JP2007224704A - Indoor building material with carpet layer and functional layer - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide an indoor building material having a carpet layer and a functional layer, specifically the indoor building material having the carpet layer and the further functional layer for maintaining comfortable indoor environment. <P>SOLUTION: The indoor building material comprises the carpet layer formed of a nylon 6, nylon 66, acrylic, PP, PTT or PET material; a coating layer comprising a composition having predetermined functions; a sound absorbing layer connected to the carpet layer; and an adhesive layer for connecting the carpet layer to the sound absorbing layer. The effective surface area of the carpet layer per 1 m<SP>2</SP>is 20-150 m<SP>2</SP>. <P>COPYRIGHT: (C)2007,JPO&INPIT

Description

  The present invention relates to an indoor building material having a carpet layer and a functional layer, and more particularly, to an indoor building material having a carpet layer and an additional functional layer for maintaining a comfortable indoor environment.

  Wall, ceiling and floor materials require robustness and functionality. Robustness refers to the ability to maintain a required shape for a period of time while forming a structure with one material together with another material. And functionality is calculated | required in order to improve the usefulness of an internal environment by the space where a raw material is used. Usually, the material for rigidity is limited, and diversity is not required in that it is not exposed to the outside, so the necessity for selection is not high. However, a material for functionality can be changed depending on a required function, and high selectivity is required due to a difference in effect due to the material.

  Functions generally required for wall, ceiling and floor materials are sound absorption, heat insulation, flame retardancy or flameproofing. In addition, antibacterial or deodorizing and decorative properties may be required depending on the intended use of the space.

  Sound absorption means that part of the sound incident on the material is absorbed in the material without being transmitted or reflected. When sound is generated on one side of the material, the sound that is not reflected corresponds to the sound that is absorbed or transmitted by the material. Since such non-reflected sound appears as if it was all absorbed, it has an apparent absorptance, and the ratio of the sound energy that appears as if it was absorbed to the incident sound energy is called the sound absorption ratio.

  In addition to sound absorption and vibration absorption functions, interior building materials must have other additional functions. Such additional functions are required for space efficiency, for example, such functions include antibacterial, deodorant, flame retardant and prevention of harmful gas generation that causes sick house syndrome. Such functions added to building materials are becoming essential functions as new building materials are developed.

  As a method for forming a functional layer on a material for indoor building, there are a method of applying a coating agent and a method of adding a substance having a necessary function in the form of a composition. As an alternative, there is a method in which two methods are mixed and a functional material is added to the adhesive or coating agent to coat the wall material.

  As a prior art related to a building material having functionality, there is “Patent Finishing Material Using Ceramic Composite and Manufacturing Method Thereof” of Patent Document 1. The object of the present invention is to generate anions, reduce heating and cooling costs, neutralize toxicity and antibacterial, insectproof, and soundproofing. And the building finishing material by this invention contains the silica bead which formed the fine hollow part in the body, and the composite ceramic mixed with the said hollow part silica bead by predetermined | prescribed volume ratio.

  As another prior art related to a functional building material, there is Patent Document 2 “Functional member, method for manufacturing the same and coating liquid”. An object of the present invention is to provide a functional member that is excellent in humidity control function, function of removing toxic chemicals and unpleasant living odors, antifouling properties, contamination concealment and flammability. The functional member according to the present invention includes a first layer formed on a combustible substrate and including a building including an inorganic porous body and an organic emulsion, and an almost entire surface of the first layer by an organic adhesive. A second layer comprising an inorganic filler that is fixed over is provided, wherein the glass transition temperature of the glass material in the organic emulsion is -5 ° C to -50 ° C, and the organic adhesive in the second layer is The amount is 30 to 300 parts by weight with respect to 100 parts by weight of the inorganic filler.

