KR100731992B1 - A carpet wallboard material with mite-free layer - Google Patents

Abstract

A carpet wallboard material with a mite-free functional layer is provided to secure both sound absorption and mite-free functions by a carpet layer and the functional layer and to keep the mite-free function for a long time and to reduce the total thickness by inserting the functional layer into the carpet layer or using a base cloth. An interior construction material is composed of a pile-shaped carpet layer(21) made of BCF(Bulky Continuous Filament) and provided with a bent surface having peaks and valleys uniformly distributed; an absorbing layer(23) formed under the carpet layer; an adhesive layer(22) for joining the carpet layer and the absorbing layer; and a mite-free functional layer(C) containing phytoncide and a germicide. An effective area of the carpet layer is 20~150m^2 per 1m^2.

Description

A Carpet Wallboard Material with Mite-free Layer

1 shows a cross section of a carpet building material according to the invention.

The present invention relates to interior building materials with carpet layers and functional layers, and more particularly to interior building materials with carpet layers of nylon, PP, PTT and PET fibers and additional functional layers for dustproofness.

Wall, ceiling and floor materials require robustness and functionality. Robustness means that the material can be formed together with other materials to maintain the required shape for a certain period of time. And functionality is required to improve the usability of the internal environment depending on the space where the material is used. In general, the material for robustness is not highly demanded because of the lack of diversity in that it is limited and not exposed to the outside. However, the material for the functional material can be changed depending on the required function and the high selectivity due to the difference in the effect depending on the material.

Commonly required functions for wall, ceiling and floor materials are sound absorption, insulation, flame retardant or flame retardant. In addition, antibacterial or deodorant and decorative properties may be required depending on the use of the used space.

Sound absorption means that some of the sound incident on the material is absorbed in the material without being transmitted or reflected. When sound is generated from one side of the material, the sound that is not reflected corresponds to the absorption or transmission of the material. Since all of these unreflected sounds appear to be absorbed, the ratio of sound energy that appears to be apparently absorbed to the incident sound energy is called sound absorption ratio.

Interior building materials should have sound absorbing and vibration absorbing as well as other additional functions. These additional functions are required for the efficiency of the space used and, for example, these functions include the prevention of harmful gases that cause antibacterial, deodorant, flame retardant and sick house syndrome. These functions, in addition to building materials, are becoming essential functions with the development of new building materials.

The method of forming the functional layer on the indoor building material includes a method of applying a coating agent and a method of adding a material having a function necessary for the material and adding it in the form of a composition. Alternatively, the two methods may be used in combination to add a functional material to an adhesive or a coating to coat a wall material.

Prior art related to building materials having a functional is 10-2002-0084252 "Building finishing material using a ceramic composite and a method of manufacturing the same". The proposed invention aims at generating negative ions, reducing heating and cooling costs, neutralizing toxic and antibacterial, insect repellent, and soundproofing effects. And the building finish according to the proposed invention is a silica bead formed a fine hollow in the body; It includes a composite ceramic mixed with the hollow silica beads in a predetermined volume ratio.

Another prior art related to functional building materials is WO2004 / 085151 "Functional members, methods for making them and coating liquids". The proposed invention aims to provide a functional member having excellent humidity control function, removal of toxic chemicals and unpleasant living odors, antifouling property, contamination concealment and flammability. And a functional member according to the proposed invention, comprising: a first layer formed on a combustible substrate and comprising a dried material comprising an inorganic porous body and an organic emulsion; And an inorganic filler fixed over the entire surface of the first layer by an organic adhesive, wherein the glass transition temperature of the glass in the organic emulsion is from -5 ° C to -50 ° C; The organic adhesive in the second layer is characterized in that the amount of 30 to 300 parts by volume relative to 100 parts by volume of the inorganic filler.

The preceding and known inventions presented propose a method in which the additional functions required are added apart from the functions of sound absorption and vibration absorption. However, indoor building materials should be formed so that additional functions can be expressed in combination with basic functions of indoor building materials such as sound absorption and vibration absorption. Therefore, there is a need to develop a material for interior construction that can have additional functions, such as sound absorption and vibration absorption, at the same time. The present invention has been made to solve the above problems and has the following object.

It is an object of the present invention to provide a material for interior construction having a carpet layer as a sound absorbing and vibration absorbing material and additionally a functional layer expressing anti-mite as a necessary function.

