KR20120113355A - Mat for prevention of noise between floors and manufacturing method of the same - Google Patents

Mat for prevention of noise between floors and manufacturing method of the same Download PDF

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Publication number
KR20120113355A
KR20120113355A KR1020110031024A KR20110031024A KR20120113355A KR 20120113355 A KR20120113355 A KR 20120113355A KR 1020110031024 A KR1020110031024 A KR 1020110031024A KR 20110031024 A KR20110031024 A KR 20110031024A KR 20120113355 A KR20120113355 A KR 20120113355A
Authority
KR
South Korea
Prior art keywords
layer
mat
sound insulation
seconds
insulation layer
Prior art date
Application number
KR1020110031024A
Other languages
Korean (ko)
Inventor
한중희
Original Assignee
주식회사 제이월드산업
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by 주식회사 제이월드산업 filed Critical 주식회사 제이월드산업
Priority to KR1020110031024A priority Critical patent/KR20120113355A/en
Publication of KR20120113355A publication Critical patent/KR20120113355A/en

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    • A—HUMAN NECESSITIES
    • A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
    • A47C—CHAIRS; SOFAS; BEDS
    • A47C27/00—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas
    • A47C27/14—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas with foamed material inlays
    • A47C27/15—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas with foamed material inlays consisting of two or more layers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/12—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by using adhesives
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/18—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by features of a layer of foamed material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/10—Properties of the layers or laminate having particular acoustical properties
    • B32B2307/102—Insulating
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2471/00—Floor coverings
    • B32B2471/04—Mats

Abstract

PURPOSE: A noise prevention mat and a producing method thereof are provided to prevent the separation phenomenon among layers forming the mat, and to improve the durability of the mat by maintaining the harmlessness to human body. CONSTITUTION: A noise prevention mat includes a foamed layer(10), a soundproof layer(20), and a combination layer(30). The foamed layer is obtained by foaming more than one polymer selected from a polystyrene resin, ABS, a polycarbonate resin, polyvinyl chloride resin, or a vinyl chloride resin. The foamed layer is attached to the bottom of the soundproof layer, and includes an embossed surface with plural concave and convex units on one side. The soundproof layer is produced with thermoplastic polyurethane in a plate shape. The combination layer combines the foamed layer and the soundproof layer by the following steps: coating the combination layer on the upper side of the foamed layer, and heat-drying the combination layer at 80 deg. C for 20-30 seconds; melting the combination layer at 200-300 deg. C for 2-3 seconds to attach the combination layer to one side of the soundproof layer using a compress roller; and cooling the combination layer at 20 deg. C for 3-4 seconds. [Reference numerals] (AA) Adhesive; (BB) Heat-compressing

Description

Mat for prevention of noise between floors and manufacturing method of the same}

The present invention relates to a mat for preventing noise and a method of manufacturing the same. Specifically, a mat of a sound absorbing layer made of thermoplastic polyurethane and another plastic material is laminated using an adhesive and thermocompression to prevent delamination and to increase durability and human friendliness. It's about blocks.

Recently, in a multi-storey building such as a multi-family house, noise or vibration of the upper floor is transmitted to the lower floor through the floor slab, which causes a problem between residents.

In order to solve such a problem, a method of covering a mat or a carpet having a sound absorption function on the floor or the living room floor of a multi-story building is mainly used, and as shown in FIG. 1, a prefabricated mat 100 is often used. The prefabricated mat 100 according to the prior art is formed along the edge of the mat body 110 and the mat body 110 formed by foam molding a synthetic resin such as polyethylene, so that the adjacent mat body 110 is fitted to be assembled. Has a simple structure consisting of the concave-convex coupling portion 120, depending on the embodiment may be formed with a plurality of anti-slip projections on the lower surface of the mat body (110).

However, in the case of the prefabricated mat 100 having the above-described structure is composed of only a single layer of foamed synthetic resin, the vibration and noise generated on the mat formed by the combination of a plurality of prefabricated mat 100 is transferred from the upper layer to the lower layer as it is in terms of life There was a problem causing a lot of inconvenience.

In addition, the above-described prefabricated mat 100 is formed of a synthetic resin foam molded article is harmful to the human body is released into the room, there is a problem that threatens the health of the user.

