JP7282634B2 - soundproof tatami - Google Patents

Description

TECHNICAL FIELD The present invention relates to a soundproof tatami mat with excellent soundproofing properties.

Since ancient times, tatami mats with a thickness of about 55 mm (so-called thick tatami mats), which are made by laminating a tatami surface on the surface of which rice straw tatami mats are used as a flooring material for houses, have been widely used. For tatami mats, the short sides without tatami rims are called frames. In general, when a tatami mat is wrapped in a tatami mat, the tatami mat is wrapped in the longitudinal direction and sewn to the tatami mat on the back side (this lateral part is called a frame), but the width of the tatami mat is cut to fit the width of the tatami mat. end up Since the tatami facing cannot be fixed if left uncut, the edge of the tatami mat is used to hide the cut edge, and at the same time, it is sewn to the tatami floor to secure it. When the tatami mat is wrapped in the tatami mat, the tatami mat is wrapped not only vertically but also horizontally, and then sewn on the reverse side in a folding manner to create a borderless tatami mat. However, even if you try to wind a general tatami surface (various item table) in the horizontal direction, it will not work because the rush of the weft will be bent at an acute angle.

However, due to recent changes in the living environment, conventional thick tatami mats have drawbacks such as unstable quality and supply of raw materials and high costs. As such, various tatami mats with a tatami facing layered on the surface have been studied. In particular, in recent years, in the housing design field, houses with no steps between Western and Japanese-style rooms have been attracting attention as barrier-free houses. In order to eliminate it, construction such as lowering the large pull of the Japanese-style room and raising the floor base of the Western-style room is necessary. Therefore, various types of thin tatami mats (so-called thin tatami mats) with a thickness of about 7 to 25 mm have been proposed, which can be easily changed between a Western-style room and a Japanese-style room.

For example, a thin tatami mat in which a cushion sheet is provided on at least the front side of a fiber board having a thickness of 5 to 15 mm, and a tatami surface is fixed thereon, and the density of the fiber board is 0.35 to 0.6 g/cm ³ . A thin tatami mat and a thin tatami mat with a metal foil or a plastic film attached to the front and back of the fiberboard (see, for example, Patent Document 1) or a tatami floor constituent material used for a tatami mat with a total thickness of 7 to 25 mm, The tatami floor constituent material is a 4 to 20 mm thick plate-like body (excluding synthetic resin foam) with a density of 0.02 to 0.5 g/cm ³ and a fiber reinforced resin sheet. A tatami floor constituent material having a bending elastic modulus of 6000 kgf/cm ² or more (for example, see Patent Document 2) has been proposed.

The thin tatami mat is thin, lightweight, easy to construct, and suitable for the above applications. Also, since it is easy to carry, a single thin tatami mat is used at a predetermined position on the floor. However, the above-mentioned thin tatami mats are 20 to 40 mm thinner than conventional thick tatami mats with a thickness of 55 mm, so the soundproofing performance is reduced, and it is possible to use it on the floor material or the base of the floor material in housing complexes and condominiums. When used in place, there was a drawback that the sound generated when walking on the thin tatami mats was transmitted directly to the room below, generating noise.

Various thin tatami mats with excellent soundproofing properties have been proposed to overcome this drawback. For example, high tensile strength is applied to both sides of a flat substrate that does not expand or contract due to moisture absorption (woody soft fiber board (insulation board), resin foam such as polystyrene, laminate of woody and resinous members, etc.). Reinforcing materials (woody heat-pressing molded plates made by mixing thermoplastic resin with fine wooden chips and heat-pressing, plastic plates such as olefin-based resin composite plates, reinforced resin sheets, etc.) are laminated, and both sides are further provided with cushioning properties. A tatami mat made by laminating cushioning materials (resin foam such as polystyrene resin, or non-woven fabric) and fixing them together, and a tatami mat that covers the entire surface of the tatami mat and is fixed to the edge of the back by folding it. A highly sound-insulating thin tatami mat (see, for example, Patent Document 3) has been proposed, characterized in that the thickness of the lowermost cushioning material, which is the back surface of the tatami mat, is thicker than the thickness of the tatami surface.

It seems that the soundproofing properties of the above high sound insulation thin tatami mats have been improved, but in accordance with JIS A 1440-1 (Method for measuring floor impact sound level reduction of floor finish structure (method using standard lightweight impact source)) The measured floor impact sound level could not clear ΔLL(I)-4.

JP-A-2004-84340 JP-A-11-336307 JP-A-2003-129647

In view of the above problems, the object of the present invention is to measure the floor impact sound level in accordance with JIS A 1440-1 (Method for measuring floor impact sound level reduction in floor finish structure (method using standard lightweight impact source)). To provide a soundproof tatami mat with excellent soundproofing property of .DELTA.LL(I)-5 or more.

