WO2008054036A1

WO2008054036A1 - Functional mat

Info

Publication number: WO2008054036A1
Application number: PCT/KR2006/004528
Authority: WO
Inventors: Jang Won Park
Original assignee: Jang Won Park
Priority date: 2006-11-02
Filing date: 2006-11-02
Publication date: 2008-05-08

Abstract

The present invention provides a functional mat, including: a foamed sheet provided therein with a plurality of cavities having desired shapes; and a filler contained in at least one selected from the cavities of the foamed sheet. The functional mat of the present invention desirably intercepts or absorbs noise and vibration, and is filled with functional materials or resins at desired locations according to the use and function thereof, unlike a conventional mat, thus performing efficiently in the case of an accident, such as a fire.

Description

Description FUNCTIONAL MAT

Technical Field

[1] The present invention relates, in general, to a mat and, more particularly, to a functional mat, which includes therein a plurality of cavities which have desired shapes and are filled with a filler, such as a material having noise absorbing and thermal insulating functions or a material having a far infrared ray emitting function. Background Art

[2] In recent years, according to the increase in the population density of cities, the dwelling patterns of urban villages have changed to emphasize multi-family residences and apartments, which are capable of efficiently using limited space. Dwellers of such residences, in which the space is divided into upper and lower spaces based on floors, are interested in soundproofing and vibration isolation ability of such residences, determined by the ability to intercept or absorb noise and vibration generated in the daily life of the dwellers.

[3] As an example of conventional soundproof and vibration isolation elements used in the multi-family residences or apartments, a soundproof sheet was proposed in Korean Patent Laid-open Publication No. 2003-0091625. The soundproof sheet is produced by repeatedly mixing EVA (Ethylene Vinyl Acetate) with PE (Polyethylene) at appropriate ratios so as to prepare several mixtures and by simultaneously foaming the mixtures to form a foamed sheet having a laminated structure comprising several layers having different densities, and is interposed as a shielding material between a reinforced concrete slab and autoclaved lightweight concrete so as to attenuate noise and vibration. In Korean Patent Laid-open Publication No. 2003-0091625, an embodiment, in which a functional material, such as elvan or loess, capable of emitting healthful far infrared rays, is added to the soundproof sheet having the laminated structure, is disclosed.

[4] The technique disclosed in Korean Patent Laid-open Publication No. 2003-0091625 is somewhat effective because a foamed sheet capable of attenuating noise and vibration is inserted as a shielding material into a floor structure made of a reinforced concrete slab, autoclaved lightweight concrete and cement mortar. However, in the technique, the foamed sheet has a laminated structure comprising several layers having different densities, and thus the technique has some problems.

[5] Described in detail, to form the layers of the soundproof sheet, which have different densities, through foaming, the mixtures for the respective layers must be separately prepared through respective mixing processes, which complicate the process of producing the soundproof sheet. Further, when the mixtures for the layers having different densities, which have been prepared through the respective mixing processes, are processed by forming crosslinks at one time so as to form a desired foamed sheet having a laminated structure, it is almost impossible to produce a foamed product having a consistent shape.

[6] Further, the functional material, such as elvan or loess, acts as a foreign substance relative to the main materials of the mixtures during the crosslinking-foaming process, so that, if the amount of the functional material added to the mixtures exceeds a predetermined level, the functional material may form irregular air bubbles in the foamed product, thus reducing the quality of the product. Therefore, the amount of the functional material added to the mixtures must be limited. However, when the limited amount of functional material is added to the mixtures, the effect of emitting the far infrared rays from the foamed product may be reduced such that the product cannot realize the desired effect. Disclosure of Invention Technical Problem

[7] Accordingly, the present invention has been made keeping in mind the above problems occurring in the related art, and is intended to provide a functional mat, which appropriately attenuates noise and vibration generated in a residential place and further performs a thermal insulation function.

[8] The present invention is also intended to provide a functional mat, which can be impregnated with a functional material, the amount of which exceeds a predetermined limit so that the mat can emit healthful far infrared rays or anions in great quantities, unlike conventional mats.