According to a preferred embodiment of the present invention, the building material according to the present invention comprises a carpet layer of nylon, polypropylene (PP), polytrimethylene terephthalate (PTT) or PET (Polyester) fibers having uniformly distributed bends; A functional layer comprising an anti-tick agent; And an absorbent layer bonded to the carpet layer; And an adhesive layer for bonding the carpet layer and the absorbent layer.

According to another suitable embodiment of the present invention, the anti-mite functional layer may be formed by dipping or spraying a phytoncide drug or disinfectant or by adding 0.3 to 0.6% by weight to latex which is a backing material of a carpet. Can be.

According to another suitable embodiment of the present invention, the fungicide can be used in combination of any one or two or more selected from the group consisting of CMIT, MIT, BIT, OIT, PHMG.

According to another suitable embodiment of the present invention, in addition to the method for forming the anti-mite agent in the coating layer or the backing material, even a bubble paper applied with a ceramic anti-mite agent in which boric acid, alkaline earth, silicic acid, etc. are compounded at a high temperature is used. Can give a tick effect.

Hereinafter, the present invention will be described in detail with reference to the accompanying drawings, which do not limit the scope of the present invention.

1 shows a cross-sectional view of an embodiment of a functional building material 1 for interior construction according to the present invention.

Referring to Figure 1, the material 20 is a coating layer (C) comprising a carpet layer 21, a composition having a function such as antibacterial, flame retardant and harmful substances removed; An adhesive layer 22 made of a material such as synthetic resin; Absorbent layer 23 in foam form; And a dustproof layer 24 made of a dustproof material such as rubber felt as required.

In FIG. 1, carpet layer 21 is composed of pile 211 and bubble paper 212, and pile 211 in carpet layer 21 is nylon 6, nylon 66, polypropylene (PP), polytrimethylene tere. It may be phthalate (PTT, Polytrimethylene terephthalate) or polyethylene terephthalate (PET) bulky continuous filament (BCF) fibers. Nylon BCF is characterized by excellent strength, abrasion resistance and elasticity, and excellent chemical resistance, microbial resistance and electrical insulation. PP BCF fibers, unlike other fibers, have a water content of zero and an extremely low absorption rate. These PP BCF fibers are characterized by low electrostatic properties and do not generate static electricity and are excellent in stain resistance and antibacterial resistance. PET BCF fibers have good shape stability and flame retardancy. The carpet layer 21 of the sound insulation material 20 according to the invention can be formed of a generally known known carpet, but is preferably formed of nylon, PP, PTT or PET fibers due to the respective advantages presented.

In addition, the bulky continuous filaments (BCF) can be prepared by any method known to those skilled in the art. Preferably a plurality of BCF yarns are cable twisted and heat set together and then weave to the primary back side. The latex adhesive and the secondary backside are then applied. Cut pile style carpets or loop pile style carpets with pile heights of approximately 2-20 mm can be made. At this time, the weight of the carpet is 400 to 4000g / m ² .

Flame retardants may be added in the precoating or backing process to increase carpet flame retardancy of the present invention.

SBR latex and calcium carbonate are mainly used in the pre-coating process. In addition, in the manufacture of tile carpets, calcium carbonate is mainly used as a backing reinforcement material together with PVC (polyvinyl chloride) or SBS (styrene butadiene styrene) resins. Can be.

The form of the pile of the carpet layer of the present invention is not particularly limited, but may be any form such as a cut pile or a loop pile. In addition, the carpet used for the carpet layer of the present invention may be used in a state in which a lapping prevention latex is coated on the bottom surface of the bubble paper, or may be used in a form completed until backing as necessary.

The carpet layer 21 according to the invention has the advantage of excellent negative absorption effect since the effective surface area is much larger than the surface layer of the known wall material. The effective surface area may be the area of the directly reaching portion without being reflected or scattered when light or sound is incident perpendicularly to the material plane.

Although the specific surface area represents an area for unit weight, the effective surface area is related to the apparent surface area, and the sound absorption performance of the sound absorbing product is more correlated with the effective surface area than the specific surface area. This effective surface area may have a larger value if the surface is not flat and has curvature. If the material surface has a roughness, it becomes difficult to measure the effective surface area substantially. Therefore, the effective surface area needs to be determined according to a certain method with respect to the cross-sectional area of the material. In the present invention, the surface area value of the fiber present in the unit area of 1 m ² of the absorbent layer is defined as the effective surface area (m ² ). The effective surface area of the carpet layer material used in the present invention was suitably 20-1500 m ² . If the effective surface area is less than 20m ^{2, the} sound absorbing effect is small and unsuitable. If the effective surface area is more than 150m ² , too much fiber per unit area or the length of pile is required to be woven.