That is, the present invention
[1] A soundproof tatami mat in which a tatami surface is laminated on the upper surface of a core material via a surface cushion sheet, wherein the surface cushion sheet has an apparent density of 0.04 to 0.2 g/cm ³ and a compression elastic modulus of 10 to A soundproof tatami mat characterized by 40 KPa and a thickness of 1 to 10 mm,
[2] The soundproof tatami mat according to [1], wherein the core material is a woody core material;
[3] The soundproof tatami mat according to [1] or [2] above, wherein the surface cushion sheet is a non-woven fiber sheet in which non-wet heat adhesive fibers are partially fused with a wet heat adhesive resin. .
[4] The above [1], wherein the surface cushion sheet is a laminated sheet of a non-woven fiber sheet and a cushioning sheet in which non-wet heat adhesive fibers are partially fused with a wet heat adhesive resin, or [2] The soundproof tatami mat according to
[5] The above [1] to [4], wherein the thickness of the core material: the thickness of the surface cushion sheet: the thickness of the tatami facing is 1: 0.5 to 2: 0.2 to 2.5 ] The soundproof tatami mat according to any one of
[6] The soundproof tatami mat according to any one of [1] to [5], wherein the surface cushion sheet and the core material are adhered with a (viscous) adhesive.
[7] The soundproof tatami mat according to any one of [1] to [6], wherein a back cushion sheet is laminated on the lower surface of the core material.
[8] The above [1] to [7] characterized in that the ends of the tatami facing and the surface cushion sheet are folded to the side surface of the core material and the leading edge of the tatami facing is bent to the lower surface of the core material and laminated. The soundproof tatami mat according to any one of
[9] The soundproof tatami mat according to [8], wherein a step adjustment sheet is laminated in the space surrounded by the lower surface of the core material and the tatami facing,
[10] The soundproof tatami according to [9], wherein a back cushion sheet is laminated on the lower surface of the tatami facing and the step adjustment sheet laminated on the lower surface of the core material,
[11] The soundproof tatami mat according to [7] or [10], further characterized in that a back surface finishing material is laminated on the surface of the back cushion sheet.
[12] The floor impact sound level measured in accordance with JIS A 1440-1 (Method for measuring floor impact sound level reduction of floor finish structure (method using standard lightweight impact source)) is ΔLL(I)-5 or more. The soundproof tatami mat according to any one of [1] to [11], characterized by
[13] A method for laying soundproof tatami mats, wherein the soundproof tatami mats according to any one of [1] to [12] are laid so that the ridges of the tatami surfaces of adjacent soundproof tatami mats are orthogonal to each other.

The structure of the soundproof tatami mat of the present invention is as described above. The sound level is ΔLL(I)-5 or more, and the sound insulation is excellent.

1 is a sectional view showing an example of a soundproof tatami mat of the present invention; FIG. FIG. 4 is a cross-sectional view showing another example of the soundproof tatami mat of the present invention. FIG. 4 is a cross-sectional view showing another example of the soundproof tatami mat of the present invention. FIG. 2 is a cross-sectional view showing an example of the structure of the frame portion of the soundproof tatami mat of the present invention. FIG. 4 is a cross-sectional view showing another example of the structure of the frame portion of the soundproof tatami mat of the present invention. 1 is a plan view showing an example of laying soundproof tatami mats of the present invention. FIG.

The soundproof tatami of the present invention is a soundproof tatami in which a tatami surface is laminated on one surface of a core material via a surface cushion sheet, and the surface cushion sheet has an apparent density of 0.04 to 0.2 g/cm ³ and is compressed. It is characterized by having an elastic modulus of 10 to 40 KMPa and a thickness of 1 to 10 mm.

The invention will now be described with reference to the drawings. FIG. 1 is a sectional view showing an example of the soundproof tatami mat of the present invention. In the figure, 1 is a core material, and a tatami facing 3 is sequentially laminated on the upper surface of the core material 1 with a surface cushion sheet 2 interposed therebetween.

FIG. 2 is a sectional view showing another example of the soundproof tatami mat of the present invention. In the figure, 1 is a core material, and a tatami surface 3 is sequentially laminated via a surface cushion sheet 2, which is formed by laminating a cushioning sheet 21 and a non-woven fiber sheet 22 on the upper surface of the core material 1, and a rear cushion sheet 4 is formed on the lower surface. are stacked.

FIG. 3 is a sectional view showing another example of the soundproof tatami mat of the present invention. In the figure, 1 is a core material, and a tatami mat surface 3 is sequentially laminated on the upper surface of the core material 1 via a front cushion sheet 2, and a back finishing material 5 is laminated on the lower surface via a back cushion sheet 4.

The core material 1 imparts mechanical strength to the soundproof tatami mat, and is not particularly limited as long as it is a core material conventionally used as a core material for tatami mats. and a closed-cell olefin-based synthetic resin foam sheet in which high-rigidity sheets are laminated on both sides.

As the wood-based core material, a wood fiber board obtained by pulping wood or other plant fibers, binding them with a binder resin, and heat-pressing them is preferable. Examples include particle board, plywood, and insulation fiber board (insulation board). , medium density fiberboard (MDF), hard fiberboard (hardboard), etc., and medium density fiberboard (MDF) is preferred.

Although the thickness of the core material 1 is not particularly limited, it is generally preferably 2 to 8 mm, more preferably 3 to 6 mm, because the thinner the core material, the lower the mechanical strength, and the thicker the material, the heavier the core material.

The surface cushion sheet 2 imparts cushioning properties and soundproofing properties to the tatami mat, and has an apparent density of 0.04 to 0.2 g/cm ³ , a compression modulus of 10 to 40 KPa, and a thickness of 1 to 10 mm.

The apparent density of the surface cushion sheet 2 is 0.04 to 0.2 g/cm 3 , preferably 0.04 to 0.04 to 0.2 g/cm ³ , because if the apparent density of the surface cushion sheet 2 is small, the cushion is reduced and tends to sag. .12 g/cm ³ . If the compression elastic modulus is small, it tends to become flattened and the soundproofing property is lowered, and if it is large, the cushioning property is lowered. Also, the thickness is 1 to 10 mm, preferably 2 to 6 mm, because the thinner the thickness, the lower the cushioning properties and soundproofing properties, and the thicker the thickness, the easier it is to sag.