[9] Further, the present invention is intended to provide a functional mat, which can have an improved appearance and can retard or suppress flames when a fire breaks out. Technical Solution

[10] In an aspect, the present invention provides a functional mat, which comprises: a foamed sheet provided therein with a plurality of cavities having desired shapes; and a filler contained in at least one selected from the cavities of the foamed sheet.

[11] In another aspect, the present invention provides a functional mat, comprising: a foamed sheet provided therein with a plurality of cavities, with a hole formed in at least one selected from the cavities such that the hole communicates with at least one selected from surfaces of the foamed sheet; a filler contained in the plurality of cavities including the at least one cavity having the hole; and a layer formed on at least one surface of the foamed sheet using the same material as that of the filler through the hole such that the layer is integrated with the filler. [12] In the functional mat, the cavities of the foamed sheet may communicate with each other. [13] Further, at least one surface of the foamed sheet may be provided with a plurality of protrusions. [14] The functional mat may further comprise: a cavity formed in at least one of the protrusions. [15] Further, at least one selected from the cavities may be filled with at least one filler selected from solids, liquids and gases. [16] Further, a plurality of grooves may be formed in at least one surface of the foamed sheet, or a plurality of through holes may be formed in the foamed sheet such that the through holes penetrate from one surface to an opposite surface of the foamed sheet. [17] Further, the filler may comprise at least one material selected from solids, liquids and gases. [18] Further, at least one surface of the foamed sheet may be provided with a fire retardant layer made of a fire retardant material. [19] Further, a surface protective layer may be formed on the fire retardant layer.

Advantageous Effects

[20] As described above, the functional mat according to the present invention is advantageous in that a plurality of cavities is formed in a foamed sheet and is filled with a functional material, so that the functional mat appropriately attenuates noise and vibration and, furthermore, stimulates the bodies of users thanks to the functional material therein.

[21] Further, in the present invention, the shape and number of cavities may be appropriately adjusted and the cavities may be filled with fillers selected from known functional materials or known resin materials according to the desired use and function, so that the functional mat of the present invention can overcome the problems experienced in the conventional mats comprising foamed products.

[22] Further, when an extinguishing agent is used as the filler of the functional mat of the present invention, the functional mat can efficiently resist fires. If no extinguishing agent is used as the filler, a fire retardant layer may be added to the surface of the functional mat, thus giving a fire retardant function to the functional mat.

Brief Description of the Drawings

[23] FIG. 1 is a perspective view of a functional mat according to the present invention;

[24] FIG. 2 through FIG. 4 are sectional views of functional mats according to embodiments of the present invention;

[25] FIG. 5 and FIG. 6 are sectional views of functional mats according to further embodiments of the present invention; [26] FIG. 7 through FIG. 9 are sectional views of functional mats according to further embodiments of the present invention;

[27] FIG. 10 is a perspective view of a functional mat according to another embodiment of the present invention;

[28] FIG. 11 is a sectional view of FIG. 10;

[29] FIG. 12 is a perspective view of a functional mat according to still another embodiment of the present invention;

[30] FIG. 13 and FIG. 14 are sectional views of functional mats according to further embodiments of the present invention;

[31] FIG. 15 through FIG. 18 are sectional views of functional mats according to further embodiments of the present invention;

[32] FIG. 19 is a perspective view of a functional mat according to yet another embodiment of the present invention; and

[33] FIG. 20 is a sectional view of FIG. 19.

[34] <Description of the reference numerals of the Elements in the Drawings>

[35] 100: foamed sheet

[36] 120, 220: cavity

[37] 200, 600: filler

[38] 300, 800: surface protective layer

[39] 400, 900: fire retardant layer

Best Mode for Carrying Out the Invention

[40] Hereinbelow, preferred embodiments of the present invention will be described in detail with reference to the accompanying drawings. In the following description, it is to be noted that a detailed description of elements well known to those skilled in the related art will be omitted.