In addition, the thickness of the carpet layer 21 or the density of the carpet layer 21 need to be limited in consideration of the weight and sound absorption performance of the product related to space autonomy or ease of construction when the soundproof material having the carpet layer is installed on the wall or ceiling. There is. The thickness of the carpet layer may be 2-20 mm, preferably 5-10 mm is suitable, and the density of the carpet layer material is 50-300 kg / m ³ . If the thickness or density of the carpet is less than the set range, the sound absorbing function is not sufficient, and if it exceeds the set range, it takes up a lot of space and it is difficult to secure the light weight, which is not preferable.

Soundproof material 20 according to the present invention is a variety of functional layers (C) for the antibacterial, deodorant or harmful substance removal is formed on the surface of the pile 211 of the carpet layer 21, or bubble paper 212 surface, preferably May be formed on the upper surface. Such functional layers C may be coated on the carpet layer. Alternatively, the material having the corresponding function may be added to the carpet for the carpet layer 21 by mixing with a pile anti-latex latex at the bottom of the bubble in the manufacturing process or mixed with the forming material of the adhesive layer 22. Can be formed.

As described above, when the adhesive layer 22 and the functional layer are integrally manufactured, a material having water repellent, noxious component removal, flame retardant, color tone formation, antibacterial, electromagnetic wave blocking, and anion or ultraviolet ray emission function may be added to the adhesive at a suitable ratio. And mix. If desired, surfactants and dispersants may be added to the mixture. The adhesive mixed with such a functional material is applied to the back side of the carpet layer bubble paper 212 to form an adhesive coating layer.

The functional layer (C) according to the invention is particularly dustproof. The functional layer (C) may be formed by preparing a pharmaceutical composition having anti-dust properties and treating it by spraying or dipping. In general, house dust mites are known to cause diseases such as atopic dermatitis, allergies, allergic rhinitis, or bronchial asthma by the dust of carcasses and excreta on the skin and respiratory system. Therefore, anti-mite refers to creating an environment that inhibits the growth of house dust mites in key habitats. Compositions for anti-mite include antibacterial or phytoncide. Phytoncide refers to a compound that exhibits antimicrobial activity mainly released from coniferous trees including compounds such as tefphene, phenolic compounds, alkaloids and glycosides.

Fungicides include CMIT (5-chloro-2-methyl1-4-isothiazolin-3-1), IT (2-methyl-4isothiazolin-3-1), BIT (1,2-benzisothizolin-3-1), OIT (2 -N-octyl-4isothizolin-3-1) or PHMG (polyhexamethylene Guanidine phosphate) medicinal agents are widely used in the industry, any one or two or more selected from these groups can be used in combination.

As a method for treating a phytoncide drug or disinfectant, the coating layer (C) may be formed by dipping or spraying the carpet pile 211, or 0.3 to 0.6 wt% is added to the latex, which is a backing material of the carpet. Can be.

In addition to the method for imparting a mite of the present invention, in addition to the method for forming the mite agent in the coating layer or the backing material, the bubble paper 212 to which the mite agent of ceramic material in which boric acid, alkaline earth, silicic acid and the like is compounded at a high temperature is used. Even if the mite effect can be given. One such bubble is SEGUROCERA, developed by ISHIZUKA GLASS, Japan.

A key technical feature of the present invention is that the surface of the carpet layer 21 is formed with a constant curved surface, which has a large surface area compared to the finishing material of a known building material. The large surface area of the outer finish is quite advantageous in terms of functional release, due to the increase in the surface area of the coating of the sound absorbing, appearance forming, antibacterial and noxious substance removal components. The pile or bubble coated layer of the present invention is a layer that can exhibit other functions except sound absorption and vibration prevention. Other functions include such things as water repellent, removal of harmful components, flame retardant, tint formation, antibacterial, electromagnetic wave absorption and anion or ultraviolet radiation emission.

