JP2009215870A - Floor covering material having visco-elasticity relieving characteristic - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a carpet capable of providing high comfortableness when a person walks thereon but visco-elastically relieved to withstand a stress in use. <P>SOLUTION: A floor covering material comprises a first textile flat surface element 2 and a fist layer 1 at least partly joined to the surface of the first textile flat surface element 2. The first layer 1 is a floor covering such as a carpet including a visco-elastic polymer foam. The first textile flat surface element 2 has an elastic modulus of 0.5 to 2.5 N/mm<SP>2</SP>. The visco-elastic polymer foam in the firs layer 1 has a compressive load deformation when compressed 40% by a load of 1 to 10 kPa. The visco-elastic polymer foam in the first layer 1 has a hysteresis of 20 to 70% when the compressive load deformation when compressed 40% is determined. <P>COPYRIGHT: (C)2009,JPO&INPIT

Description

  The present invention includes a floor covering (1) comprising a first textile planar element and a first layer at least partially bonded to the first textile planar element on a surface thereof, the first layer comprising a viscoelastic polymer foam. floor covering). The floor finish may be, for example, a carpet. The invention further relates to a method for producing the floor covering.

  Carpets can be used in a variety of applications. In personal or commercial living spaces, carpets are used for decorative purposes, as well as for heat insulation and sound insulation. One possibility for making a carpet is to fix the fibers in the carpet backing and then back-foam the carpet backing on its back side.

It is generally known to line carpet lining with viscoelastic foam. In this regard, DE 33 13 624 A1 discloses a flexible polyurethane foam for soundproofing purposes, its production process and its use. The described soft polyurethane foam for soundproofing purposes with a density of less than 90 kg / m ³ and an elastic modulus of less than 106 N / m ² has a loss factor of at least 0.3 and a viscoelastic property in the temperature range of −20 ° C. to + 80 ° C. Have

  The flexible foam can be obtained by reacting the isocyanate with a polyol having at least one component having an OH number of 180-400. The foam is particularly suitable for absorbing and mitigating airborne sound and for mitigating solid transmission sound. According to this description, flexible polyurethane foam can be used to line and foam automobile cowl or floor carpet. In some embodiments, a specially manufactured carpet with a soundproof sheet was added to the foaming mold as needed to reach a sufficient foam density. After application of the normal separating agent, the reaction mixture was added and the mold cover was closed. After 2.5 to 3 minutes, the molded product could be taken out.

  DE 39 42 330 A1 is obtained per se a) ai) from water and glycerin or trimethylolpropane or using a starter mixture of average functionality 2.2 to 2.8 consisting of water, glycerin and trimethylolpropane A special block polyoxypropylene-polyoxyethylene polyol mixture having a hydroxyl number of 14 to 65 and a terminally linked ethylene oxide unit content of 2 to 9% by weight, and aii) the total weight of polymerizable alkylene oxide units with an oxyethylene unit content of A polyoxyalkylene polyol mixture comprising at least one difunctional or trifunctional polyoxypropylene polyoxyethylene polyol having a hydroxyl number of 20 to 80, based on 60 to 85% by weight, and b) required Low molecular weight depending on Reacting the chain extender with c) an organic and / or modified organic polyisocyanate in the presence of d) catalyst, e) blowing agent, f) adjuvant and / or additive and polyoxyalkylene polyol mixture (a). Discloses a method for producing a flexible polyurethane soft foam having viscoelastic and solid transmission sound relaxation characteristics in a temperature range of -20 ° C to + 80 ° C.

  The flexible polyurethane foams obtained by this method are used in interior areas, for example in carpet backing foam to mitigate footsteps, as interior backing and, for example, in motor room encapsulation or foam foam backing layers Therefore, it can be used in the automobile industry for reducing solid noise and for suppressing internal noise.

  Carpet linings used in the automotive area to mitigate noise are generally rigid structures because it has been found that it is not desirable to step into or sink into the carpet.

