a direction-changing
fashion in repeating patterns.
11. The sound-absorbing device as defined in claim 5, wherein
ridges proceed irregularly in a direction-changing fashion.
12. The sound-absorbing device as defined in claim 5, wherein the
ridges do not intersect one another.
13. The sound-absorbing device as defined in claim 5, wherein
multiple ridges respectively form ridge groups that proceed in
different fashions.
14. The sound-absorbing device as defined in claim 5, wherein
ridges (4, 9, 13) proceed in the shape of a wave or meander.
15. The sound-absorbing device as defined in claim 5, wherein
ridges (18-21) proceed in closed patterns.
16. The sound-absorbing device as defined in claim 15, wherein
ridges (18-21) proceed so as to form circles, spirals, or
polygons.
17. The sound-absorbing device as defined in claim 5, wherein the
cross section of the protrusions (4, 9, 13, 18-21, 35) can be
curved, rectangular, triangular, lenticular, or trapezoidal.
18. The sound-absorbing device as defined in claim 1, wherein the
protrusions (4, 9, 13, 18-21, 35) have a height of 0.1 to 8 mm,
preferably 0.5 to 6 mm.
19. The sound-absorbing device as defined in claim 1, wherein
protrusions (4, 9, 13, 18-21) of different heights are present.
20. The sound-absorbing device as defined in claim 1, wherein the
protrusions (4, 9, 13, 18-21, 35) have a base width of 5 to 20 mm,
preferably 8 to 12 mm.
21. The sound-absorbing device as defined in claim 1, wherein the
spacing of the protrusions (4, 9, 13, 18-21, 35) ranges from 0 to
10 mm.
22. The sound-absorbing device as defined in claim 1, wherein the
surface coverage of the protrusions (4, 9, 13, 18-21, 35) at the
base of the ridges ranges from 60 to 100%.
23. The sound-absorbing device as defined in claim 1, wherein the
protrusions (4, 9, 13, 18-21, 35) are made of polyurethane,
polystyrene, polyether, or silicone elastomer.
24. The sound-absorbing device as defined in claim 1, wherein the
polymer foam has a density of 0.2 to 2.5 kg/m.sup.3, preferably 0.5
to 1.5 kg/m.sup.3.
25. The sound-absorbing device as defined in claim 1, wherein the
polymer foam has a Shore A hardness of 20 to 70, preferably 30 to
50.
26. The sound-absorbing device as defined in claims 1, wherein the
polymer foam has a water uptake of less than 2%.
27. The sound-absorbing device as defined in claim 1, wherein the
support is embodied as at least one continuous, embossed, or
perforated support film (2, 7, 11, 15, 34).
28. The sound-absorbing device as defined in claim 27, wherein the
support film (2, 7, 11, 15, 34, 37) is made from paper, paperboard,
board, plastic, or metal, or combinations thereof.
29. The sound-absorbing device as defined in claim 27, wherein the
support film (2, 7, 11, 15, 34, 37) is embodied as a vapor barrier
or liquid barrier.
30. The sound-absorbing device as defined in claim 27, wherein the
support film (2, 7, 11, 15, 34, 37) is assembled from film layers
of different materials.
31. The sound-absorbing device as defined in claim 27, wherein the
sound-absorbing layer (36) is enclosed between two support films
(34, 37).
32. The sound-absorbing device as defined in claim 27, wherein the
support film(s) (2, 7, 11, 15, 34, 37) has or have a weight of
between 20 and 200 g/m.sup.2, preferably 35 and 100 g/m.sup.2.
33. The sound-absorbing device as defined in claim 27, wherein the
support film(s) (2, 7, 11, 15, 34, 37) has or have a thickness of
between 10 and 500 .mu.m.
34. The sound-absorbing device as defined in claim 1, wherein the
support has a rigid or semirigid covering layer, or is constituted
thereby.
35. The sound-absorbing device as defined in claim 1, wherein the
support comprises at least one textile support material, or is
constituted thereby.
36. The sound-absorbing device as defined in claim 35, wherein the
textile support material is embodied as consolidated nonwoven
fabric, as spun-bonded fabric, woven fabric, knitted fabric, yarn
layers or yarn lattices, or as a combination thereof.
37. The sound-absorbing device as defined in claim 36, wherein the
nonwoven fabric is made of PE, PP, PET, PVAc, PVC, or similar
commodity plastics, or of glass.