The adhesive layer 22 of the present invention may be a variety of known thermoplastic resins, for example, those selected from acrylic resins, polyurethane resins, polyolefin resins, low-melting point PET resins in the form of powder, pellets or hot melt film Can be applied as Spraying the thermoplastic resin powder on one side to which the carpet layer and the absorbent layer are attached, or pellets are arranged at regular intervals or in the form of a hot melt film and heat-melted to close the carpet layer and the absorbent layer to be pressed and attached. At this time, the polyolefin-based resin may be polyethylene, polypropylene, ethylene-vinyl acetate resin (EVA resin) and the like, and the hot melt film is preferably used hot melt film with holes punctured at regular intervals for smooth sound absorption performance of the final product. Do. The adhesive layer 22 is for bonding the carpet layer 21 and the absorbent layer 23, so there is no particular limitation in form and material. However, the thinner the thickness, the more advantageous it can be formed to a thickness of 1 to 6 mm. Substantially direct contact of carpet layer 21 and absorbent layer 23 is advantageous for the absorption of sound and vibration or shock.

The absorbent layer 23 of the present invention may be made of any known sound absorbing and shock absorbing material, but may preferably be formed of mineral wool, urethane foam, melamine foam or felt, nonwoven fabric. . The absorbent layer 23 has sound absorbing or shock and vibration absorbing functions. Substantially the sound may be partially absorbed by the carpet layer 21 and the rest may be removed by the absorbent layer 23. Shock and vibration absorptions are equally exhausted, partly by the carpet layer 21 and partly by the absorbent layer 23. Since the absorbent layer 23 forms the inner layer of the soundproof material 20, problems such as appearance or generation of fine materials may not occur. However, it should be formed taking into account the complete absorption of sound and shock or the complete blocking of transmission to the outside. Therefore, the absorbing layer 23 needs to have a suitable thickness and strength. The absorbent layer 23 can be thick enough and have a small enough strength compared to the carpet layer 21. The thickness for sufficient absorption of sound or shock and vibration is 10 to 50 mm, preferably 20 to 30 mm, and the density of the absorbent layer is suitably 50 to 300 kg / m ³ . If the thickness or density of the absorber layer is less than the set range, the sound absorbing function is not sufficient, and if the thickness exceeds the set range, it takes up a lot of space and is difficult to secure the light weight, which is not preferable.

The present invention also includes a dustproof layer 24 made of a dustproof material, such as rubber felt, as needed.

<Property evaluation method>

1) Carpet Surface Area Evaluation

The effective surface area of the carpet layer is cut into a 0.01 m ² area of 10 cm in length and width, respectively, and then the weight of the fiber is cut off as close as possible to the fiber at the top of the bubble paper.

Take a portion of the chopped fibers and measure the specific surface area (m ² / g) by nitrogen adsorption according to standard ASTM D3663-92 based on the Brunauer-Emmett-Teller (BET) method and cut the fibers at 0.01 m ² The effective surface area (m ² ), which is the surface area value of the fiber present in 1 m ² , was obtained by multiplying the weight (g) by 100.

The effective surface area of polyethylene terephthalate (PET) felt has a value of 1 per m ² since the surface is a two-dimensional plane with no bending.

2) Evaluation of Sound Absorption Rate

When the negative energy incident on the surface of the sound absorbing material is Ei and the negative energy reflected on the surface is Er, the sound absorption rate α is defined as follows.

 α = 1- (Er / Ei)

Absorption rate was measured by the reverberation chamber method sound absorption rate measured in the reverberation chamber in which the conditions near random incidence were realized according to KS F 2805 standard.The sound absorption rate is the arithmetic mean value of the absorption rate at the center frequency 250, 500, 1000, 2000Hz. Indicated.

3) Anti-mite evaluation

For the test insects, Dermatophagoides farinae or Dermatophagoides pteronyssinus was used by the Korea Consumption Science Research Center (FITI) using the insect pest test standard FC-TM-401, 402. Evaluation was made under several conditions.

1. Antimicrobial Test Using Intrusion Prevention Method

: Observe whether the tick moves from the medium to the attractant included in the test sample.

2. Antimicrobial Test Using Diffusion Blocking Method

: Observation of selective invasion of ticks when mixed with attractant and test sample

3. Antimicrobial Testing Using In Vitro

: Observe whether the tick moves through the test sample to the attractant

Example 1

After dyeing the carpet woven in 1100den / 68fila nylon BCF in the form of cut piles with acid dyes, a 2% aqueous solution was applied to the surface of the carpet by spraying with an industrial mildew and cured at 120 ° C. for 4 minutes to form a coating layer. After back coating with latex, the backing by bonding to the secondary bubble paper of PP material using PVC resin was used as the carpet layer. The backing carpet layer had a thickness of 9 mm and a density of 180 kg / m ³ .