Recently, a multi-layered mat using PVC and PE materials is used instead of a single layer.However, in case of fixing by heat welding between the layers constituting the mat, there is a problem that the layers are separated from each other after cooling. Deterioration, there is a problem that the function of waterproof and antifouling. In addition, PVC is harmful to the human body and heavy weight problems such as transport and installation, PE has a weak durability and less resistance to noise.

An object of the present invention is to form a multi-layered mat by combining materials having high durability and harmless to the human body and lightweight materials.

In addition, it is an object to improve the durability of the mat by preventing different materials are separated after bonding.

In order to achieve the above object, in the present invention, a thermoplastic polyurethane material, a sound insulating layer formed in a plate shape; It is formed by foam molding one or more polymers selected from polystyrene resin, ABS resin, polycarbonate resin, polyvinyl chloride resin, and vinyl chloride, and is disposed under the sound insulation layer to be bonded. A foam layer formed on at least one of upper and lower surfaces of the embossed surface formed adjacent to each other; It is applied to the upper surface of the foam layer and dried by heating at 80 ° C. for 20 to 30 seconds, and then heated to 200 to 300 ° C. for 2 to 3 seconds, and disposed to contact one surface of the sound insulation layer by a pressing roller in a melted state. Cooling for 3 to 4 seconds to provide a noise preventing mat comprising a; bonding layer for integrally combining the foam layer and the sound insulation layer.

At this time, the adhesive comprises a modified polyurethane, characterized in that it is dissolved in at least one solvent of toluene (methylbenzene), MEK (methyl ethyl ketone), ethyl acetate (ethyl acetate).

In addition, the sound insulation layer is formed by combining a plurality of plastic layers, the sound insulation layer disposed on the top is a thermoplastic polyurethane material, the sound insulation layer except the sound insulation layer disposed on the top is polyurethane, polystyrene resin, ABS resin. At least one polymer selected from polycarbonate resin, polycarbonate resin, and polyvinyl chloride may be formed by foam molding.

In addition, the corners of the sound insulation layer are provided with irregularities protruding outwardly along the corners, and the space between the irregularities is formed as a groove concave inside the mat, the shape corresponding to the irregularities Of the concave-convex coupling portion is provided, the concave-convex portion and the concave-convex coupling portion of the adjacent mat can be fitted together.

In the present invention, the adhesive liquefied using a volatile solvent is applied to the upper surface of the foam layer formed by foam molding one or more polymers selected from polystyrene resin, ABS resin, polycarbonate resin, polyvinyl chloride resin, and vinyl chloride. Making; A drying step of evaporating the volatile component of the solvent by heating and drying the foamed layer coated with the adhesive in a drying oven at 80 ° C. for 20 to 30 seconds; Melting step of melting the dried adhesive by applying an infrared ray of 200 ~ 300 ℃ for 2-3 seconds to the foam layer coated with the dried adhesive; A laminate layer in which the melted adhesive is applied to the foamed layer and a thermoplastic soundproofing layer formed in a plate shape for 3 to 4 seconds between a pair of pressing rollers preheated to 115 to 120 ° C; After passing through the pressing roller using a cooling water to form a cooling step for 3 to 4 seconds at 20 ℃; Including, including the foam layer made of plastic and the sound insulating layer made of thermoplastic polyurethane integrally coupled to the noise prevention mat Provide a method.

At this time, in the step of applying the adhesive, the adhesive is a solid containing a modified polyurethane, dissolved in one or more solvents of toluene (methylbenzene), MEK (methyl ethyl ketone), ethyl acetate (ethyl acetate) and liquefied state It is characterized in that it is applied to the upper surface of the foam layer (10).

In the present invention, the purpose is to form a multi-layered mat by combining materials having high durability and harmless to the human body and light weight.

In addition, it is an object to improve the durability of the mat by preventing different materials are separated after bonding.

1 is a perspective view of a mat according to the prior art.
2A and 2B are bottom perspective and side cross-sectional views, respectively, of the mat according to the first embodiment of the present invention.
3A and 3B are perspective and side cross-sectional views, respectively, of a mat according to a second embodiment of the present invention.
4A and 4B are perspective and side cross-sectional views, respectively, of a mat according to a third embodiment of the present invention.
Figure 5 is a schematic side cross-sectional view showing the structure and lamination process of the mat of the present invention.