  There are several considerations in practical use of carpets having effective and therefore comfortable improving relaxation properties, including carpet backing lined with viscoelastic foam. If such a carpet is to be used as a floor covering that a person walks on and not only rests like in an automobile, the carpet must be suitable to withstand pressure and shear stress. In particular, carpet backing, carpet fiber and backing foam composites should not collapse.

  Finally, it can be understood that walking on a pure layer of viscoelastic foam that is thick enough to achieve a sufficient relaxation effect is not very comfortable. This may be due to the instability that occurs when the foot sinks into the foam after reaching the foam.

From the above it is clear that there is still a need for viscoelastically relaxed carpets that exhibit a high degree of comfort as people walk on them, but at the same time withstand the stress of use. .
DE 33 13 624 A1 DE 39 42 330 A1

  The present invention seeks to overcome at least one of the above disadvantages in the art. In particular, an object of the present invention is to provide the carpet.

  In accordance with the present invention, this object is a floor covering comprising a first textile planar element and a first layer at least partially bonded on the surface of the first textile planar element, the first layer being a viscous material. Achievable with floor coverings comprising elastic polymer foam.

Floor covering according to the invention, the first textile planar element has a 0.5 N / mm ² or more 2.5 N / mm ² modulus below, in the first layer, the viscoelastic polymer foam 1kPa than 10kPa or less In the first layer, the viscoelastic polymer foam has a hysteresis of 20% or more and 70% or less in determining the compression load deflection at 40% compression. And

  As used herein, the terms “(a”) and (“the”) are synonymous and are used interchangeably with one or more. Thus, for example, reference to a single fiber ("a fiber") in the specification or in the claims can refer to a single fiber or to one or more fibers. Unless otherwise specified, all numerical values are understood to be modified by the word “about”.

  In the sense of the present invention, floor coverings are to be understood not only as carpets, foot mats etc., but also as seat cushions for furniture or as mattresses.

  The first textile planar element may be, for example, a woven fabric, a nonwoven layer of fibers, a fleece or a knitted fabric. Also, the fibers may protrude from the first textile planar element, so that an assembly corresponding to a carpet backing is achieved. In addition, textiles may be embedded in the polymer. The first textile planar element is bonded to the first layer on its surface, which means that both major surfaces face each other. In other words, the first textile planar element and the first layer are stacked on top of each other.

According to the present invention, the first textile planar element has a 0.5 N / mm ² or more 2.5 N / mm ² modulus below. This should be understood as the modulus of elasticity for stretching along the planar direction of the planar element. Modulus, 0.8N / mm ² or more 2.0 N / mm ² in the range, or may be in the range of 1.0 N / mm ² or more 1.5 N / mm ² or less. The elastic modulus is determined using the standard DIN 53504 / ISO 37. The first textile planar element can be defined to exhibit the elasticity of stretching the fabric, for example in the case of a woven fabric, and to exhibit the elasticity of the individual yarns of the textile after further stretching. In this case, the selected modulus of elasticity according to the invention means the elasticity of stretching the fabric.

  Bonding has the effect of moving mechanical forces, in particular shear stress, from the first textile planar element to the first layer. The bond may be a substance-substance bond, a forced fitting bond or a form fitting bond. Examples of suitable bonds include adhesives, welding, backing foaming between the first textile planar layer and polymer foam, velcro, zippers, pushbuttons and / or materials that lead to sewing.

  Bonding may be performed entirely or partially. Partial bonding can be achieved by selectively forming bonding points or by arranging the bonding points in a specific pattern.

  The first layer comprises a viscoelastic polymer foam. In principal, this means that in addition to the viscoelastic polymer foam, further components such as fillers, colorants may be present. The polymer foam may have a uniform density, and the density may vary depending on the location in the foam, for example, throughout the foam. Specific examples of suitable polymer groups include polyurethane, polyethylene, polypropylene, polystyrene, acrylonitrile-butadiene-styrene (ABS) and polycarbonate or natural or synthetic latex. For example, the first layer may have a thickness of 10 mm to 60 mm, preferably 15 mm to 30 mm.