In the present invention, the compression elastic modulus is defined in accordance with JIS K 7181 (2011 Plastics-Determination of compression properties), and is pressed at a speed of 10 mm/min with a cylindrical indenter having a diameter of 30 mm and a flat bottom surface. It was obtained by the value of the inclination when the cushion sheet was compressed so that the strain was 10% to 20%.

The surface cushion sheet is not particularly limited as long as it has a cushioning property with an apparent density of 0.04 to 0.2 g/cm ³ and a compression modulus of 10 to 40 KPa. Sheet; Elastomer sheet; Cushioning sheets conventionally used as cushion sheets for tatami mats, such as woven fabrics, knitted fabrics, non-woven fabrics, mats, and felts, made of organic fibers such as natural fibers and synthetic fibers, and inorganic fibers.

As the surface cushion sheet, a non-woven fiber sheet in which non-wet heat adhesive fibers are partially fused with a wet heat adhesive resin has a low apparent density, an excellent compression modulus, and a high mechanical strength. preferably used.

As the non-wet heat adhesive fibers, non-wet heat adhesive general-purpose fibers can be used, and examples thereof include hemp fibers, cotton fibers, polyethylene fibers, polypropylene fibers, urethane fibers, polyacrylic fibers, polyester fibers, and polyamide fibers. polyester fibers and polyamide fibers are preferred.

The wet heat adhesive resin is a thermoplastic resin that can self-adhere or adhere to the non-wet heat adhesive fibers at high temperature and high humidity, and examples thereof include ethylene-vinyl alcohol copolymers and polylactic acid resins.

In the above nonwoven fiber sheet, non-wet heat adhesive fibers are partially fused with a wet heat adhesive resin. It is preferably uniformly distributed throughout the nonwoven fibrous sheet.

Therefore, it is preferable that the non-wet heat adhesive fibers are partially fused with the wet heat adhesive resin fibers made of the wet heat adhesive resin. Also, the wet heat adhesive resin fiber may be a core-sheath type fiber in which the surface of the non-wet heat adhesive fiber is coated with the wet heat adhesive resin.

The average fineness of the non-wet heat adhesive fiber and the wet heat adhesive resin fiber is preferably 0.1 to 30 dtex, more preferably 0. .5 to 20 dtex. Moreover, the cross-sectional shape is not particularly limited, and examples thereof include circular, elliptical, and polygonal shapes.

In addition, the length of the non-wet heat adhesive fiber and the wet heat adhesive resin fiber is generally 5 to 100 mm, preferably 10 to 80 mm, because the shorter the length, the lower the mechanical strength and soundproofing properties, and the longer the length, the more difficult the production. is.

The ratio of the non-wet heat adhesive fiber and the wet heat adhesive resin is not particularly limited, but is generally 50 to 200 parts by weight of the wet heat adhesive resin per 100 parts by weight of the non-damp heat adhesive fiber, preferably 80 to 150 parts by weight. be.

The method for producing the non-woven fiber sheet is not particularly limited. A method of heating and humidifying by blowing hot water or steam from above and below while applying pressure is exemplified. The non-woven fiber sheet produced by the above method is evenly bonded as a whole, and the mechanical strength (particularly, compressive elastic modulus) of the whole sheet is uniform and excellent. When a web is produced using core-sheath type fibers in which the surface of non-wet heat-adhesive fibers is coated with a wet heat-adhesive resin, the web may be produced only from the core-sheath type fibers.

The surface cushion sheet 2 may be a laminated sheet in which two or more thin non-woven fiber sheets are laminated, or may be a laminated sheet in which two or more thin cushioning sheets are laminated. Furthermore, a laminated sheet in which one or more thin non-woven fiber sheets and one or more thin cushioning sheets are laminated may be used.

When the surface cushion sheet is constructed by laminating the nonwoven fiber sheet and the cushioning sheet, it does not matter whether the nonwoven fiber sheet or the cushioning sheet is on top, but the cushioning sheet is in contact with the tatami facing. Preferably, the nonwoven fiber sheet is laminated so as to be in contact with the core material.

The surface cushion sheet in which the nonwoven fiber sheet and the cushioning sheet are laminated has an apparent density of 0.04 to 0.2 g/cm ³ , a compression modulus of 10 to 40 KPa, and a thickness of 1 to 10 mm as a whole sheet. . The apparent density and compressive modulus of the cushioning sheet may slightly deviate from these ranges, but the apparent density and compressive modulus of the nonwoven fiber sheet are preferably within these ranges. The apparent density and compressive modulus of both sheets are preferably within this range.

The total thickness of the nonwoven fiber sheet and the cushioning sheet is 1 to 10 mm, and the ratio of the thickness of the nonwoven fiber sheet to the thickness of the cushioning sheet is preferably 1:2 to 2:1.

In addition, if the basis weight of the surface cushion sheet ² is small, it is likely to become flattened, and if it is large, the cushioning properties and soundproofing properties are deteriorated. ² .

The tatami facing 3 is a tatami facing that has been conventionally used as a tatami facing. A large number of (synthetic) rushes are arranged in parallel as horizontal culms, and hemp, manila hemp, cotton, etc. are used as warp, and the weft, grub, It is woven by a pull-mesh weave such as a large eye.

The tatami mat may be a natural tatami mat manufactured from igsa, or a synthetic tatami mat manufactured from synthetic igsa made of synthetic resin such as polyethylene resin or polypropylene resin. Synthetic tatami mats are commercially available from Sekisui Seisei Co., Ltd. under the name of "Migusa (registered trademark)", for example. Methods for producing synthetic igsa are described in, for example, Japanese Patent Nos. 3,254,492 and 3,149,551.