Hereinafter, preferred embodiments of the present invention will be described in detail with reference to the accompanying drawings. Prior to this, terms and words used in the present specification and claims should not be construed as limited to ordinary or dictionary terms, and the inventor should appropriately interpret the concepts of the terms appropriately The present invention should be construed in accordance with the meaning and concept consistent with the technical idea of the present invention.

Therefore, the embodiments described in the specification and the drawings shown in the drawings are only the most preferred embodiments of the present invention and do not represent all of the technical idea of the present invention, various modifications that can be substituted for them at the time of the present application It should be understood that there may be equivalents and variations.

2A and 2B show bottom perspective and side cross-sectional views of the mat 1 according to the first embodiment of the present invention, respectively, and FIGS. 3A and 3B show the mat 1 according to the second embodiment of the present invention, respectively. ) Is a perspective view and a side cross-sectional view, and FIGS. 4A and 4B show a perspective view and a side cross-sectional view of the mat 1 according to the third embodiment of the present invention, respectively.

As shown, the mat 1 of the present invention is provided with a sound insulating layer 20 at the top and a foam layer 10 at the bottom contacting the bottom. At this time, the sound insulation layer 20 is formed of a non-toxic, harmless thermoplastic polyurethane (TPU: Thermoplastic Polyurethane), there is no harm to the human body using the mat (1), the heat resistance temperature is 150 ℃ to wash and disinfect by hot water can do. In addition, since the TPU is a soft material and excellent in elasticity, it is resistant to impact and has good adhesion, so that the TPU does not slide with the foam layer 10 in the bonding layer 30, and is safe and transported, installed, washed, dried, and lightweight. Easy to store

An upper surface of the sound insulation layer 20 may be provided with an antimicrobial coating or a pattern layer. The sound insulation layer 20 may be separately stacked on the top surface of the sound insulation layer 20 as well as the sound insulation layer 20 is manufactured. Of course, the upper surface of the coating or the pattern layer may be manufactured integrally to be provided.

In addition, the sound insulation layer 20 may be formed by combining a plurality of plastic layers, and the sound insulation layer disposed on the top is preferably made of thermoplastic polyurethane material to enhance durability of the surface of the mat 1. The sound insulation layers other than the sound insulation layer disposed on the top may be used by foam molding one or more polymers selected from polyurethane, polystyrene resin, ABS resin, polycarbonate resin, polyvinyl chloride resin, and vinyl chloride.

The foam layer 10 is laminated on the lower surface of the sound insulation layer 20 to cushion and sound the vibration and noise transmitted to the lower through the sound insulation layer 20 again, various materials may be used, the present invention Foams and compresses polymers obtained by polymerization of polystylene, ABS (Acrylonitrile Butadiene Styrene copolymer), polycarbonate (Polycarbonate), polyvinyl chloride (Vinyl Chloride), vinyl chloride (Vinyl Chloride) It is preferable to use various synthetic resin foam moldings that can cushion and absorb sound such as molded sponge, styrofoam or urethane foam, latex foam, foamed silicone, and the like. As shown in FIGS. 2A and 2B, the foamed layer 10 is provided with an embossed surface 11 having convex portions and concave portions. The embossing surface 11 is an egg-shaped concave-convex surface and forms an air layer A between the bottom of the embossing surface 11 and the bottom when the foam layer 10 is in contact with the bottom. The air layer (A) not only reduces the interlayer noise by blocking the vibration transmitted to the floor through the foam layer 10, but also minimizes the area where the floor and the foam layer 10 are in contact with the vibration transmitted to the floor. And it serves to minimize the noise, and has a non-slip function to prevent the mat 1 of the present invention to slip on the floor surface.

In the above description, an example in which the embossed surface 11 is formed on the lower surface of the foam layer 10 has been described. However, as shown in FIGS. 3A and 3B, the embossed surface 11 is formed on the upper surface of the foam layer 10. An air layer A is formed between the sound insulation layer 20, or the embossed surface 11 is provided on both top and bottom surfaces of the foam layer 10 as shown in FIGS. 4A and 4B. Of course, it can be configured to form the air layer (A) not only between the 20 and the bottom.

On the other hand, the foam layer 10 is thicker than the sound insulation layer 20, for example, the foam layer 10 is 15 to 20mm, so that the sound insulation layer 20 is formed to a thickness of 10 ~ 15mm In addition, it is preferable to finally absorb the vibration transmitted to the lower portion through the sound insulation layer 20 in the foam layer 10. In addition, it is preferable that the compressive strength of the sound insulation layer 20 is greater than that of the foam layer 10 so that the vibration or noise first transmitted to the sound insulation layer 20 is reflected upwards and only a minimum amount is transmitted downward. Do.

