EP-4739501-A1 - SOUNDPROOFING MEMBRANE

Abstract

A sound reduction membrane and a composite that includes a sound reduction material or equivalent and the membrane laminated as a composite face structure to the sound reduction material. The composite face structure includes an outer fabric layer, a central film layer, and an inner adhesive layer, wherein the central film layer and the inner adhesive layer include distinct materials having distinct properties. The composite face structure is thermally laminated to one side of the sound reduction material along the inner adhesive layer.

Inventors

• RANCICH, MICHAEL JOSEPH
• JOHNSON, Taylor Kelly

Assignees

• Illinois Tool Works Inc.

Dates

Publication Date

20260513

Application Date

20240627

Claims (20)

1. 1. In a sound reduction covering having a sound reduction material, the improvement comprising a multilayer composition including an outer fabric layer, a central film layer, and an inner adhesive layer, the adhesive layer configured to adhere the multilayer composition to the sound reduction material, thereby incorporating mechanical strength and barrier properties to the sound reduction material.
2. 2. In the sound reduction covering of Claim 1, wherein each layer of the multilayer composition is extrusion or adhesive laminated or extrusion coated to an adjacent layer.
3. 3. In the sound reduction covering of Claim 1, wherein the adhesive layer is extrusion coated into a unitary film with the central film layer.
4. 4. In the sound reduction covering of Claim 1, wherein the outer fabric layer is approximately 0.5 to 2 oz/yd 2 , preferably about 0.9 oz/yd 2 .
5. 5. In the sound reduction layer of Claim 1, wherein the central film layer is a strength layer comprising a cross-laminated film.
6. 6. In the sound reduction covering of Claim 1, wherein the central film layer comprises a high-density polyethylene film imparting properties of strength, liquid water and water vapor barrier, and crack isolation.
7. 7. In the sound reduction covering of Claim 1, wherein the adhesive layer comprises an inner copolymer layer adapted for thermal lamination to the sound reduction material.
8. 8. In the sound reduction covering of Claim 7, wherein the inner copolymer layer comprises an ethylene methyl acrylate (EMA) copolymer having an acrylate content of around 20%.
9. 9. In the sound reduction covering of Claim 7, wherein the inner copolymer layer has a thickness of about 0.5 mil to 2.0 mil, and preferably about 1.0 mil.
10. 10. In the sound reduction covering of Claim 1, further comprising a homopolymer or copolymer layer positioned between the central film layer and the outer nonwoven fabric layer.
11. 11. A moisture resistant sound reduction composite, comprising: a sound reduction material; a multilayer face structure laminated to a surface of the sound reduction material, the multilayer face structure including: an outer fabric layer, preferably an outer non-woven fabric layer; a central film layer; and an inner adhesive layer, wherein the central film layer and the inner adhesive layer comprise distinct materials having distinct properties; and wherein the composite face structure is laminated to the surface of the sound reduction material along the inner adhesive layer.
12. 12. The sound reduction composite of Claim 11, wherein the sound reduction material comprises rolls, panels or sheets formed of rubber, foam, cork, or open cell insulation.
13. 13. The sound reduction composite of Claim 11, wherein each layer of the multilayer face structure is laminated or extrusion coated to an adjacent layer.
14. 14. The sound reduction composite of Claim 11, wherein the inner adhesive layer is extrusion coated into a unitary film with the central film layer.
15. 15. The sound reduction composite of Claim 11, wherein the outer nonwoven fabric layer is approximately 0.5 to 2 oz/yd 2 , preferably about 0.9 oz/yd 2 .
16. 16. The sound reduction composite of Claim 11, wherein the central film layer is a strength layer comprising a cross-laminated film.
17. 17. The sound reduction composite of Claim 16, wherein the central film layer comprises a high-density polyethylene film imparting strength, liquid water and water vapor barrier, and crack isolation properties.
18. 18. The sound reduction composite of Claim 11, wherein the inner adhesive layer comprises an ethylene methyl acrylate (EMA) copolymer having an acrylate content of around 20%.
19. 19. The sound reduction composite of Claim 18, wherein the inner adhesive layer has a thickness of about 0.5 mil to 2.0 mil, and preferably about 1.0 mil.
20. 20. A method of imparting structural and barrier properties to a sound reduction roll, panel or sheet, the method comprising thermal laminating an independent and unitary multilayer composition to a separate sound reduction roll, panel or sheet, the multilayer composition including an outer fabric layer, preferably a nonwoven fabric layer, a central film layer, and preferably an inner adhesive layer, the adhesive layer configured to adhere the multilayer composition to the sound reduction roll, panel or sheet, thereby incorporating mechanical strength and barrier properties to the sound reduction roll, panel or sheet.