As the thickness of the tatami facing 3 increases, the cushioning and soundproofing properties are improved. ~8 mm, preferably 1.5-3 mm.

The soundproof tatami mat of the present invention is generally a square or rectangular substantially rectangular tatami mat having a thickness of 8 to 55 mm. When the thickness increases, the mechanical strength decreases, and when the thickness increases, the cushioning properties and soundproofing properties decrease. Further, when the ratio of the surface cushion sheet 2 and the tatami facing 3 becomes small, the cushioning property and the soundproofing property deteriorate, and when the ratio becomes large, the mechanical strength deteriorates.

Therefore, the thickness ratio of the core material 1, the surface cushion sheet 2 and the tatami facing 3 is 1:0.5 to 2:0.2 to 2.5, preferably 1:0.8 to 1.5:0. .5 to 2.

A back cushion sheet may be laminated on the lower surface of the core material 1 in order to impart cushioning and soundproofing properties to the soundproof tatami mat. Since the back cushion sheet 4 imparts cushioning and soundproofing properties to the soundproof tatami mat, it is not particularly limited as long as it is conventionally used as a cushion sheet for tatami mats. Non-woven fabrics, woven fabrics, mats, and felts of fibers such as polyethylene fiber, polypropylene fiber, urethane fiber, polyacrylic fiber, and polyester fiber; polystyrene resin foam sheet, polyethylene resin foam sheet, polypropylene resin foam sheet, urethane foam sheet, rubber foam sheet foamed sheets such as;

When the apparent density of the backside cushion sheet decreases, it tends to sag and its cushioning properties decrease ^. Nonwoven fabrics of fibers such as hemp fibers, cotton fibers, polyethylene fibers, polypropylene fibers, urethane fibers, polyacrylic fibers, and polyester fibers are preferred, and polyester fiber nonwoven fabrics are more preferred.

The basis weight of the back cushion sheet is preferably from 100 to 800 g/m ² , more preferably from 150 to 500 g/m ² , because the smaller the basis weight, the lower the cushioning properties, and the larger the basis weight, the lower the soundproofing.

The thickness of the back cushion sheet 4 is not particularly limited, but is generally 1 to 10 mm, preferably 1.5 to 5 mm. Also, the back cushion sheet 4 may be formed by laminating two or more thin cushion sheets.

As the back cushion sheet, the non-woven fiber sheet described above can also be suitably used. The thickness of the nonwoven fiber sheet in this case is preferably 1 to 5 mm.

If the ratio of the back cushion sheet is small, the cushioning properties and soundproofing properties are lowered, and if the ratio is large, the mechanical strength is lowered. is 1:0.4-1.

Further, a back finishing material may be laminated on the lower surface of the core material or the back cushion sheet. The back finishing material is a sheet laminated on the surface of the core material or the back cushion sheet for the purpose of slip resistance, reinforcement, waterproofing, and the like.

Examples of non-slip backing materials include non-slip sheets made of resins with anti-slip properties such as silicone resins, acrylic resins, acrylic silicone resins, hemp fibers, cotton fibers, polyethylene fibers, and polypropylene fibers. Non-woven fabrics, woven fabrics, mats, felts, etc. made of fibers such as urethane fiber, polyacrylic fiber, polyester fiber, etc. Forming granular, linear, grid-shaped protrusions such as silicon-based resin, acrylic-based resin, and acrylic-silicon-based resin anti-slip sheets, and foamed sheets made of polyethylene resin, polypropylene resin, polystyrene resin, etc., having granular, linear, grid-like projections formed on the back surface, and the like. Examples of the back surface finishing material for reinforcement include kraft paper, paperboard, cardboard, cardboard, chipboard, synthetic resin sheet, cloth adhesive tape, etc. Examples of back surface finishing materials for waterproofing include: Synthetic resin sheets such as polyethylene resin, polypropylene resin, and polystyrene resin can be used.

The method of manufacturing the soundproof tatami mat of the present invention is not particularly limited, and any conventionally known manufacturing method may be employed, and generally includes the following manufacturing methods.
(1) The tatami facing 3, the surface cushion sheet 2 and the core material 1 are laminated, and the end of the tatami facing 3 is bent from the side surface of the surface cushion sheet 2 and the core material 1 along the bottom surface and fixed to the bottom surface of the core material 1. Form and integrate the frame.
(2) The tatami facing 3, the surface cushion sheet 2 and the core material 1 are laminated, and the ends of the tatami facing 3 and the surface cushion sheet 2 are bent from the sides of the core material 1 along the bottom surface and fixed to the bottom surface of the core material 1. Form and integrate the frame.
(3) The tatami facing 3, the surface cushion sheet 2 and the core material 1 are laminated, and the edge of the surface cushion sheet 2 is placed along the side surface of the core material 1 so that the tip surface of the surface cushion sheet 2 is flush with the bottom surface of the core material 1. Along with folding, the ends of the tatami facing 3 are folded from the ends of the surface cushion sheet 2 and the side surface of the core material 1 along the bottom surface, fixed to the bottom surface of the core material 1 to form a frame portion, and integrated.

When the frame portion is formed and manufactured in this way, a step is generated between the edge of the tatami facing 3 and the lower surface of the core material 1 and between the edge of the tatami facing 3 and the surface cushion sheet 2 and the lower surface of the core material 1 . In the space surrounded by the edge of the tatami facing 3 and the lower surface of the core material 1 or the edge of the tatami facing 3 and the surface cushion sheet 2 and the lower surface of the core material 1, a step adjusting sheet is laminated in order to eliminate the step. preferable.