[41] FIG. 1 is a perspective view of a functional mat according to a first embodiment of the present invention. As shown in FIG. 1 , the functional mat according to the present invention is characterized in that it comprises a foamed sheet 100 having a plurality of cavities 120 therein, and a filler 200, which is contained in the respective cavities 120.

[42] In the present invention, the main material of the foamed sheet 100 may be selected from EVA or PE, or may be a mixture prepared by mixing EVA and PE at an appropriate ratio. When such a selected main material is processed through foaming, the foamed sheet 100 preferably has a light weight and can be produced at low cost. However, it should be understood that, in the present invention, the main materials of the foamed sheet 100 may be selected from a variety of kinds of rubber or resin capable of being processed by forming crosslinks, without being limited to EVA and PE. Further, in the present invention, the foamed sheet 100 may have a laminated structure comprising a plurality of layers made of different materials, unlike the single- layered structure shown in the drawings.

[43] In the present invention, the cavities 120 are formed in the foamed sheet 100 during a crosslinking-foaming process of forming the foamed sheet 100. The shape and number of cavities 120 may be appropriately adjusted according to the use and function of the mat. A variety of embodiments of the cavities are shown in FIG. 2, FIG. 5 and FIG. 6.

[44] In the present invention, the cavities 120 may be independently formed in the foamed sheet such that the cavities 120 are isolated from each other. Alternatively, the cavities of the present invention may be configured such that all of the cavities communicate with each other or such that the cavities are grouped into a plurality of communicating cavity groups, in which neighboring cavities, among all of the cavities, communicate with each other and form a communicating cavity group. As a further alternative, the cavities of the present invention may be configured such that cavities having the same functions, determined according to the fillers contained in the cavities, communicate with each other.

[45] The filler 200 is a material, which is contained in at least one of the cavities 120 formed in the foamed sheet 100 and allows the foamed sheet 100 to perform a desired function, such as a heat insulating, noise attenuating or vibration absorbing function, a healthful far infrared ray or anion emitting function, an antibacterial and deodorizing function, or a fire preventing and fire extinguishing function.

[46] In the present invention, the filler 200 may comprise at least one selected from solid materials including formed materials having predetermined shapes, liquid materials having predetermined fluidities and gaseous materials including air, without being limited as to the phases or kinds of the materials. In the above case, the filler 200 can be freely selected from the above-mentioned materials according to the desired use and function of the functional mat. Further, the filler 200 may be melamine powder for executing a fire preventing function or a fire extinguishing agent for executing a fire extinguishing function.

[47] FIG. 2 shows an embodiment of the present invention, in which gas 260 is contained as fillers in the cavities 120 of the foamed sheet 100 so as to execute a function of appropriately intercepting or absorbing noise and vibration, which are lower than predetermined levels, as well as a heat insulating function. FIG. 3 shows an embodiment in which a variety of resins 240, such as polyurethane, are contained as fillers in the cavities 120 so as to execute a function of appropriately intercepting or absorbing noise and vibrations that are equal to or greater than predetermined levels. FIG. 4 shows an embodiment in which a functional material 220, such as nano silver powder, elvan, jade, germanium or loess for emitting healthful anions or healthful far infrared rays, or an antibacterial or deodorizing material, is contained as fillers in the cavities 120.

[48] Further, in the present invention, the functional mat may be configured such that it can execute a plurality of functions at the same time. FIG. 5 shows an embodiment in which the cavities 122, 123 and 124 are configured to have different shapes and sizes according to the heights thereof in the foamed sheet, and any one 242 selected from a variety of resins, any one 222 selected from a variety of functional materials and any one 262 selected from gases are contained in the respective cavities 122, 123 and 124. FIG. 6 shows an embodiment in which all of the cavities are configured such that they are arranged in a horizontal line and have different shapes and sizes according to the locations of cavities 126 performing the function of attenuating noise and vibration and cavities 127 performing the function of emitting far infrared rays or anions, and any one 244 selected from a variety of resins and any one 224 selected from a variety of functional materials are contained in the respective cavities 126 and 127 according to the uses and functions of the cavities.