  The viscoelastic properties of the polymer foam in the first layer lead to energy entering the foam with a time delay. The characteristic is characterized in that the compressive load deflection at 40% compression is 1 kPa or more and 10 kPa or less. This compressive load deflection may be in the range of 1.1 kPa to 3 kPa, or 1.2 kPa to 2 kPa. Furthermore, the viscoelasticity of the polymer foam is characterized in that the hysteresis in determining the compressive load deflection at 40% compression is 20% or more and 70% or less. The hysteresis may be in the range of 30% to 60% or 35% to 50%.

  Compressive load deflection, ie CLD, is measured according to DIN EN ISO 3386-1-98 at 23 ° C. ± 2 ° C., 50% ± 5% relative humidity, 40% compression, one measurement cycle. CLD is given in kPa (kilopascal). Hysteresis (%) is also measured according to DIN EN ISO 3386-1-98. Hysteresis is calculated by multiplying the quotient of the area enclosed between the characteristic curves for stress and recovery by a factor of 100. The hysteresis number gives information on the ratio of applied energy to dissipated energy. For example, a hysteresis number as small as about 5% mainly exhibits elastic behavior. For example, a large hysteresis number such as about 90% mainly exhibits viscous (plastic) behavior.

  Alternatively, the viscoelastic polymer foam may be characterized in that the foam has a resilience measured according to DIN EN ISO 8307 of 1% or more and 15% or less. This impact resilience may be in the range of 3% to 10% or 5% to 9%.

The viscoelastic polymer foam has a density of 45 kg / m ³ or more and 120 kg / m ³ or less according to DIN EN ISO 3386-1-98, preferably 50 kg / m ³ or more and 70 kg / m ³ or less, DIN EN ISO 1798-1- 50 kPa to 90 kPa tensile strength according to 00, 150% to 210% elongation according to DIN EN ISO 1798-1-00, 2% to 5% under dry conditions according to DIN EN ISO 1856-2000 You may have the following compression set and compression set of 75% compression according to DIN EN ISO 1856-96 and 2% or more and 5% or less at 95% humidity.

  In the present invention, the feeling of comfort when walking over a floor covering is achieved by a selected combination of the elasticity of the first textile planar element and the viscoelasticity of the polymer foam layer. For further elucidation, it should be assumed how a person walks on the floor covering according to the invention. In the first stage, the foot heel or shoe heel is placed on the floor covering. This involves high pressure on the cover. Due to the elasticity of the first textile planar element, this concentrated load is absorbed. Further, when entering the walking process, the person rolls with his / her foot until the entire foot stands on the flooring material. This roll motion is mitigated by the viscoelastic polymer foam of the first layer. Finally, the foot performs another roll motion until the thumb ball or toe leaves the floor finish contact. In the subsequent extrusion operation from the floor, the mechanical force is alleviated or sent back, respectively. The end result is a comfortable feeling when walking, which does not cause fatigue due to the floor being too soft. Since the floor covering is also protected by the elastic first textile planar element, in particular the first layer with the polymer foam is not damaged while walking on it.

  In one embodiment of the invention, the first layer of viscoelastic polymer foam is a polyurethane foam. Polyurethane is particularly suitable for the polymer foam layer according to the present invention because its viscoelasticity can be adjusted over a wide range. Polyurethane foam monomers include polyether polyols and / or polyester polyols or mixtures thereof, and at least difunctional isocyanates from the group of aliphatic or aromatic isocyanates, and commonly known adjuvants, catalysts and stabilizers. You may choose from a group. Specific examples thereof are described in the above-mentioned patent documents and EP 0 331 941 A1.

  In a further embodiment of the invention, the viscoelastic polymer foam of the first layer is a crosslinked foamed foam derived from synthetic latex or natural latex.

  In a further embodiment of the invention, the material of the first textile planar element comprises polyurethane and / or thermoplastic polyurethane.