The step adjustment sheet is preferably a sheet that has an unevenness adjustment function and also has cushioning properties and soundproofing properties. As the step adjustment sheet, for example, non-woven fabric, woven fabric, mat, felt of fiber such as hemp fiber, cotton fiber, polyethylene fiber, polypropylene fiber, urethane fiber, polyacrylic fiber, polyester fiber; polystyrene resin foam sheet, polyethylene resin foam Sheets, foamed sheets such as polypropylene resin foamed sheets, urethane foamed sheets and rubber foamed sheets;

As a step adjustment sheet, the lower the apparent density, the more likely it is to sag and the cushioning properties to decrease. Nonwoven fabrics of fibers such as fibers, polyacrylic fibers, and polyester fibers are preferable, and polyester fiber nonwoven fabrics are more preferable. m ² is preferred, more preferably 200-500 g/m ² .

Alternatively, it may be a non-woven fiber sheet having an apparent density of 0.04 to 0.2 g/cm ³ and a compression elastic modulus of 10 to 40 KPa.

The thickness of the step adjusting sheet is not particularly limited, but is preferably equal to or slightly thicker than the thickness of the tatami facing 3, generally 1 to 9 mm, preferably 1.5 to 4 mm. Also, the level difference adjusting sheet may be formed by laminating two or more thin level difference adjusting sheets.

The method of laminating the core material, the front cushion sheet, the tatami mat surface, and optionally the back cushion sheet and the adjustment sheet is not particularly limited. Adhesive, ethylene-vinyl acetate copolymer, linear low-density polyethylene resin or other polyolefin hot-melt adhesive, heat-sealing, suturing with thread, hitting with a tucker, etc. be done.

However, in the method of laminating the tatami surface and surface cushion sheet on the core material, rolling the tatami surface around the bottom surface of the core material and hitting it with a tucker, the tatami surface and the surface cushion may deteriorate over time after manufacturing or when the soundproof tatami is used. If the sheet is displaced, the edge of the surface cushion sheet of the soundproof tatami mat will weaken and the soundproofing will deteriorate, so it is preferable that the sheet is adhered with a (viscous) adhesive.

At least the core material and the surface cushion sheet are preferably fixedly adhered with a (visco)adhesive. The core material may be adhered to the surface cushion sheet only on a part of its surface in contact with the surface cushion sheet, but it is preferable that the entire surface is adhered. Also, it is preferable that the surface cushion sheet is adhered to the side surface of the core material. Moreover, the tatami facing and the surface cushion sheet, and the non-woven fiber sheet and the cushioning sheet do not necessarily need to be adhered, and may simply be superimposed.

FIG. 4 is a cross-sectional view showing an example of the structure of one end portion (frame portion) of the soundproof tatami mat of the present invention. In FIG. 1, reference numeral 1 denotes a core material. A tatami surface 3 is sequentially laminated on the upper surface of the core material 1 with a front cushion sheet 2 interposed therebetween, and a rear cushion sheet 4 is laminated on the lower surface. The ends of the surface cushion sheet 2 are bent along the side surfaces of the core material 1 and reach the bottom surface of the core material 1 so that the bottom surface of the core material 1 and the tip of the surface cushion sheet 2 are flush with each other. The ends of the tatami facing 3 are folded along the sides of the core material 1 together with the surface cushion sheet 2 , and are further folded from the lower surface of the front end of the surface cushion sheet 2 to the lower surface of the core material 1 . That is, the end of the surface cushion sheet 2 is interposed between the side surface of the core material 1 and the tatami facing 3 . In addition, a step adjusting sheet 6 is inserted in a space formed by the lower surface of the core material 1, the end portion of the tatami facing 3, and the back cushion sheet 4. - 特許庁

FIG. 5 is a cross-sectional view showing a different example of the structure of one end portion (frame portion) of the soundproof tatami mat of the present invention. In FIG. 1, reference numeral 1 denotes a core material. A tatami surface 3 is sequentially laminated on the upper surface of the core material 1 with a front cushion sheet 2 interposed therebetween, and a rear cushion sheet 4 is laminated on the lower surface. The surface cushion sheet 2 is formed by laminating a cushioning sheet 21 and a nonwoven fiber sheet 22 , and the nonwoven fiber sheet 22 is arranged so as to be in contact with the upper surface of the core material 1 . The non-woven fiber sheet 22 is laminated on the core material 1 so that the ends thereof are flush with the side surfaces of the core material 1 . The ends of the cushioning sheet 21 are folded along the sides of the non-woven fiber sheet 22 and the side of the core 1, and the tip of the cushioning sheet 21 is placed flush with the lower surface of the core 1. reaches the bottom surface of the The ends of the tatami facing 3 are folded along the sides of the core material 1 together with the cushioning sheet 21 , and further folded from the lower surface of the leading edge of the non-woven fiber sheet 21 to the lower surface of the core material 1 . That is, the end of the cushioning sheet 21 is interposed between the side surface of the core material 1 and the tatami facing 3 . In addition, a step adjusting sheet 6 is inserted in a space formed by the lower surface of the core material 1, the end portion of the tatami facing 3, and the back cushion sheet 4. - 特許庁

The tatami facing 3 consists of a large number of (synthetic) rushes arranged in parallel as weft culms, and hemp, manila hemp, cotton, etc. yarns as warp yarns, and the (synthetic) rushes and warp yarns intersecting at right angles. It is woven by a pull stitch weave such as. 4 and 5, the ends of the tatami facing 3 in the warp direction are bent from the lower surface of the front end portion of the surface cushion sheet 2 (cushioning sheet 21) to the lower surface of the core material 1. As shown in FIGS. That is, the tatami facing 3 is laminated so that the (synthetic) rush, which is a horizontal culm, is parallel to the side surface of the core material 1 (perpendicular to the paper surface in FIGS. 4 and 5).