The above-mentioned prior invention and the known invention propose a method in which necessary additional functions are added separately from the functions of sound absorption and vibration absorption. However, the indoor building material must be formed so that an additional function can be expressed in combination with the basic functions that the indoor building material should have, such as sound absorption and vibration absorption. Therefore, there is a need to develop an indoor building material that can basically exhibit additional functions while having functions of sound absorption and vibration absorption. The present invention is for solving such problems and has the following objects. In this specification, the sound absorbing layer means a layer having a function of absorbing not only sound but also any wave generated by vibration or impact.
Korean Patent Application No. 10-2002-0084252 WO2004 / 085151

  An object of the present invention is to provide an indoor building material having a carpet layer as a sound absorbing material and a functional layer that further exhibits a necessary function.

  The interior building material according to the present invention includes a carpet layer, a synthetic resin adhesive layer, a functional layer formed integrally with the adhesive layer, or a separated layer, and a sound absorbing layer. Furthermore, the sound absorbing layer can include a rubber layer or a felt layer for further vibration prevention.

  According to a suitable embodiment of the present invention, a sound-absorbing material according to the present invention comprises a carpet layer comprising a pile and a base fabric having a curved surface and a coating layer comprising a composition having a certain function, An adhesive layer made of a synthetic resin, a sound absorbing layer, and a dustproof layer made of an elastic material can be included.

  According to another suitable embodiment of the invention, the pile having a constant bent surface is any selected from the group consisting of nylon 6, nylon 66, acrylic, polypropylene, polytrimethylene terephthalate and polyethylene terephthalate fibers. It is preferable that it is one.

  According to still another suitable embodiment of the present invention, the sound absorbing layer may include a rubber layer for preventing further vibration, or a felt layer.

  According to still another suitable embodiment of the present invention, the sound absorbing layer may be any one selected from the group consisting of melamine foam, urethane foam, non-woven fabric, and rock wool.

  According to still another suitable embodiment of the present invention, the coating layer is treated with respective agents for imparting flame retardant, antibacterial, antifouling, deodorizing, and tick-proofing effects alone or in combination. , To show one or more functionalities.

  According to still another suitable embodiment of the present invention, the adhesive layer is formed of any one selected from the group consisting of an acrylic resin, a polyurethane resin, a polyolefin-based resin, and a low melting point polyester (PET) resin. be able to.

According to still another suitable embodiment of the present invention, the effective surface area of the carpet layer per 1 m ² can be ²⁰ to 150 m ² in the material.

  According to still another suitable embodiment of the present invention, the thickness of the carpet layer, the adhesive layer and the sound absorbing layer can be 2 to 20 mm, 1 to 6 mm and 10 to 50 mm, respectively.

  According to still another suitable embodiment of the present invention, a wall surface material including the material can be provided.

  In the present invention, a carpet layer having a large apparent area is formed, and a functional layer is formed below, so that the sound absorption and vibration or noise absorption are excellent, and the necessary function of the functional layer can be easily expressed. Have. The indoor building material according to the present invention having such advantages can be used not only as a wall surface material, a ceiling material, and a floor material, but also as partition materials in various forms.

  DESCRIPTION OF THE PREFERRED EMBODIMENTS The best mode for realizing the present invention will be described below with reference to the drawings.

  FIG. 1 shows a cross-sectional view of an embodiment of a sound absorbing material 20 that is a functional material for indoor building according to the present invention.

  Referring to FIG. 1, a sound absorbing material 20 includes a carpet layer 21, a coating layer including a composition having functions such as antibacterial, flame retardant, and harmful substance removal, and an adhesive layer 22 made of a material such as a synthetic resin. The sound-absorbing layer 23 in the form of foam and, if necessary, a dust-proof layer 24 made of a dust-proof material such as rubber felt.

  In FIG. 1, a carpet layer 21 is composed of a pile 211 and a base fabric 212. The pile 211 in the carpet layer 21 is nylon 6, nylon 66, acrylic, polypropylene (PP), polytrimethylene terephthalate (PTT), or polyethylene. It can consist of bulky continuous filament (BCF) fibers of terephthalate (PET). Nylon BCF is characterized by excellent strength, wear resistance and elasticity, and excellent chemical resistance, resistance to microorganisms and electrical insulation. Unlike other fibers, PP BCF fibers are characterized by having a moisture content of 0 and an extremely low absorption rate. Such PP BCF fibers are characterized in that they do not generate static electricity due to their low absorption rate, and are excellent in stain resistance and antibacterial resistance. PET BCF fibers are characterized by good form safety and flame resistance. The carpet layer 21 of the sound-absorbing material 20 according to the present invention can be formed of commonly known carpets, but for each of the above advantages, nylon, acrylic, PP, PTT, or PET. It is preferably formed of fibers.

