JP3243848B2 - Cushioning material for flooring - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a cushioning material for flooring. More specifically, the present invention relates to a cushioning material for flooring, which has excellent soundproofing and sound absorbing properties, and also has an excellent walking feeling by preventing sinking of the floor.

[0002]

2. Description of the Related Art Resin tiles, tatami mats, carpets, and wooden flooring materials are used as flooring materials for single-family homes and condominiums. In recent years, demand has been increasing not only for new construction but also for renovation, because there is no need to worry, it is easy to clean and clean.

[0003] By the way, when constructing floor materials, it is necessary to take care to prevent noise from being transmitted downstairs. Such floor noise includes a heavy impact sound generated when a child jumps or runs around, and a light impact sound generated by dragging a chair or dropping a spoon. The degree to which the heavy impact sound is transmitted mainly depends on the basic structure of the building,
The degree to which the light impact sound is transmitted largely depends on the material and structure of the floor material. Therefore, various attempts have conventionally been made to reduce the degree of propagation of light impact noise by using a cushioning material for the flooring, etc. In this case, industrially, the degree of propagation is JIS A1418. It is required to clear the sound insulation grade level L value 45 of light impact noise caused by the above.

[0004] For example, in the case of a wooden floor material directly used as a floor material for a house (a floor having a small thickness and directly attached to a concrete slab, etc., a total floor thickness of 10 to 30 mm), a sound insulation grade level is required. In order to clear the L value of 45, for example, about 10 to 20 layers of a card web containing about 15 to 30% by weight of a sheath / core type polyester heat-fusible fiber having a thickness of about several deniers are laminated, A cushioning material for flooring manufactured by performing needle punching to prevent peeling of the fibers and to obtain a predetermined thickness, and further performing dry heat treatment with hot air to fuse the heat-fused fibers is used. In addition, a buffer material for a floor material in which a hot melt resin film is laminated on one side of the nonwoven fabric layer formed in this way to improve moisture proofing property and workability, and a thin nonwoven fabric layer by T-die lamination. A three-layer cushioning material for flooring provided with a thermoplastic resin layer is also used.

[0005] More recently, with regard to the sound insulation grade level of light impact sound, a cushioning material has been demanded which clears the L value of 40 from the L value of 45 with better sound insulation. Attempts to soften the texture of the nonwoven fabric layer of the cushioning material by reducing the thickness of the fibers used or increasing the number of layers of the card web, thereby achieving a sound insulation class level L value of 40. Have been.

[0006]

However, in the case where the sound insulation is improved by softening the texture of the non-woven fabric layer of the cushioning material for flooring, such a cushioning material for flooring and the flooring material are actually used. When it walks on it, it sinks greatly and there was a problem that walking feeling was very bad. Therefore, when the nonwoven fabric layer is hardened in order to improve walking feeling, there is a disadvantage that sound insulation is reduced, and it is impossible to achieve both high sound insulation and excellent walking feeling at the same time with the structure of the conventional cushioning material for flooring. There was a problem that it was very difficult.

[0007] The present invention is intended to solve the above-mentioned problems of the prior art, and the cushioning material for flooring has excellent sound insulation and soundproofing properties against light impact noise and excellent walking feeling. The aim is to be able to acquire at the same time.

[0008]

The inventor of the present invention achieves the above object by forming a reinforcing member in a nonwoven fabric layer of a cushioning material for flooring that can withstand a load from a floor. They found that they could do this and completed this invention.

That is, the present invention provides a cushioning material for flooring comprising a nonwoven fabric layer, wherein a reinforcing member is provided in the thickness direction of the nonwoven fabric layer, and the reinforcing member forms the nonwoven fabric layer.
Loop pile or cut pile tufted to base
The present invention provides a cushioning material for flooring , which is characterized by being an il .

As described above, the present invention is characterized in that a reinforcing member is provided on the nonwoven fabric layer, and the other configuration can be the same as the conventional one. Here, the reinforcing member, when the cushioning material for flooring of the present invention is applied to the floor, prevents the nonwoven fabric layer from being compressed by applying a load from the floor to prevent the floor from sinking greatly, and This is for preventing settling. Therefore, it is provided in the nonwoven fabric layer in the thickness direction so as to be able to withstand the load from the floor. As such a reinforcing member, for example, a loop pile or a cut pile tufted based on a nonwoven fabric layer can be exemplified as the reinforcing member.