In the soundproof tatami mat of the present invention, if the surface cushion sheet near the ends (stiles) weakens and becomes thinner, the soundproofing performance is reduced. As shown in 5, it is preferable that the tatami facing and the surface cushion sheet (non-woven fiber sheet) are laminated so as to form a substantially right angle.

The other end (the end opposite to the one end) of the soundproof tatami mat of the present invention is also a frame portion and has the same structure as the one end. Also, an end portion perpendicular to the frame portion (hereinafter referred to as a "returned end portion") may have the same structure as the frame portion. However, at the return end, the (synthetic) rush, which is the horizontal culm of the tatami facing 3, is laminated perpendicular to the side surface of the core material 1, so the length of the tatami facing 3 is limited by the length of the (synthetic) rush. However, the end of the (synthetic) igsa of the tatami facing 3 is folded along the side surface of the surface cushion sheet 2 and the core material 1 because the shape of the surface cushion sheet 2 becomes complicated and it is difficult to manufacture. Furthermore, it is common that the core material 1 is folded and laminated to the lower surface, and it is practical to interpose the surface cushion sheet 2 between the return end of the core material 1 and the tatami mat surface 3 (rush). isn't it. That is, in general, only the tatami mat surface 3 (rush) is laminated on the side surface of the core material 1 at the return end, and the surface cushion sheet 2 is not interposed.

For example, in the soundproof tatami mat shown in FIG. 4, after the surface cushion sheet 2 is adhered to the surface of the core material 1 and, if necessary, the side surface, the tatami surface 3 is superimposed on the upper surface of the surface cushion sheet 2, and the edge of the tatami surface 3 is The edge of the tatami facing 3 is folded along the side surface of the core material 1 together with the surface cushion sheet 2, and further folded from the bottom surface of the front end of the surface cushion sheet 2 to the bottom surface of the core material 1 so as not to apply a load to the surface cushion sheet 2. The part may be integrated with the lower surface of the core material 1 by bonding, hammering with a tucker, or the like.

In the soundproof tatami mat shown in FIG. 5, a nonwoven fiber sheet 22 is adhered to the surface of the core material 1 so that both side surfaces are flush with each other, and then a cushioning sheet 21 and a tatami mat surface are placed on the nonwoven fiber sheet 22 . 3 are superimposed, the tip of the cushioning sheet 21 is folded (bonded as necessary) so that it is flush with the lower surface of the core material 1, and then the end of the tatami facing 3 is placed on the side of the cushioning sheet 21. Further, the edge of the tatami facing 3 is folded from the lower surface of the tip portion of the cushioning sheet 21 to the lower surface of the core material 1 so that no load is applied to the surface cushioning sheet 2 (the cushioning sheet 21 and the non-woven fiber sheet 22). may be integrated with the lower surface of the core material 1 by a method such as bonding or hammering with a tucker.

The structure of the soundproof tatami mat of the present invention is as described above. The sound level is ΔLL(I)-5 or higher.

Any conventionally known method may be employed for laying a plurality of soundproof tatami mats of the present invention. However, while the surface cushion sheet and the tatami facing are folded and laminated on the frame portion, only the tatami facing is folded and laminated on the return end portion. That is, the surface cushion sheet is laminated between the side surface of the core material and the tatami facing at the frame portion, but the surface cushion sheet is not laminated between the side surface of the core material and the tatami facing at the return end portion. Therefore, when laying the soundproof tatami mats, if the stile portions or the stile portion and the return end are in contact with each other, the surface cushion sheet is interposed between the adjacent soundproof tatami mats, resulting in excellent soundproofing. If you lay it so that the return ends touch each other, the surface cushion sheet will not be interposed between the adjacent soundproof tatami mats, so the soundproofing will decrease. preferable. By doing so, the surface cushion sheet is always interposed between the adjacent soundproof tatami mats, so that the soundproofing is excellent without deteriorating.

Therefore, when laying the soundproof tatami mats of the present invention, it is preferable to lay the tatami surfaces of the adjacent soundproof tatami mats so that they are perpendicular to each other. FIG. 6 is a plan view showing a state in which the soundproof tatami mat of the present invention is laid. In the figure, 10a, 10a, . Therefore, the end in the direction of arrow a is the return end, and the end perpendicular thereto is the frame. A surface cushion sheet is laminated on the frame portion, and no surface cushion sheet is laminated on the return end portion. 10b, 10b, . Therefore, the end in the direction of the arrow b is the return end, and the end perpendicular thereto is the frame. The surface cushion sheet is also laminated on the frame portion, and the surface cushion sheet is not laminated on the return end portion.

All the adjacent soundproof tatami mats 10a, 10a, 10b, 10b, . The return ends are adjacent to each other, and the surface cushion sheet is interposed between all the adjacent frame portions and the return end portions, so that soundproofing is excellent.

Next, examples of the present invention will be described, but the present invention is not limited to these examples.