38. The sound-absorbing device as defined in claim 37, wherein the
woven fabric, knitted fabric, yarn layer or yarn lattice is made of
PE, PP, PA, or PET, or glass.
39. The sound-absorbing device as defined in claim 36, wherein the
woven fabric, knitted fabric, yarn layer, or yarn lattice is made
of spun, texturized, multifilament, or monofilament yarns or
ribbons.
40. The sound-absorbing device as defined in claim 27, wherein the
support comprises a combination of support film and textile support
material.
41. A floor covering or wall covering (31) having a covering layer
(32), and having a sound-absorbing device (33) as defined in claim
1.
42. The floor covering or wall covering as defined in claim 41,
wherein the sound-absorbing device (33) rests loosely against the
underside of the covering layer (32).
43. The floor covering or wall covering as defined in claim 41,
wherein the sound-absorbing device (33) is joined to the underside
of the covering layer (32).
44. The floor covering or wall covering as defined in claim 41,
wherein the covering layer is embodied as a panel (32) or as a
plastic web.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS AND CLAIM PRIORITY
[0001] This application is based upon application number 04 014
185.5, filed Jun. 17, 2004 with the European Patent Office, the
disclosure of which is incorporated herein by reference and to
which priority is claimed.
FIELD OF THE INVENTION
[0002] The invention concerns a sound-absorbing device for a wall
covering, ceiling covering, or floor covering, having a support
that comprises at least one sound-absorbing layer made of polymer
foam, which layer constitutes a plurality of protrusions so as to
form interstices between the protrusions. The invention further
concerns a wall covering or floor covering that is equipped with
the aforesaid sound-absorbing device.
BACKGROUND OF THE INVENTION
[0003] In order to improve sound absorption, in particular footstep
sound absorption for floor panels, it is known to equip a panel on
the rear side, which is intended for placement onto the floor or
wall, with a sound-absorbing device that comprises a
sound-absorbing layer. Cork plies, polymer foams, elastomers, or
the like have been proposed as sound-absorbing layers (cf. WO
02/053858). The sound-absorbing layer can be immovably joined to
the panel, or can be inserted loosely between the panel and the
floor or wall. The sound-absorbing layer can also be combined with
further layers.
[0004] JP 112 56 802 discloses a plate having a sound-absorbing
layer made of a plastic foam. GB 1 103 895 A indicates a plate in
which the sound-absorbing layer is made of a multi-layer plastic
network. JP 7 102 744 discloses a plate having a sound-absorbing
layer that constitutes a plurality of downwardly projecting
semicircular ridges. A sound-absorbing layer of this kind is also
evident from JP 2 001 050 551 A, the sound-absorbing layer being
made of a rigid plastic foam that is covered on the underside with
an additional layer.
[0005] DE-A-26 59 551 discloses a sound-absorbing device having a
sound-absorbing layer that is made of foamed material, which layer
constitutes a lattice made up of foamed material mullions with
closed orifices. Production of such a lattice is, however,
relatively complicated. EP 1 209 301 A2 presents a sound-absorbing
device in which a sound-absorbing layer made of polymer foam is
applied onto a support, the sound-absorbing layer being formed from
a plurality of protrusions that are spaced apart from one another
so as to form interstices. The protrusions are embodied as
continuous or interrupted ridges, or as point-like protrusions. The
interstices between the protrusions are sufficiently large that
straight lines continuing over the surface of the support can be
projected through them.
[0006] The previously known sound-absorbing devices bring about a
sound absorption that is not entirely satisfactory. It is therefore
the object of the present invention to create a sound-absorbing
device for a wall covering or floor covering that brings about
improved sound absorption.
SUMMARY OF THE INVENTION
[0007] According to the present invention, this object is achieved
in that the protrusions are arranged with a distribution such that
a straight line that is continuous over the surface of the support
is not projectable through the interstices. Experiments have
indicated that the radial propagation of sound as a result of the
impact of, for example, a foot on the covering is substantially
reduced, and sound absorption accordingly is considerably improved.
Because the sound waves cannot propagate linearly in any direction
without encountering protrusions of the sound-absorbing layer, they
are intercepted after a short distance, with the consequence that
sound absorption is particularly effective. The sound-absorbing
device is characterized by ease of manufacture, for example by
extrusion of the protrusions.