  In a further embodiment of the invention, the bond between the first textile planar element and the first layer is achieved by an elastomeric adhesive. According to the invention, particularly suitable adhesives are one-component and two-component polyurethane adhesives. Such one-component adhesives comprise an isocyanate containing a prepolymer that cures under the influence of moisture. The corresponding two-component adhesive comprises a polyol component and an isocyanate component and is mixed before application. Preferably, the cured adhesive layer has an elastic modulus of 100 MPa to 1500 MPa, 300 MPa to 1000 MPa, or 500 MPa to 800 MPa, determined according to DIN EN ISO 527. The use of an elastomeric adhesive makes it possible to easily produce the floor finish according to the invention from separately available parts. Furthermore, the desired effect according to the invention when walking on a floor covering is also obtained by elasticity.

  In a further embodiment of the invention, the fibers penetrate the first textile planar element into the first layer and the fibers are secured in the first layer by an elastomeric adhesive. This fiber leads to a further strengthening of the bond between the first textile planar element and the first layer. This increases the resilience to shear stress. In particular, elastomeric one-component and two-component polyurethane adhesives are suitable for the present invention. The fibers may protrude outwardly from the first textile planar element to constitute the stepping surface of the floor finish. The fibers may be incorporated into the first textile planar element by methods such as tufts.

In a further embodiment of the invention, the first layer further comprises an embedded second textile planar element having an elastic modulus of 1000 N / mm ² or more and 2000 N / mm ² or less. This should be understood as the modulus of elasticity for stretching along the planar direction of the planar element. The elastic modulus is determined using the standard DIN 53504 / ISO 37. Modulus may be 1200 N / mm ² or more 1800 N / mm ² or less, or 1400 N / mm ² or more 1600 N / mm ² within the following ranges. The second textile planar element can be, for example, woven, non-woven layers of fibers, fleece or knitted. Advantageously, the second textile planar element is orientated to the first layer at its surface, which means that the two main surfaces of the second textile planar element and the first layer are facing each other. To do.

  The second textile planar element may be located at any height in the first layer, as viewed vertically, but is advantageously located at the lower end of the first layer towards the floor. By incorporating a second textile planar element having elastic properties selected according to the present invention, the effect of increasing the horizontal tear strength of the floor covering is obtained. Furthermore, the introduction of a relatively high horizontal elastic modulus has the effect of increasing the horizontal dimensional stability of the floor covering. By positioning at the lower end of the first layer, the influence of the second textile planar element on the relaxation properties of other components of the floor covering is reduced. Thus, a vertical relaxation gradient due to the associated comfort can be further established while a person walks on the floor covering. As an example, the second textile planar element may be bonded to the first layer with a form fitting bond, a substance-material bond, or it may be integrated into the foam of the first layer.

  In a further embodiment of the invention, the floor covering is arranged on the side of the first layer opposite to the first textile planar element, e.g. a second layer at least partly bonded to the first layer, e.g. by substance-substance. The second layer further comprises a polymer foam having a compressive load deflection at 40% compression of 15 kPa to 150 kPa. The substance-substance bond can be realized by an adhesive or by welding. Elastomeric one-component and two-component polyurethane adhesives are suitable for the present invention. The second layer may have a thickness of 10 mm to 40 mm, preferably 15 mm to 30 mm, for example.

The polymer foam having the compressive load deflection may be an agglomerated polyurethane foam. The polymer foam has a density of 60 kg / m ³ or more and 200 kg / m ³ or less according to DIN EN ISO 3386-1-98, a tensile strength of 40 kPa or more and 150 kPa or less according to DIN EN ISO 1798-1-00, and DIN EN ISO 1798-1 It may have an elongation of 40% or more and 90% or less according to -00. High compression load deflection and restoring force are used to provide a stiffer layer on the floor side of the floor covering. This has the advantage of better supporting the heels of the feet or shoes when walking on the floor covering. The comfort is improved when walking on the floor covering, and at the same time the thickness of the first layer can be kept small. A further advantage is cost savings by using cheaper agglomerated foam.

In the above floor covering embodiment comprising a second layer, this further comprises a third textile planar element having an elastic modulus of 1000 N / mm ² or more and 2000 N / mm ² or less, wherein the third textile plane The element is arranged on the side of the second layer opposite the first layer, and the third textile planar element is at least partially bonded to the second layer. The elastic modulus is to be understood as the elastic modulus for stretching along the planar direction of the planar element.