[49] As described above, the present invention is characterized in that the shape, size and number of the cavities formed in the foamed sheet can be appropriately adjusted and the cavities formed in the foamed sheet can be filled with materials appropriately selected from a variety of materials according to the uses and functions of the cavities, thus allowing the mat to execute desired functions.

[50] Further, the functional mat according to the present invention may be configured such that, as shown in FIG. 7, one or both surfaces of the foamed sheet having therein the cavities 264 filled with fillers may further comprise a plurality of protrusions 160. When the mat having the foamed sheet provided with the protrusions 160 on both or either surface thereof is used as a shielding material, which is inserted into a floor structure or a wall structure in a building, an air layer is formed between the flat surface part, having no protrusions, and the protrusions 160 of the foamed sheet, so that the mat can appropriately function as a shielding material and as an effective heat insulating material in the floor or wall structure.

[51] Further, in the present invention, at least one selected from the protrusions 160 may be provided therein with an additional cavity 162, which is different from the cavities 126 formed in the foamed sheet, as shown in FIG. 8 and FIG. 9. Further, in the present invention, at least one selected from the additional cavities 162 formed in the protrusions 160 may be filled with a filler 164, which has a function equal to or similar to that of a filler contained in the cavity formed in the foamed sheet.

[52] In the same manner as that described for the cavities 126 formed in the foamed sheet, the shape and size of the additional cavity 162 formed in the protrusions 160 may be freely set. When a plurality of additional cavities 162 is formed in the protrusions 160, the communication between the additional cavities may be freely set in the same manner as that described for the cavities of the foamed sheet. Further, the filler 164 that is contained in the cavities 162 of the protrusions 160 is the same as the filler contained in the cavities of the foamed sheet, and further explanation is thus not deemed necessary.

[53] Further, in the present invention, a plurality of grooves 166 may be formed in at least one selected from the two surfaces of the foamed sheet, as shown in FIG. 8. Further, a plurality of through holes 168 may be formed in the foamed sheet such that the through holes 168 vertically penetrate from the upper surface to the lower surface of the foamed sheet, as shown in FIG. 9.

[54] When the functional mat according to the present invention is used as a finishing material in a floor structure or a wall structure of a building, each of the grooves 166 and the through holes 168 forms a channel through which another finishing material, such as concrete, can flow into the mat, thus increasing the fastening strength between the finishing materials. Further, the grooves 166 and the through holes 168 also cause noise and vibrations to be naturally attenuated in the mat.

[55] Further, as shown in FIG. 8 and FIG. 9, the grooves 166 and the through holes 168 may be configured such that they communicate with the cavities 126 formed in the foamed sheet or such that they are independently formed in the foamed sheet so as to be isolated from the cavities 126. In other words, the structure of the grooves and the through holes in the present invention is not limited to any specific structure. Further, in each of the embodiments shown in FIG. 7 and FIG. 8, the grooves 166 or the through holes 168 are formed in a foamed sheet having the protrusions 160 provided with the additional cavities 162. However, it should be understood that the grooves or the through holes of the present invention may be adapted to the other embodiments described above without being limited to the embodiments of FIGS. 8 and 9.

[56] Still another embodiment of the functional mat according to the present invention is characterized in that at least one surface of the foamed sheet 100 is provided with a fire retardant layer 400. The embodiment is intended to increase the fire resistance of the functional mat when a fire breaks out. The material of the fire retardant layer is not limited to any specific material, but the fire retardant layer is preferably layered on the surface of the foamed sheet using melamine powder, which is prepared by mixing an appropriate material in a liquid melamine resin and drying the mixture prior to pulverizing the dry melamine mixture.