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

Adhesion between the carpet layer and the absorbent layer was applied by spreading the polyethylene powder at 400g / m ² on the back side of the carpet layer, heating and melting with 150 ° C. hot air, and passing the cooling pressure roll while superimposing the absorber layer material.

Example 2

In the process of weaving in cut pile form with 1100den / 68fila nylon BCF, we use bubble paper containing SEGUROCERA (Inorganic anti-dust mite agent) (ISHIZUKA GLASS, Japan). The adhesive backing was used as the carpet layer. The backing carpet layer had a thickness of 9 mm and a density of 170 kg / m ³ .

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

Adhesion between the carpet layer and the absorbent layer was applied by spreading the polyethylene powder at 400g / m ² on the back side of the carpet layer, heating and melting with 150 ° C. hot air, and passing the cooling pressure roll while superimposing the absorber layer material.

Comparative Example 1

Same as Example 1 except for using a PET compressed felt having a thickness of 10 mm and a density of 190 kg / m ³ instead of a carpet layer.

The method of treating industrial fungal zero is also prepared in the same manner as in Example 1.

Table 1

Effective surface area (㎡) Sound absorption rate (α) Anti-mite (%) Intrusion Prevention Act Diffusion Blocking Law In vitro Example 1 72 0.81 91.4-93.7 91.9 ~ 93.2 99.9 Large leg mites 91.0-92.9 90.3 ~ 93.3 99.9 Vertical Pattern Dust Mite Example 2 71 0.79 91.9-93.5 92.1 ~ 93.6 99.9 Large leg mites 92.7 ~ 94.4 91.9 ~ 95.3 99.9 Vertical Pattern Dust Mite Comparative Example 1 One 0.74 88.2 ~ 89.6 86.2 ~ 87.3 98.5 Large leg mites 878 ~ 88.3 87.5-87.9 97.4 Vertical Pattern Dust Mite

As can be seen from Table 1, the sound absorbing material for indoor construction having excellent sound absorption rate and mite performance in Examples 1 to 2 of the present invention is obtained.

On the other hand, Comparative Example 1 is a case in which PET compressed felt is used on the surface instead of the carpet layer, and the sound absorbing performance is lowered, and the anti-tick effect treatment effect is somewhat lower than that of the carpet layer sound absorbing material having a large effective surface area, and the carpet layer is formed on the surface. It is not very desirable as interior material for walls and ceiling because it cannot give color or pattern effect when it is made.

It has been described in detail using the embodiments presented above. The embodiments presented are exemplary and one of ordinary skill in the art may make various modifications and modifications to the embodiments presented without departing from the spirit of the invention. Such modifications and variations are not intended to limit the scope of the invention.

The building material according to the present invention has the advantage of being anti-mite, including a functional layer having sound absorption and at the same time antibacterial due to the carpet layer. The functional layer having anti-tickiness can be included in the carpet layer or formed into bubble paper, which not only maintains the function for a long time but also has the advantage of reducing the thickness of the whole building material.

Claims (4)

In the material for interior construction, A carpet layer of pile form made of bulky continuous filaments and having a curved surface with evenly distributed mountains and valleys; An absorbent layer formed under the carpet layer; An adhesive layer bonding the carpet layer and the absorbent layer; And A dustproof functional layer comprising a phytoncide and a fungicide, Interior surface material, characterized in that the effective surface area per 1 m ² of the carpet layer is 20 ~ 150m ² . The anti-mite functional layer of claim 1 may be formed by treating a phytoncide component or a disinfectant by dipping or spraying, or adding 0.3 to 0.6% by weight to latex, which is a backing material of a carpet. Building material characterized in that. The building material according to claim 1, wherein the bubble paper used in the manufacture of the carpet layer can be a bubble paper in which an inorganic anti-mite agent is made of a ceramic material obtained by complexing boric acid, alkaline earth, and silicic acid at a high temperature. The building material according to claim 2, wherein the fungicide is one or two or more selected from the group consisting of CMIT, MIT, BIT, OIT, and PHMG.

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