The modulus of elasticity is also determined using the standard DIN 53504 / ISO 37. Modulus may be 1200 N / mm ² or more 1800 N / mm ² or less, or 1400 N / mm ² or more 1600 N / mm ² within the following ranges. The third textile planar element can be, for example, woven, non-woven fabric of fibers, fleece or knitted.

  It is advantageous if the second layer is arranged on the side of the first layer opposite to the first textile planar element and that the second layer is at least partly bonded to the first layer by means of a substance-material bond . In this respect, it is also advantageous if the third textile planar element is arranged on the side of the second layer opposite to the first layer and if it is at least partly bonded to the second layer.

  Generally speaking, the arrangement of this embodiment has the advantage of increasing the horizontal tear strength of the floor covering. Furthermore, the introduction of a relatively high horizontal elastic modulus has the effect of increasing the horizontal dimensional stability of the floor covering. By positioning at the lower end of the second layer, the influence of the third textile planar element on the relaxation properties of other components of the floor covering is reduced. Thus, a vertical relaxation gradient due to the associated comfort can be further established while a person walks on the floor covering. As an example, the third textile planar element may be bonded to the second layer with a form fitting bond or a substance-substance bond. A further advantage is cost savings by using cheaper agglomerated foam.

  In a further embodiment of the invention, the floor finish further comprises a microencapsulated perfume. A microencapsulated fragrance in the sense of the present invention is a substance in a pure form, solution or mixture that stimulates human olfaction and is contained in a capsule. The capsule has a maximum dimension of 1 μm to 1 mm, preferably 10 μm to 100 μm. The microencapsulated perfume can be incorporated in the first layer, in the first textile planar element and / or in the optionally present fibers protruding from the first textile planar element, for example as a carpet tuft. When walking on the floor covering according to the invention, the capsule is broken and the perfume is released. This creates a pleasant sensation for each person and contributes to the comfortable impression of the floor finish.

  According to the present invention, it is included that the above embodiments can exist not only in a single form, but also can be freely combined with each other.

  A further aspect of the present invention is a method for producing a floor covering according to the present invention comprising the step of backing foaming a first textile planar element with a reaction mixture which becomes a first layer polymer foam. By backing foaming, a substance-to-material bond between the first textile planar element and the first layer is easily achieved.

  In one embodiment of the process according to the invention, the reaction mixture comprises a polyol and an isocyanate. Thus, a viscoelastic polyurethane foam is formed during the backing foam. Polyurethane foam monomers include polyether polyols and / or polyester polyols or mixtures thereof, and at least difunctional isocyanates from the group consisting of aliphatic or aromatic isocyanates, as well as conventional adjuvants, catalysts and stabilizers. You may choose from a group. Specific examples are described in the aforementioned patent documents and EP 0 331 941 A1.

  In the process according to the invention, it is also possible for the reaction mixture to contain a prepolymer and water. Suitable prepolymers are obtained inter alia based on di- or polyisocyanates and polyols.

  FIG. 1 shows a floor covering according to the invention. The first layer 1 comprises a viscoelastic polymer foam. This layer 1 is placed on the floor underneath. On top of layer 1 a first textile plane element 2 is located. A substance-material bond joins the first layer 1 and the first textile planar element 2. On the upper side of the floor finish, the fibers 3 protrude outward. The fiber 3 extends through the first textile planar element and into the first layer 1 at its lower end. Preferably, the fibers are fixed to the first layer 1 with an elastomer adhesive (not shown). This prevents the fibers from being pulled from the floor finish during use.

  FIG. 2 shows another floor covering according to the present invention. In addition to the polymer foam, the first layer 1 located towards the floor here comprises a second textile planar element 2. Here, this is depicted as a woven fabric. The second textile plane element 4 is located at the lower end of the first layer 1. A substance-substance bond exists between the first textile planar element 2 and the first layer 1. In the first layer 1, the fibers 3 covering the surface of the floor finish are incorporated. Due to its elasticity, the second textile planar element can absorb mechanical forces that result from walking on the floor covering and are not absorbed or relaxed by the layer having the first textile planar element 2 and the viscoelastic polymer 1.