(Example 1)
Core-sheath type staple fibers (fineness 3.3 dtex, fiber length 51 mm, fiber length 51 mm, A carded web was prepared by a carding method using a core/sheath weight ratio of 1:1, a number of crimps of 21/25 mm, and a crimp rate of 13.5%.

The obtained card web was sandwiched between two wire mesh belts, and while being pressurized, high temperature steam of 0.25 MPa was injected from above and below to melt and bond the sheath portion of the core-sheath type staple fiber (ethylene-vinyl alcohol copolymer, A nonwoven fibrous sheet was obtained.

The resulting nonwoven fiber sheet had a thickness of 3.0 mm, an apparent density of 0.05 g/cm ³ , a compression modulus of 18.8 KPa, and a basis weight of 150 g/m ² .

As shown in FIG. 4, the obtained nonwoven fiber sheet was placed on the upper surface of a core material 1 made of medium density fiberboard (MDF) having a thickness of 4 mm, a density of 0.48 g/cm 3 and a flexural modulus of 3.4 MPa. The sheets were stacked to form a surface cushion sheet 2, and a 2 mm-thick artificial tatami facing 1 (manufactured by Sekisui Seisei Co., Ltd., trade name "MIGUSA") was laminated thereon so that the artificial rush was perpendicular to the paper surface in FIG. .

Next, the surface cushion sheet 2 is folded along the side edges of the core material 1 so that the end surface of the surface cushion sheet 2 is flush with the bottom surface of the core material 1, and the artificial tatami mat surface 3 is folded along the bottom surface of the core material 1 from the side edges. It was folded and temporarily fixed with an adhesive tape to form a frame portion.

Further, the artificial tatami mat surface 3 projecting from the core material 1 was folded along the lower surface from the side end of the core material 1 and temporarily fixed with an adhesive tape to form a return end. Next, a polyester fiber nonwoven fabric having a thickness of 2 mm and a basis weight of 200 g/m ² was superimposed as a back cushion sheet 4 on the back surface of the core material 1 and integrated with a tucker.

Further, the rear cushion sheet 4 was finished by attaching a cloth adhesive sheet having a thickness of 0.7 mm as a rear finishing material to obtain a soundproof tatami mat having a thickness of 16.7 mm. In the space formed by the artificial tatami mat surface 3, the core material 1, and the back cushion sheet 4, a polyester fiber nonwoven fabric having a thickness of 2.0 mm was laminated as a step adjustment sheet 6. As shown in FIG.

(Example 2)
A nonwoven fiber sheet having a thickness of 4 mm was obtained in the same manner as in Example 1. The obtained nonwoven fiber sheet with a thickness of 4 mm and the polyester fiber nonwoven fabric with a thickness of 2 mm and a basis weight of 240 mg/m ² were superimposed to obtain a surface cushion sheet with a thickness of 6 mm. The obtained surface cushion sheet had a thickness of 6.0 mm, an apparent density of 0.07 g/cm ³ , a compression modulus of 34.0 KPa, and a basis weight of 440 g/m ² .

As shown in FIG. 5, the resulting surface cushion sheet 2 was placed on the upper surface of a core material 1 made of medium density fiberboard (MDF) having a thickness of 4 mm, a density of 0.48 g/cm 3 and a flexural modulus of 3.4 MPa. The woven fiber sheet 22 was laminated on the core material 1 side. The size and shape of the nonwoven fiber sheet 22 are the same as those of the upper surface of the core material 1, and the side surfaces of the nonwoven fiber sheet 22 and the core material 1 are laminated so as to be flush with each other. Moreover, the polyester fiber nonwoven fabric 21 was folded along the sides of the nonwoven fiber sheet 22 and the core material 1 so that the tip surface was flush with the lower surface of the core material 1 .

A 2 mm thick artificial tatami mat surface 3 (manufactured by Sekisui Seisei Co., Ltd., trade name "MIGUSA") was laminated on the surface cushion sheet 2 so as to be in contact with the polyester fiber nonwoven fabric 21 so as to be perpendicular to the paper surface in FIG. .

Next, the artificial tatami mat surface 3 protruding from the core material 1 was folded from the side end portion of the core material 1 along the lower surface and temporarily fixed with an adhesive tape to form a frame portion. Next, a polyester fiber nonwoven fabric having a thickness of 2 mm and a basis weight of 200 g/m ² was superimposed as a back cushion sheet 4 on the back surface of the core material 1 and integrated with a tucker.

Further, the rear cushion sheet 4 was finished by attaching a cloth adhesive sheet having a thickness of 0.7 mm as a rear finishing material to obtain a soundproof tatami mat having a thickness of 16.7 mm. In the space formed by the artificial tatami mat surface 3, the core material 1, and the back cushion sheet 4, a polyester fiber nonwoven fabric having a thickness of 2.0 mm was laminated as a step adjustment sheet 6. As shown in FIG.

(Example 3)
A linear low-density polyethylene resin sheet having a thickness of 40 μm and two of the obtained non-woven fiber sheets were superimposed on the entire upper surface of the core material 1, and an ultrasonic welder (manufactured by Seidensha Denshi Kogyo Co., Ltd., trade name “SONOPET Σ” was applied. A soundproof tatami mat of the present invention having a thickness of 16.7 mm was obtained in the same manner as in Example 1, except that the core material 1 and the lower non-woven fiber sheet were heat-sealed using the same method as that of Example 1.