The bulky continuous filament (BCF) can be manufactured by any method known to those skilled in the art. Preferably, a number of BCF yarns are cable flammable and heat-set together and then woven as the primary back. Subsequently, a latex adhesive and a secondary back are applied. Cut pile style carpets having a pile height of about 2 to 20 mm or loop pile style carpets can be produced. At this time, the weight of the carpet is 400 to 4000 g / m ² .

  As a method for increasing the flame retardancy of the carpet of the present invention, a flame retardant can be added in a pre-coating or backing step.

  In the pre-coating process, SBR latex and calcium carbonate are mainly used. When manufacturing tile carpets, calcium carbonate is mainly used as a backing reinforcement together with PVC (polyvinyl chloride) or SBS (styrene-butadiene-styrene) resin. It can be substituted for an inorganic flame retardant to impart flame retardancy.

  The inorganic flame retardant is preferably a metal oxide such as magnesium hydroxide, aluminum hydroxide, or calcium hydroxide. The inorganic flame retardant can be added in a mixture of two or more.

  Aluminum hydroxide has the advantage of being relatively inexpensive compared to other inorganic flame retardants, but in order to ensure sufficient flame retardancy, it must be added in a considerably large amount, In the process, since a thin coating layer is formed as compared with the backing process, a large amount of the flame retardant cannot be used, and there is a limit to improving the flame retardancy.

  In the pre-coating or backing step, it is preferable to use 50 to 300 parts by weight of the metal hydroxide compound flame retardant for the flame retardant effect with respect to 100 parts by weight of SBS latex or PVC resin. If it is less than 50 parts by weight, the flame retardant effect is insufficient, and if it is 300 parts by weight or more, it cannot be applied due to a decrease in physical properties of the coating surface or backing surface.

  The particle size of the metal hydroxide compound flame retardant varies depending on the type of the flame retardant, but the average particle size of calcium carbonate, aluminum hydroxide and magnesium hydroxide is suitably 0.5 to 2.0 μm and has been developed recently. If a drug having a nano particle size is used, the dispersibility becomes better and the mixture is uniformly mixed, and the mechanical properties of the resin layer are hardly lowered, and a more preferable result can be obtained.

  The pile form of the carpet layer of the present invention is not particularly limited, and any form such as a cut pile and a loop pile may be used.

  Further, the carpet used for the carpet layer of the present invention may be used in a state where the lower surface of the base fabric is coated with latex for preventing pile removal, and may be used in a form in which backing is completed if necessary. The carpet layer 21 according to the present invention has an advantage that the sound absorbing effect is excellent because the surface area is much larger than the surface layer of a known wall surface material. The effective surface area can be the area of the part that reaches directly without reflection or scattering when light or sound is incident perpendicular to the material surface.

The specific surface area indicates the area per unit weight, but the effective surface area is related to the apparent surface area, and the sound absorbing performance of the sound absorbing product is more correlated with the effective surface area than the specific surface area. Such an effective surface area can have a larger value if the surface is not flat and has a bend. When the material surface is rough, it becomes difficult to measure the effective surface area substantially. Therefore, the effective surface area needs to be determined by a certain method in relation to the cross-sectional area of the material. The unit area of the sound absorbing layer means the unit area of a two-dimensional geometrical pseudo plane parallel to the sound absorbing layer. In the present invention, the surface area value of the fiber existing within the unit area 1 m ² of the sound absorbing layer is defined as the effective surface area (m ² ). The effective surface area of the carpet layer material used in the present invention is preferably ²⁰ to 150 m ² . If the effective surface area is less than 20 m ² , the sound absorption effect is small and unsuitable, and if it exceeds 150 m ² , there are excessively many fibers per unit area, or the pile length must be woven long, It is not preferable because the weight of the material becomes large and it is difficult to ensure light weight.