5 is a schematic side cross-sectional view showing the structure and lamination process of the mat 1 of the present invention. Mat 1 of the present invention, as described above, the sound insulation layer 20 is disposed on the top, and the foam layer 10 is disposed on the bottom and laminated together, the lower surface and the upper foam layer of the sound insulation layer 20 The upper surface of the 10 is laminated by thermocompression bonding to form the bonding layer 30.

Referring to the drawings, a manufacturing method of the mat 1 will be described. First, an adhesive is applied to the upper surface of the foam layer 10 as shown in FIG. At this time, the adhesive is a modified polyurethane as a main raw material, a liquid phase using at least one of toluene (methylbenzene), MEK (methyl ethyl ketone), ethyl acetate (ethyl acetate) as a solvent, the foam layer 10 Apply to The applied adhesive is heated and dried in a drying oven at 80 ° C. for 20 to 30 seconds to evaporate the volatile components of the solvent, leaving only the solid adhesive component. At this time, the adhesive is not only dried in the drying oven but also annealed to improve adhesion performance. The dried adhesive is heated and melted at 200 to 300 ° C. for 2 to 3 seconds using infrared rays of the heater to restore adhesive strength.

The foam layer 10 and the sound insulation layer 20 are laminated together in a state in which an adhesive is melted, and the foam layer 10 passes through the foam layer 10 and the sound insulation layer 20 between a pair of preheated compression rollers. The foam layer 10 and the sound insulation layer 20 are adhered by an adhesive applied to an upper surface. The pressing roller is preheated to 115 ~ 120 ℃ and press the foam layer 10 and the sound insulation layer 20 for 3 to 4 seconds to combine. When the temperature of the roller during the compression is less than 115 ℃ the adhesive hardens the compression effect, if it exceeds 120 ℃ there is a problem that the TPU used as the foam layer 10 is damaged, it is preferable to maintain 115 ~ 120 ℃ Do. The mat 1 passed through the pressing roller is molded by cooling at 20 ° C. for 3 to 4 seconds using cooling water.

In this way, the foam layer 10 and the sound insulation layer 20 made of different materials are laminated using a modified polyurethane-based adhesive and thermal compression to increase the adhesion between the mat 1 and the floor, as well as the mat 1. The foam layer 10 and the sound insulation layer 20 may be integrated while improving the durability of the upper surface.

In addition, although not shown, the mat 1 of the present invention may be used singly or may be used in combination with another mat 1 as one block itself. In this case, when used in connection with another mat, the edge of the sound insulation layer 20 is provided with irregularities protruding outwardly spaced along the edge, the space between the irregularities is the mat (1) It is formed as a groove concave inward, the concave-convex coupling portion of the shape corresponding to the concave-convex portion is provided, the concave-convex portion and the concave-convex coupling portion of the adjacent mat (1) can be fitted together.

1 Mat 10 Foam Layer 11 Embossed Cotton
A air layer 20 sound insulation layer 30 bonding layer

Claims (6)