Hereinafter, the present invention will be described in detail with reference to the drawings.

FIG. 1 is a sectional view of a preferred embodiment of a cushioning material for flooring according to the present invention. The cushioning material for flooring 10 has a structure in which a loop pile 2 is tufted based on a nonwoven fabric layer 1. . By providing the loop pile 2 in this way, it is possible to withstand the load from the floor while preventing the texture of the nonwoven fabric layer 1 from softening the sound insulation properties, and to prevent the floor from sinking more than necessary, Further, it is possible to prevent the non-woven fabric layer 1 from settling and realize an excellent walking feeling.

The nonwoven fabric layer 1 is made of the cushioning material 1 for floor material of the present invention.
It is a part that is responsible for sound insulation and sound insulation of 0, and can use the conventional nonwoven fabric used for the purpose of sound insulation and sound insulation.
For example, a thermobonded nonwoven fabric, a needle punched nonwoven fabric, or the like can be used. Also, by changing the type, blending ratio, basis weight, thickness, processing conditions, etc. of the fibers used, the sound insulation against light impact noise based on JIS A1418 is changed to, for example, L value 40, L value 45 or L value 50. Can be done.

The basis weight of the nonwoven fabric layer 1 depends on the purpose of use,
Although it varies depending on the type of fiber used, the thickness of the fiber, etc., when used for a wood-based directly bonded floor, the thickness as a nonwoven fabric is generally several mm to 15 mm.
It is preferably １０００1000 g / m ² .

As the loop pile 2, a loop pile used for ordinary tufted carpet can be used, and for example, acrylic fiber, polyester fiber, nylon fiber, polypropylene fiber, etc. can be used.
These may be either filaments or spun yarns. Further, a loop pile may be formed by fibers impregnated with a thermoplastic resin.

The thickness and the density of the fibers of the loop pile 2 can be appropriately determined according to the purpose of use.
For example, if the total surface load of the expected floor load is 50
In order to be able to withstand a load of 2.4 to 3 g per loop pile at 0 kg / 6 tatami mats, tufting at 5 lines / inch (stitch) and 3 lines / inch (gauge) results in 24,000 lines / m. Loop pile by ² (total 20
8800 lines). By doing so, the load per loop pile is 500 kg ÷ 2
08800 pieces = 2.4 g. In this case, if the driving density of the loop pile 2 is excessively large, the sound insulating property is reduced. Therefore, it is necessary to determine the density in consideration of the desired sound insulating performance.

A resin layer 4 as shown in FIG. 2 is provided on the surface of the non-woven fabric layer 1 on the side where the needle is driven in tufting, in order to improve the workability in the field and further securely fix the loop pile 2. Preferably, it is provided. As a resin constituting such a resin layer 3, a polyolefin resin such as polyethylene or polypropylene, an ethylene-vinyl acetate copolymer, or the like, which is used for a resin layer constituting a conventional cushioning material for flooring, may be used. Can be. The thickness of the resin layer 3 can be appropriately determined according to the purpose of use. Further, a resin foam may be used as the resin layer 3.

Although FIG. 1 shows an example in which the loop pile 2 is employed as the reinforcing member of the nonwoven fabric layer 1, the same effect can be obtained by shearing the loop pile 2 as the cut pile 3 (FIG. 3).

A cushioning material for a flooring material having a toughened pile as a reinforcing member such as a loop pile 2 or a cut pile 3 as shown in FIG. 1 or FIG. When a nonwoven fabric containing adhesive fibers is used, first, the nonwoven fabric layer 1 is heat-treated and fused, then tufted to form a pile 2 and, if necessary, a side for driving a tufting needle. It can be manufactured by applying a thermoplastic resin to the surface of the nonwoven fabric layer 1 to form the resin layer 3. Alternatively, first, the pile 2 is formed by tufting the nonwoven fabric layer 1 and then heat-treated to fuse the heat-fusible fibers, and if necessary, the nonwoven fabric layer 1 on the side where the tufting needle is driven. It can be manufactured by applying a thermoplastic resin to the surface to form a resin layer 3. When the heat treatment is performed after the tufting as in the latter case, the pile and the heat-sealing fiber can be heat-fused, and the strength as a cushioning material for flooring can be improved.