Sound absorption and light absorption are related to surface bending. The carpet layer 21 of the sound absorbing material 20 according to the present invention forms a curved surface with a constant surface. The bent surface is divided into a crest and a trough, and such crests and troughs are continuously arranged. The greater the difference in height between the crest and trough on the bent surface, the better the sound absorption effect. When a sound absorbing material having a carpet layer is applied to a wall or ceiling, the thickness of the carpet layer 21 is determined by comprehensively considering the weight of the product and the sound absorbing performance related to space occupancy and ease of installation. Must be limited or density limited. The carpet layer has a thickness of 2 to 20 mm, preferably 5 to 10 mm, and the carpet layer material has a density of 50 to 300 kg / m ³ . If the thickness or density of the carpet is less than the set range, the sound absorbing function is insufficient, and if it exceeds the set range, the space will occupy a large space, making it difficult to secure light weight and making construction difficult. .

  In the sound absorbing material 20 according to the present invention, the carpet layer 21 has a coating layer C exhibiting effects such as antifouling, removal of harmful components, deodorization, flame retardant, antibacterial, mite, electromagnetic wave absorption and anion, or ultraviolet emission. It can be formed on the surface of the pile 211 or on the surface of the base fabric 212, preferably on the top surface. These coating layers C can be coated on the carpet layer. As an alternative, a substance having the corresponding function may be added to the underside of the base fabric in the carpet manufacturing process for the carpet layer 21 as a method of mixing with the latex for preventing the pile from being removed, or mixed with the forming material of the adhesive layer 22. It can be formed by a method. Each functional agent for imparting such various effects is processed alone or in combination to exhibit one or more functionalities.

  As described above, when the adhesive layer 22 and the functional layer are manufactured integrally, water repellency, removal of harmful components, flame retardancy, color tone formation, antibacterial properties, electromagnetic wave shielding and anion, or ultraviolet light A substance having a release function is added to the adhesive in an appropriate ratio and mixed. If necessary, surfactants and dispersants can be added to the mixture. The adhesive mixed with such a functional substance is applied to the back surface of the carpet base fabric 212 to form an adhesive coating layer.

  Since the present invention forms a certain bent surface on the surface of the carpet layer 21, it has a feature that it has a large surface area as compared with a known finishing material of a building material. When the surface area of the external finishing material is increased, it is considerably advantageous from the viewpoint of functional release as the surface area of sound absorption, appearance formation, coating of antibacterial substances and harmful substance removing components increases. The coating layer of the pile or base fabric of the present invention is a layer that can exhibit other functions except for sound absorption and vibration prevention. Other functions can include antifouling, removal of harmful components, deodorization, flame retardant, antibacterial, anti-mite, electromagnetic wave absorption and anion, or ultraviolet emission functions.

  The adhesive layer 22 of the present invention can be formed of various types of known thermoplastic resins, such as those selected from acrylic resins, polyurethane resins, polyolefin resins, and low-melting point PET resins. Or, it can be applied to a hot melt film form. The carpet layer and the sound absorbing layer are heated and melted by spraying thermoplastic resin powder on one surface where the carpet layer and the sound absorbing layer are adhered, or by arranging the pellets at regular intervals or in the form of a hot melt film. Are made to adhere, pressurize, and stick. At this time, polyethylene, polypropylene, ethylene-vinyl acetate resin (EVA resin), etc. are used as the polyolefin resin used, and the hot melt film is a hot melt perforated at regular intervals for smooth sound absorption performance of the final product. It is preferable to use a film. Since the adhesive layer 22 is for bonding the carpet layer 21 and the sound absorbing layer 23, there is no particular limitation on the form and material. However, the smaller the thickness, the more advantageous, and it can be formed preferably with a thickness of 1 to 6 mm. Substantially direct contact between the carpet layer 21 and the sound absorbing layer 23 is advantageous for sound and vibration or shock absorption.