(Example 4)
A non-woven fiber sheet is superimposed on a linear low-density polyethylene resin sheet with a thickness of 40 μm superimposed on the entire upper surface of the core material, and an ultrasonic welder (manufactured by Seidensha Denshi Kogyo Co., Ltd., trade name “SONOPET Σ-1200” is used. ), a soundproof tatami mat of the present invention having a thickness of 16.7 mm was obtained in the same manner as in Example 2, except that the core material and the nonwoven fiber sheet were heat-sealed.

(Comparative example 1)
16.7 mm thick soundproof tatami mats in the same manner as in Example 1, except that two polyester fiber nonwoven fabrics with a thickness of 2 mm and a basis weight of 240 g/m ² were used as the front cushion sheet and the back cushion sheet. got The surface cushion sheet had an apparent density of 0.12 g/cm ³ and a compression modulus of 50.2 KPa.

(Comparative example 2)
As the front cushion sheet, a polyester fiber nonwoven fabric with a thickness of 4 ^{mm and a basis weight of 480 mg/m 2 was} used. A soundproof tatami mat having a thickness of 16.7 mm was obtained in the same manner as in Comparative Example 1, except that the product name "SSK-K" (manufactured by Co., Ltd.) was laminated. The surface cushion sheet had an apparent density of 0.12 g/cm ³ and a compression modulus of 66.9 KPa.

The soundproofing properties of the soundproof tatami mats obtained in Examples 1 to 4 and Comparative Examples 1 and 2 were measured according to JIS A 1440-1 (method for measuring floor impact sound level reduction in floor finishing structure (method using standard lightweight impact source)). Table 1 shows the results. For reference, reference values for floor impact sound levels of ΔLL(I)-4 and ΔLL(I)-5 are also shown.

In addition, a plurality of soundproof tatami mats obtained in Examples 1 to 4 were laid, a measuring instrument was installed so as to straddle the plurality of soundproof tatami mats, and the soundproofing was measured according to JIS A 1440-1 (floor impact noise of floor finish structure). It was measured according to the level reduction amount measurement method (method using a standard lightweight impact source), and the results are shown in Tables 2 and 3. In the table, "center" was measured at the center of the soundproof tatami mat. In addition, "frame, frame" is laid so that the frame and frame of the soundproof tatami are in contact with each other, and "frame, return" is laid so that the frame and return end of the soundproof tatami are in contact, and "return, return". was laid so that the return ends of the soundproof tatami mats were in contact with each other.

The soundproof tatami mat of the present invention has a floor impact sound level of ΔLL(I) measured in accordance with JIS A 1440-1 (Method for measuring floor impact sound level reduction of floor finish structure (method using standard lightweight impact source)). -5 or higher, soundproofing is excellent, so even when placed on the flooring in a high-rise building, the sound generated by the load or impact applied to the soundproof tatami is soundproofed, and the room downstairs. Since it is difficult to transmit directly to the inside, it can be suitably used in place of conventional tatami mats in housing complexes and condominiums. A reference value of -5 is also shown.

REFERENCE SIGNS LIST 1 core material 2 surface cushion sheet 21 cushioning sheet 22 non-woven fiber sheet 3 tatami surface 4 back cushion sheet 5 back finishing material 6 step adjustment sheet

Claims (13)

A soundproof tatami mat in which a tatami surface is laminated on the upper surface of a core material via a surface cushion sheet, wherein the surface cushion sheet has an apparent density of 0.04 to 0.2 g/cm ³ , a compression elastic modulus of 10 to 40 KPa, and a thickness of 10 to 40 KPa. A soundproof tatami mat having a thickness of 1 to 10 mm. 2. The soundproof tatami mat according to claim 1, wherein the core material is a wooden core material. 3. The soundproof tatami mat according to claim 1, wherein the surface cushion sheet is a non-woven fiber sheet in which non-wet heat adhesive fibers are partially fused with a wet heat adhesive resin. 3. The soundproofing according to claim 1 or 2, wherein the surface cushion sheet is a laminated sheet of a non-woven fiber sheet and a cushioning sheet in which non-wet heat adhesive fibers are partially fused with a wet heat adhesive resin. tatami. The thickness of the core material: the thickness of the surface cushion sheet: the thickness of the tatami facing is 1: 0.5 to 2: 0.2 to 2.5. Soundproof tatami mats as described. The soundproof tatami mat according to any one of claims 1 to 5, wherein the surface cushion sheet and the core material are adhered with a (viscous) adhesive. The soundproof tatami mat according to any one of claims 1 to 6, wherein a back cushion sheet is laminated on the lower surface of the core material. 8. The tatami facing and the end portions of the surface cushion sheet are folded to the side surface of the core material, and the leading edge of the tatami facing is folded to the lower surface of the core material and laminated. soundproof tatami mats. 9. The soundproof tatami mat according to claim 8, wherein a step adjusting sheet is laminated in a space surrounded by the lower surface of the core material and the tatami facing. 10. The soundproof tatami mat according to claim 9, wherein a rear cushion sheet is laminated on the lower surface of the tatami facing and the step adjustment sheet laminated on the lower surface of the core material. 11. The soundproof tatami mat according to claim 7 or 10, further comprising a rear surface finishing material laminated on the surface of the rear cushion sheet. Confirm that the floor impact sound level measured in accordance with JIS A 1440-1 (Measurement method for floor impact sound level reduction of floor finishing structure (method using standard lightweight impact source)) is ΔLL(I)-5 or more. The soundproof tatami mat according to any one of claims 1 to 11. A method of laying soundproof tatami mats, comprising laying the soundproof tatami mats according to any one of claims 1 to 12 so that the ridges of the tatami surfaces of adjacent soundproof tatami mats are orthogonal to each other.

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