[0008] The protrusions can be embodied in point-like fashion, and
can constitute circular or polygonal surfaces. Embodiment of the
protrusions as ridges is particularly useful, the ridges proceeding
in a direction-changing fashion. They can be interrupted, but also
continuous.
[0009] An improvement in sound absorption is already achieved even
if only some of the ridges proceed in a direction-changing fashion,
but other ridges proceed in a straight line. It is preferred,
however, for all of the ridges to proceed in a direction-changing
fashion. The ridges can also proceed in different
direction-changing fashions, so that a tangled structure is
achieved. As an alternative thereto or in combination therewith,
ridges can also be present that proceed parallel to one another in
a direction-changing fashion. This can also be the case for all the
ridges.
[0010] According to a further embodiment of the invention,
provision is made for ridges to proceed in a direction-changing
fashion in repeating patterns. As an alternative thereto or in
combination therewith, ridges can be provided that proceed
irregularly, in which context the ridges can also intersect one
another. Multiple ridges can form ridge groups that proceed in
different fashions.
[0011] Concretely, ridges can proceed, individually or in groups,
in the shape of a wave, zigzag, or meander. As an alternative
thereto or in combination therewith, ridges can also proceed in
closed patterns, for example so as to form circles, spirals, or
polygons, which also include triangles and rectangles. It is
understood that the various embodiments of the ridge paths can also
be combined with one another, i.e. wave-shaped, zigzag-shaped,
meander-shaped, and/or closed patterns.
[0012] The protrusions should have a height of 0.1 to 8 mm,
preferably 0.5 to 6 mm; the base width should be between 5 and 20
mm, preferably 8 mm to 12 mm. At the base, the spacing of the
protrusions should be from 0 to a maximum of 10 mm. The protrusions
can have any desired cross sections. For example, the protrusions
can also have a rectangular shape. Preferably, however, they should
taper, for example in a curved, triangular, or trapezoidal shape.
The surface coverage of the protrusions at the base should be
between 60 and 100%.
[0013] Viscoelastic foams made, for example, of polyurethane,
polystyrene, polyether, or silicone elastomer, are suitable as the
material for the protrusions. The foam should have a density of 0.2
to 2.5 kg/m.sup.3, preferably 0.5 to 1.5 kg/m.sup.3. The Shore A
hardness should be between 20 and 70, preferably between 30 and 50.
Water uptake should be less than 2%, preferably tending toward
zero.
[0014] The support for the sound-absorbing layer can be embodied,
for example, as at least one support film. This can be made from
paper, paperboard, board, plastic such as, for example, PE, PET,
PP, or PA, or metal such as, for example, aluminum, tin, and/or
copper, or combinations thereof. The support film can also be
assembled from film layers of different materials. If more than one
support film is provided, it may be useful to enclose the
sound-absorbing layer between two support films. The support film
can also be embodied as a vapor barrier or liquid barrier.
[0015] The support film(s) should have a weight of between 20 and
200 g/m.sup.3, preferably 35 to 100 g/m.sup.3. The thickness can be
between 10 and 500 .mu.m.
[0016] As an alternative thereto, provision can be made for the
support to have a rigid or semirigid covering layer, or to be
constituted thereby. The combination of sound-absorbing layer and
covering layer can simultaneously constitute the wall covering or
floor covering.
[0017] The support can, however, also comprise at least one textile
support material, or be constituted thereof. Suitable for this, for
example, are consolidated nonwoven fabric, spun-bonded fabric,
woven fabric, knitted fabric, yarn layers or yarn lattices, or
combinations of these materials. Commodity plastics such as PE, PP,
PET, PVAc, or PVC, or also glass, can be used for the nonwoven
fabric. If a woven fabric, knitted fabric, yarn layer or yarn
lattice is used, PE, PP, PA, or PET, or glass, is suitable. These
materials can be made of spun, texturized, multifilament, or
monofilament yarns or ribbons.
[0018] Also part of the invention is a floor covering or wall
covering having a covering layer as well as a sound-absorbing
device as described in detail above. The sound-absorbing device can
rest loosely against the underside of the covering layer, or can be
joined to it, for example by adhesive bonding. The covering layer
can be embodied as a panel or as a plastic web.