Description

SOUNDPROOFING MEMBRANE BACKGROUND OF THE INVENTION FIELD OF THE INVENTION This invention relates generally to a sound reduction membrane and composite particularly suited for soundproofing floors or other surfaces while providing enhanced tile adhesion, liquid water, and water vapor barrier, and/or crack isolation. DESCRIPTION OF PRIOR ART Currently, where there is a need for sound reduction as well as water vapor barrier and/or surface crack isolation, a separate material layer for each function is applied at the installation site. Therefore, there exists a need for a sound reduction material that adds relatively little additional weight to materials and installations, is easy to transport, handle and install, and provides the benefits of water- or water vapor-proofing and crack isolation, as well as providing for tile adhesion useful for further top-surface installation. SUMMARY OF THE INVENTION The present invention is directed to a structural membrane for use in sound reduction installations, and a sound reduction roll, panel or sheet including the membrane. The unitary membrane composition of this invention generally includes a strong film layer to provide structural crack isolation and/or high barrier to liquid and gaseous water penetration, all with less installation steps as compared to the prior art. As used herein “sound reduction” or “soundproofing” generally refers to preventing, either partially or fully, sound transmission, such as by sound dampening, sound absorption, sound deflection, or other means. The invention includes a multilayer membrane composition for use in a sound reduction composite having a sound reduction material. The multilayer membrane composition of embodiments of this invention includes an outer fabric layer, preferably a nonwoven fabric, a central film layer, and preferably an inner adhesive layer. The adhesive layer is configured to adhere (e.g., by thermal laminating) the multilayer composition to the sound reduction material to incorporate mechanical strength and barrier properties to the sound reduction material. The membrane is useful in sound reduction installations for floors or other surfaces, while also providing enhanced surface/decorative cladding (e.g., tile) adhesion, liquid water and water vapor barrier, and crack isolation or bridging (e.g., covering and preventing propagation of existing or future subfloor cracks into the floor covering). These improvements are provided by a unitary multilayer membrane lamination composition incorporating a structural fdm such as a VALERON® fdm, which can be thermally laminated or otherwise adhered to a crumb rubber or other sound reduction material to form a sound reduction composite. This saves the installer time as multiple material layer installations are not required. The sound reduction composite including the multilayer membrane would, for example, typically be bonded to the floor of a multi-story building with adhesive. The finished (upper) floor covering can be bonded to the fabric surface of the membrane with additional application of a suitable adhesive (e.g., thin set adhesive in the case of tile). In some instances, when the water and water vapor barrier is needed closer to the concrete subfloor, the sound reduction composite can be installed with the nonwoven to the surface and the sound reduction material up. While this may reduce the performance of the product somewhat, it will still provide effective soundproofing, water and water vapor barrier and crack isolation. A membrane of this invention can also be adhered to both sides of the sound reduction material. A preferred version of the membrane contains a thermal laminating layer as the adhesive layer, but other methods of laminating to the sound reduction material can be used, such as laminating and pressure sensitive adhesives. The multilayer membrane can also be installed to the sound reduction material in the field, but this eliminates some of the saved installation time. A potential benefit of the sound reduction membrane is that it prevents penetration of the adhesive used to bond the flooring material into the top surface of the sound reduction material. In porous materials this is believed to improve the sound reduction performance of the installation. The invention further includes a moisture resistant sound reduction composite. The composite includes a multilayer face structure laminated to a surface of a sound reduction material. The multilayer face structure includes an outer fabric layer, a central film layer, and an inner adhesive layer. The central film layer and the inner adhesive layer are distinct materials having distinct properties. The composite face structure is laminated to the surface of the sound reduction material along the inner adhesive layer. The invention further includes a method of imparting structural (e.g., crack isolation) and barrier properties to a sound reduction roll, panel or sheet. The method includes a step of