The sound-absorbing layer 23 of the present invention can be made of any known sound-absorbing and shock-absorbing material, but can preferably be formed of rock wool, urethane foam, melamine foam, felt, or nonwoven fabric. The sound absorbing layer 23 has a function of absorbing sound or absorbing shock and vibration. In effect, the sound can be partially absorbed by the carpet layer 21 and the rest can be removed by the sound absorbing layer 23. Similarly, a part of the shock and vibration absorption is removed by the carpet layer 21 and the remaining part is removed by the sound absorbing layer 23. Since the sound absorbing layer 23 forms the inner layer of the sound absorbing material 20, problems such as appearance or generation of fine substances do not occur. However, it must be formed in consideration of complete absorption of sound and shock, or complete interruption of transmission to the outside. Therefore, the sound absorbing layer 23 needs to have an appropriate thickness and strength. The sound absorbing layer 23 can be made sufficiently thicker than the carpet layer 21 and must be sufficiently small in strength. The thickness for sufficient absorption of sound or shock and vibration is 10 to 50 mm, preferably 20 to 30 mm, and the density of the sound absorbing layer is suitably 50 to 300 kg / m ³ . If the thickness and density of the sound-absorbing layer are less than the set range, the sound-absorbing function is insufficient. .

  If necessary, the present invention includes a dustproof layer 24 made of a dustproof material such as rubber felt.

<Physical property evaluation method>
1) Evaluation of effective surface area After the carpet layer is cut in an area of 0.01 m ² of 10 cm in width and length, the fiber existing on the upper stage of the base fabric is cut out so as to be as close as possible to the base fabric, and the weight ( g) is measured.

A specific surface area (m ² / g) was measured by a material adsorption method according to standard ASTM D3663-92 based on the BET (Brunauer-Emmett-Teller) method after taking a part of the machined fiber. the weight of fibers carved in .01M ² and (g), was determined effective surface area (m ²⁾ of surface area of the fibers present in 1 m ² is multiplied by 100.

The effective surface area of polyethylene terephthalate (PET) felt has a value of 1 per m ² because the surface is a two-dimensional plane without bending.

2) Evaluation of sound absorption coefficient When the energy of sound incident on the surface of the sound absorption material is Ei and the energy of sound reflected from the surface is Er, the sound absorption coefficient (α) is defined as follows.

  α = 1- (Er / Ei)

  The sound absorption coefficient is evaluated by the reverberation room method sound absorption coefficient measured in a reverberation room where conditions close to random incidence are realized according to the KS F 2805 standard. The sound absorption coefficient values are at center frequencies of 250, 500, 1000, and 2000 Hz. It was shown by the arithmetic mean value of the sound absorption coefficient.

3) Deodorization rate evaluation (gas detector tube method)
The conditions used in the experiment were evaluated by using a gas detector tube method that calculates the deodorization rate by analyzing the concentration of residual ammonia over time after each sample and a certain amount of ammonia were charged into the chamber. Is as follows.

Test piece: 10 × 10 cm ²
Test container: 2 liters Deodorization time: 60 minutes Charge: 4 μl of ammonia
Deodorization rate (%) = (Cb−Cs) / Cb × 100
Cb: Concentration of the test gas remaining after each lapse of time in the test vessel in which the test piece was not put Cs: Concentration of the test gas remaining after lapse of each time in the test vessel containing the test piece

4) Antibacterial degree evaluation It progressed based on the standard of the antibacterial test method of KS K 0823 carpet, and the bacteria reduction rate was shown in%.

  Test bacteria: Staphylococcus aureus, Neisseria pneumoniae

  1100 denier / 68 filament nylon BCF woven carpet in cut pile form is dyed with acid dye, and after drying, photocatalytic agent with deodorizing function (SLOST-250, Yenbi Korea, Titanium dioxide average particle size 10nm or less) in water The processing solution diluted 4 times was processed on the pile portion of the carpet by a spray method, dried at 120 ° C., and cured at 150 ° C. for 3 minutes to form a functional layer. And after back-coating with latex, it adhered to the secondary base fabric of PP material using PVC resin, and the backing was used as a carpet layer.

The backing carpet layer has a thickness of 9 mm and a density of 180 kg / m ³ .

As the sound absorbing layer, melamine foam having a thickness of 25 mm and a density of 12 kg / m ³ was used.