A thermoplastic polyurethane material, the sound insulation layer 20 formed in a plate shape;
It is formed by foam molding at least one polymer selected from polystyrene resin, ABS resin, polycarbonate resin, polyvinyl chloride resin, and vinyl chloride resin, and is disposed under the sound insulating layer 20 to be bonded to each other. Foam layer 10 formed on at least one surface of the upper and lower embossed surface formed adjacent to the convex portion;
It is coated on the upper surface of the foam layer 10 and dried by heating at 80 ° C. for 20 to 30 seconds, and then heated at 200 to 300 ° C. for 2 to 3 seconds to be in contact with one surface of the sound insulation layer 20 by a pressing roller in a melted state. A bonding layer 30 that is disposed and cooled to 20 ° C. for 3 to 4 seconds to integrally couple the foam layer 10 and the sound insulation layer 20;
Noise prevention mat, characterized in that comprises a.
The method of claim 1,
The adhesive comprises a modified polyurethane,
A noise preventing mat, which is dissolved in one or more solvents of toluene (methylbenzene), MEK (methyl ethyl ketone), and ethyl acetate (ethyl acetate).
The method of claim 1,
The sound insulation layer 20 is formed by combining a plurality of plastic layers,
The sound insulation layer disposed on the top is made of thermoplastic polyurethane,
The sound insulation layer except for the sound insulation layer disposed on the top is formed by foam molding one or more polymers selected from polyurethane, polystyrene resin, ABS resin, polycarbonate resin, polyvinyl chloride resin, and vinyl chloride. Anti-noise mat.
The method of claim 1,
Corners of the sound insulation layer 20 is provided with irregularities protruding outwardly spaced apart along the corners,
In the space between the concave-convex portion is formed in the groove concave into the mat (1), the concave-convex coupling portion of the shape corresponding to the concave-convex portion is formed,
An anti-corrosion mat characterized in that the concave-convex portion and the concave-convex coupling portion of the adjacent mat (1) are fitted together.
Applying a liquefied adhesive to the upper surface of the foam layer 10 formed by foam molding one or more polymers selected from polystyrene resin, ABS resin, polycarbonate resin, polycarbonate resin, polyvinyl chloride resin and vinyl chloride. ;
Drying the adhesive-coated foam layer 10 by heating in a drying oven at 80 ° C. for 20 to 30 seconds to evaporate the volatile components of the solvent;
A melting step of dissolving the dried adhesive by applying infrared rays at 200 to 300 ° C. for 2 to 3 seconds to the foamed layer 10 to which the dried adhesive is applied;
A laminated step of pressing for 3 to 4 seconds between the foamed layer 10 to which the fused adhesive is applied and a pair of compression rollers preheated to 115 to 120 ° C. between the foamed sound insulating layer 20 formed of a thermoplastic polyurethane material;
A molding step of cooling the sound insulation layer 20 and the foamed layer 10 that have passed through the pressing roller to 20 ° C. for 3 to 4 seconds using cooling water;
Including, the foam layer (10) and the sound insulating layer (20) made of thermoplastic polyurethane is integrally coupled to the manufacturing method of the noise prevention mat.
The method of claim 5,
In the step of applying the adhesive,
The adhesive is a solid containing a modified polyurethane,
Method for producing a noise preventing mat, characterized in that it is dissolved in one or more solvents of toluene (methylbenzene), MEK (methyl ethyl ketone), ethyl acetate (ethyl acetate) and applied to the upper surface of the foam layer 10 in a liquefied state. .
KR1020110031024A 2011-04-05 2011-04-05 Mat for prevention of noise between floors and manufacturing method of the same KR20120113355A (en)

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Application Number Priority Date Filing Date Title
KR1020110031024A KR20120113355A (en) 2011-04-05 2011-04-05 Mat for prevention of noise between floors and manufacturing method of the same

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
KR1020110031024A KR20120113355A (en) 2011-04-05 2011-04-05 Mat for prevention of noise between floors and manufacturing method of the same

Publications (1)

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KR20120113355A true KR20120113355A (en) 2012-10-15

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Cited By (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
KR200475949Y1 (en) * 2014-08-28 2015-01-19 주식회사앤제이컴퍼니 Block type pad for indoor entertainment
KR20150067725A (en) * 2013-12-10 2015-06-18 전영천 Eco-friendly fabric for mat, eco-friendly mat manufacturing using it and co-friendly mat manufacture method
KR20190027444A (en) * 2017-09-07 2019-03-15 주식회사 넬라켐 Method of manufacturing green mat and green mat manufactured thereby
KR20200007216A (en) * 2018-07-12 2020-01-22 (주)대산케미텍 Buffer mats and their manufacturing methods
KR20210041907A (en) * 2019-10-08 2021-04-16 송용규 Mat for infant

Cited By (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
KR20150067725A (en) * 2013-12-10 2015-06-18 전영천 Eco-friendly fabric for mat, eco-friendly mat manufacturing using it and co-friendly mat manufacture method
KR200475949Y1 (en) * 2014-08-28 2015-01-19 주식회사앤제이컴퍼니 Block type pad for indoor entertainment
KR20190027444A (en) * 2017-09-07 2019-03-15 주식회사 넬라켐 Method of manufacturing green mat and green mat manufactured thereby
KR20200007216A (en) * 2018-07-12 2020-01-22 (주)대산케미텍 Buffer mats and their manufacturing methods
KR20210041907A (en) * 2019-10-08 2021-04-16 송용규 Mat for infant

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