The reinforcing member of the cushioning material for flooring according to the present invention is not limited to the tufted pile as described above. For example, in FIG. 2 and FIG. A columnar resin protrusion may be provided in the thickness direction of the nonwoven fabric layer, and the protrusion may be used as a reinforcing member.

[0021]

According to the cushioning material for flooring of the present invention, since the reinforcing member capable of resisting the load from the floor is provided in the thickness direction of the nonwoven fabric layer, the texture of the nonwoven fabric layer does not deteriorate the sound insulation characteristics. While being soft, it is possible to withstand the load from the floor. For this reason, it becomes possible to prevent the floor from sinking more than necessary, and to further prevent the nonwoven fabric layer from being set, thereby realizing an excellent walking feeling.

[0022]

DESCRIPTION OF THE PREFERRED EMBODIMENTS The present invention will be specifically described below with reference to embodiments, but the present invention is not limited to these embodiments.

Example 1 A basis weight of 400 g / m ² comprising a blend of 20% by weight of a polyester-based fused fiber and 80% by weight of a polyester fiber.
Thermo-bonding was performed by passing hot air through the needle-punched nonwoven fabric.

Using a tufting machine, 2,000-denier polyester fiber is used to drive a loop pile into the non-woven fabric at a density of 20 stitches / 10 cm.
A buffer material for flooring was manufactured by forming a resin layer by coating at g / m ² (dry).

The floor cushioning material was measured for the sound insulation level of light impact noise according to JIS A1418. As a result, 6
The sound insulation for the octave band center frequencies of 3 Hz, 125 Hz, and 500 Hz are L values of 28.8, 4 respectively.
5.6 and 41.5, indicating a sound insulation of L-45 class.

Further, when a base material for L-45 class, in which the cushioning material for flooring material and the wooden flooring material were bonded, was actually applied to the floor, and the walking feeling was examined, it was found that Showed a feeling of walking.

Example 2 A cushioning material for flooring was manufactured by repeating Example 1 except that thermobonding was performed after tufting, and the loop pile was changed to a cut pile.

The sound insulation level of the light impact sound of this cushioning material for flooring was measured in accordance with JIS A1418. As a result, 6
The sound insulation for the octave band center frequencies of 3 Hz, 125 Hz, and 500 Hz are L values 31.3, 4 respectively.
6.2 and 42.0, indicating sound insulation of L-45 class.

An L-45 grade base material obtained by bonding the floor cushioning material and the wooden flooring material is actually applied to the floor,
When the walking feeling was examined, it did not sink much, and showed an excellent walking feeling.

Comparative Example 1 A cushioning material for flooring was produced by repeating Example 1 except that no tufting was performed.

The cushioning material for flooring was measured for the sound insulation level of light impact noise according to JIS A1418. As a result, 6
The sound insulation for octave band center frequencies of 3 Hz, 125 Hz, and 500 Hz are L values of 33.0, 4 respectively.
It was 7.0 and 45.7, indicating a sound insulation of approximately L-45 grade. However, when an L-45 grade base material in which the floor cushioning material and the wooden flooring material were bonded to each other was actually applied to the floor and the walking sensation was examined, the siding greatly lowered and the unfavorable gait was shown. Was.

[0032]

The cushioning material for flooring of the present invention can achieve both excellent sound insulation and soundproofing against light impact noise and excellent walking feeling at the same time.

[Brief description of the drawings]

FIG. 1 is a sectional view of a preferred embodiment of a cushioning material for flooring of the present invention.

FIG. 2 is a cross-sectional view of another embodiment of the nonwoven fabric for flooring of the present invention.

FIG. 3 is a cross-sectional view of another embodiment of the cushioning material for flooring of the present invention.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Nonwoven fabric layer 2 Loop pile 3 Resin layer 4 Cut pile

──────────────────────────────────────────────────続 き Continued on front page (58) Field surveyed (Int. Cl. ⁷ , DB name) A47G 27/02

Claims (1)

(57) [Claims] 1. A cushioning material for flooring comprising a nonwoven fabric layer, wherein a reinforcing member is provided in the thickness direction of the nonwoven fabric layer, and the reinforcing member is tufted based on the nonwoven fabric layer.
Loop pile or cut pile.
A cushioning material for flooring.