Adhesion between the carpet layer and the sound absorbing layer is achieved by spraying polyethylene powder on the back surface of the carpet layer at 400 g / m ² , heating with hot air at 150 ° C., melting, and then cooling and pressing rolls while layering the sound absorbing layer material. Pasted.

  Anti-bacterial finishing agent (EB54R, Inviti Inc., average particle size 20 nm) with antibacterial function is diluted to about 100 PPm in carpet woven in loop pile form with 2700 denier / 120 filament original PP BCF. The liquid was treated by a pad method and cured at 120 ° C. for 5 minutes to form a functional layer.

Then, after back coating with latex, a PVC resin was adhered to a secondary base fabric of PP material, and the backing was used as a carpet layer. The thickness of the backing carpet layer is 7 mm and the density is 140 kg / m ³ .

As the sound absorbing layer, a melamine foam having a thickness of 25 mm and a density of 12 kg / m ³ was used.

Adhesion between the carpet layer and the sound absorbing layer is achieved by spreading EVA powder on the back surface of the carpet layer at 100 g / m ² , heating it with 120 ° C hot air, melting it, and then stacking the sound absorbing layer material on the cooling pressure roll. Pasted.

Comparative Example 1

Functional layer application method using photocatalyst agent (SLOST-250, Yenbi Korea) as in Example 1 except that PET compression felt having a thickness of 10 mm and a density of 190 kg / m ³ is used instead of the carpet layer. Is produced in the same manner as in Example 1.

Comparative Example 2

A functional layer to which an antibacterial processing agent (EB54R, Inviti Co., Ltd.) is applied, except that a PET compression felt having a thickness of 10 mm and a density of 190 kg / m ³ is used instead of the carpet layer. The application method is the same as in Example 2.

  As can be seen from Table 1, in Example 1 of the present invention, the deodorization rate is excellent at 90% or more, and a sound absorbing material having an excellent sound absorption rate is obtained. In Example 2 of Table 2, the antibacterial degree is 99% or more. A sound absorbing material for indoor building having a carpet layer that is excellent and has a high sound absorption coefficient can be obtained.

  In comparison, Comparative Examples 1 and 2 use a PET compression felt on the surface instead of the carpet layer, and when the functional layer is applied to the surface, the carpet has a large effective surface area as well as lowering the sound absorption performance. Compared to the layer sound-absorbing material, the functional layer processing effect is also low.

  In the above, it explained in detail using the example which the present invention presents. The above embodiments are illustrative, and those having ordinary knowledge in this field can make various modifications and modified inventions to the above embodiments without departing from the technical idea of the present invention. Such variations and modifications do not limit the scope of the present invention.

It is a figure which shows sectional drawing with respect to embodiment of the raw material which concerns on this invention.

Explanation of symbols

  20: sound absorbing material for indoor building, 21: carpet layer, 22: adhesive layer, 23: sound absorbing layer, 24: dustproof layer, 211: pile, 212: base fabric.

Claims (7)

A sound absorbing material for indoor buildings,
A carpet layer composed of a pile and a base fabric, the surface of which has a certain bending surface;
A coating layer comprising a composition having a certain function;
An adhesive layer made of synthetic resin;
Including a sound absorbing layer,
In the material, sound absorbing material for interior architecture, wherein the effective surface area of 1 m ² per carpet layer is 20~150m ^2.   The material according to claim 1, wherein the coating layer is formed on a surface of a pile of a carpet layer or a surface of a base fabric.   The pile having a certain bent surface is formed of any one selected from the group consisting of nylon 6, nylon 66, acrylic, polypropylene, polytrimethylene terephthalate and polyethylene terephthalate fibers. The material according to claim 1.   The material according to claim 1, wherein the sound absorbing layer includes a rubber layer or a felt layer for further vibration prevention.   The material according to claim 1, wherein the adhesive layer is formed of any one selected from the group consisting of an acrylic resin, a polyurethane resin, a polyolefin resin, and a low-melting polyester (PET) resin.   The material according to claim 1, wherein the sound absorbing layer is formed of any one selected from the group consisting of rock wool, urethane foam, melamine foam, and nonwoven fabric. The wall surface material containing the raw material as described in any one of Claims 1-6.

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