[0019] The sound-absorbing device according to the present
invention can be manufactured in such a way that the
sound-absorbing layer is applied onto the support by means of
nozzles. As an alternative thereto, however, the sound-absorbing
layer can also be configured so that firstly a foam layer is
applied in planar fashion onto the support, and then the
not-yet-cured foam is embossed with a negative die, preferably so
that compressed zones are created in the valleys between the
protrusions. This can also be assisted by the fact that the
embossing takes place at elevated temperatures, so that the foam
melts together in the valleys and thereby becomes even further
compressed.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] The invention is illustrated in more detail, with reference
to several schematically depicted exemplifying embodiments, in the
drawings, in which:
[0021] FIG. 1 is a plan view of a sound-absorbing device having
wave-shaped ridges;
[0022] FIG. 2 is a plan view of a second sound-absorbing device
having ridges proceeding in zigzag fashion;
[0023] FIG. 3 is a plan view of a third sound-absorbing device
having ridges proceeding in trapezoidal fashion;
[0024] FIG. 4 is a plan view of a sound-absorbing device having
groups of concentrically arranged ridges;
[0025] FIG. 5 is a perspective plan view of the sound-absorbing
device according to FIG. 2; and
[0026] FIGS. 6 to 9 are cross-sections through panels having
sound-absorbing devices that comprise ridges of various cross
sections.
DESCRIPTION OF THE PREFERRED EMBODIMENT(S)
[0027] The exemplifying embodiment according to FIG. 1 shows a
sound-absorbing device 1 that comprises a support film 2 having a
sound-absorbing layer 3 applied thereonto. Sound-absorbing layer 3
is constituted by ridges (labeled 4 by way of example) that follow
a wave-shaped path, such that ridges 4 proceed substantially
parallel to one another. The path of each ridge 4 is respectively
symbolized by a line. The spacing of ridges 4 from one another is
so close that interstices (labeled 5 by way of example) into which
a continuous straight line cannot be projected are formed. In this
fashion, the sound waves moving out from a point encounter ridges 4
after only a short distance, i.e. cannot propagate over the entire
surface of sound-absorbing device 1, but instead are broken up in
each case by the particular shape and arrangement of ridges 4.
[0028] FIG. 2 shows a second sound-absorbing device 6 having a
support film 7 and a sound-absorbing layer 8 applied thereonto. The
latter is constituted by ridges (labeled 9 by way of example) that
in this instance proceed in zigzag fashion but otherwise parallel
to one another. Here as well, the path of each ridge 9 is
respectively symbolized by a line. In this sound-absorbing device
6, the spacing of ridges 9 from one another is likewise so small
that a straight line continuing over the surface of sound-absorbing
layer 6 could not be projected into the interstices between ridges
9.
[0029] FIG. 3 depicts a further sound-absorbing device 10 in which
a sound-absorbing layer 12, comprising ridges (labeled 13 by way of
example) proceeding back and forth in trapezoidal fashion, is
present on a support film 11. Ridges 13 are once again symbolized
by lines. They extend parallel to one another and have such a small
spacing that a continuous straight line could not be placed into
the interstices.
[0030] FIG. 4 shows a sound-absorbing device 14. In this
sound-absorbing device 14, circle groups (labeled 16 by way of
example) separated from one another, which are arranged in offset
rows one behind another and together form a sound-absorbing layer
17, are applied onto a support film 15. Each circle group 16
comprises one central point-like ridge 18 as well as ridges 19, 20,
21 concentric therewith.
[0031] The interstices between ridges 18, 19, 20, 21 form closed
rings. Circle groups 16 are offset from one another in such a way
that a straight line continuing over the surface of sound-absorbing
device 14 could not be projected into the interstices between
circle groups 16.
[0032] FIGS. 6 through 9 depict examples of various ridge cross
section shapes, identical or identically functioning parts being
labeled with the same reference numbers. Floor coverings 31, each
comprising a wood panel 32 and a sound-absorbing device (labeled 33
in its entirety) that is adhesively bonded onto the underside of
the respective wood panel 32, are depicted in cross section. Each
sound-absorbing device 33 has on the panel side a support film 34
whose underside is equipped with ridges (labeled 35 by way of
example). Ridges 35 in each case form a sound-absorbing layer
36.
[0033] In FIG. 6, ridges 35 have a semicircular cross section, in
FIG. 7 a triangular cross section, in FIG. 8 a trapezoidal cross
section, and in FIG. 9 a lenticular cross section. In the example
depicted in FIG. 9, ridges 35 are covered with an external film 37,
so that sound-absorbing layer 36 and its ridges 35 are enclosed by
support film 34 on one side and by external film 37 on the other
side.
* * * * *