  FIG. 3 shows another floor covering according to the invention. The second layer 5 is located directly below the first layer 1. This second layer comprises a polymer foam. The polymer foam has higher compressive load deflection and restoring force than the viscoelastic polymer foam of the first layer 1. This makes it possible to absorb mechanical forces that arise from walking on the floor covering and are not absorbed or relaxed by the layer having the first textile planar element 2 and the viscoelastic polymer 1.

  FIG. 4 shows another floor covering according to the present invention. A second layer 5 is located directly below the first layer 1 and a third textile planar element 6 is located directly below the layer 5. This second layer 5 comprises a polymer foam. The polymer foam has higher compressive load deflection and restoring force than the viscoelastic polymer foam of the first layer 1. The third textile plane element 6 comprises a woven fabric. The third textile plane element 6 and the second layer 5 can absorb mechanical forces that result from walking on the floor covering and are not absorbed or relaxed by the layer having the first textile plane element 2 and the viscoelastic polymer 1.

The invention will be further described with reference to the following figures.
FIG. 1 is a diagram showing a floor finish according to the present invention. FIG. 2 is a view showing another floor finish according to the present invention. FIG. 3 is a diagram showing another floor finish according to the present invention. FIG. 4 is a diagram showing another floor finish according to the present invention.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 1st layer which comprises viscoelastic polymer foam 2 1st textile plane element 3 Fiber 4 2nd textile plane element 5 2nd layer which comprises polymer foam 6 3rd textile plane element

Claims (13)

A floor covering comprising a first textile planar element and a first layer at least partially bonded to the first textile planar element on its surface, the first layer comprising a viscoelastic polymer foam, textile planar element has a 0.5 N / mm ² or more 2.5 N / mm ² modulus below, in the first layer, the viscoelastic polymer foam compression load deflection at 40% compression 1kPa least 10kPa or less And a floor finish, wherein the viscoelastic polymer foam has a hysteresis of 20% or more and 70% or less when determining a compressive load deflection at 40% compression in the first layer.   The floor covering of claim 1, wherein the first layer viscoelastic polymer foam is a polyurethane foam.   The floor covering according to claim 1, wherein the first layer viscoelastic polymer foam is a crosslinked foamed foam derived from synthetic latex or natural latex.   The floor covering according to claim 1, wherein the material of the first textile planar element comprises polyurethane and / or thermoplastic polyurethane.   The floor covering of claim 1, wherein the bond between the first textile planar element and the first layer is achieved by an elastomeric adhesive.   The floor covering of claim 1, further comprising fibers that penetrate the first textile planar element and into the first layer, the fibers being secured in the first layer by an elastomeric adhesive. The floor covering according to claim 1, wherein the first layer further comprises an embedded second textile planar element having an elastic modulus of 1000 N / mm ² or more and 2000 N / mm ² or less.   It further includes a second layer disposed on the first layer side opposite to the first textile plane element and at least partially bonded to the first layer, and the second layer is at 40% compression of 15 kPa to 150 kPa. The floor covering of claim 1, comprising a polymer foam having a compressive load deflection of: And further comprising a third textile planar element having an elastic modulus of 1000 N / mm ² or more and 2000 N / mm ² or less, the third textile planar element being disposed on the second layer side opposite to the first layer, 9. A floor covering according to claim 8, wherein the textile planar element is at least partially bonded to the second layer.   The floor finish according to claim 1, further comprising a microencapsulated fragrance.   The method for producing a flooring material according to claim 1, comprising a step of backing and foaming the first textile planar element with a reaction mixture that becomes the polymer foam of the first layer.   The method of claim 11, wherein the reaction mixture comprises a polyol and an isocyanate.   The method of claim 11, wherein the reaction mixture comprises a prepolymer and water.

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