[57] Further, in the present invention, a surface protective layer 300 may be formed on at least one surface of the foamed sheet 100 or on the fire retardant layer 400 of the foamed sheet so as to protect the surface of the foamed sheet 100 or the surface of the fire retardant layer 400 from the environment. [58] The material and shape of the surface protective layer 300 can be freely selected, without being limited to any specific material or shape, as long as the surface protective layer 300 can efficiently protect the foamed sheet or the fire retardant layer from the environment. However, when the functional mat according to the present invention is used as a mat instead of being used as a finishing material in a floor structure or a wall structure of a building, a film-shaped pattern sheet having a variety of patterns is preferably used as the surface protective layer 300 because the pattern sheet can impart a good appearance to the functional mat.

[59] FIG. 10 and FIG. 11 are a perspective view and a sectional view of an embodiment of the functional mat, which comprises a foamed sheet 100, a surface protective layer 300 and a fire retardant layer 400.

[60] In the embodiment of FIGS. 10 and 11, the fire retardant layer 400 and the surface protective layer 300 are sequentially layered on the surface of the foamed sheet 100 in respective layers. However, it should be understood that the surface protective layer and the fire retardant layer of the present invention may be configured as a single integrated layer. Further, in the present invention, the functional mat having the fire retardant layer 400 and the surface protective layer 300 may further comprise the protrusions 160, which may have empty cavities or cavities filled with a filler, the grooves 166, and/or the through holes 168.

[61] Further, as shown in FIG. 12, the present invention also proposes a functional mat, which has a structure somewhat different from those of the above-mentioned embodiments. The functional mat of FIG. 12 is characterized in that it comprises a foamed sheet 100 having a cavity 520, a filler 600 contained in the cavity 520, and a layer 700 formed on the foamed sheet 100. In the embodiment of FIG. 12, most elements may remain the same as those of the above-mentioned embodiments, or may be adapted in the form of modified elements, and thus further explanation for the elements is deemed unnecessary.

[62] As shown in FIG. 12, FIG. 13 and FIG. 14, a plurality of cavities 520 is preferably formed in the foamed sheet 100, and at least one selected from the cavities 520 is preferably provided with at least one hole 540 which communicates with at least one selected from surfaces of the foamed sheet 100. In each of the embodiments of FIG. 12, FIG. 13 and FIG. 14, the plurality of cavities 520 communicates with the upper surface of the foamed sheet 100 through the holes 540.

[63] The material of both the filler 600 and the layer 700 is contained in at least one selected from the cavities 520 of the foamed sheet 100 and is integrally layered on at least one surface of the foamed sheet 100 while it is contained in the holes 540 of the cavities 520, thus allowing the foamed sheet 100 to perform a desired function, such as a heat insulating, noise attenuating and vibration absorbing function, a healthful far infrared ray or anion emitting function, or a fire preventing and fire extinguishing function.

[64] In the present invention, the material of both the filler 600 and the layer 700 may be freely selected from among a plurality of materials according to the use and function of the functional mat, without being limited as to the phases or kinds of the materials. In the present invention, examples of the materials used as that material of the filler 600 and the layer 700 are a variety of resins, such as polyurethane, a variety of functional materials, such as nano silver powder, elvan, jade, germanium and loess, and fire retardants, such as melamine powder.

[65] FIG. 13 shows an embodiment in which a material selected from a variety of resins is used as the material for both the filler 620 and the layer 720, so that the functional mat of the present invention can execute a thermal insulating function and can efficiently intercept or absorb noise and vibration. FIG. 14 shows an embodiment, in which a material selected from a variety of functional materials 620, such as nano silver powder, elvan, jade, germanium and loess, capable of emitting the healthful anions or the far infrared rays, and antibacterial or deodorizing materials, is used as the material of both the layer 740 and the filler 640 of the cavities 520.

[66] Further, in the present invention, as described above for the embodiment of FIG. 5, a plurality of additional cavities, which are different from the main cavities filled with fillers, may be formed in the foamed sheet, so that the mat can execute several functions at the same time. An embodiment that has the additional cavities and is thus able to execute several functions at the same time is shown in FIG. 15.

[67] Described in detail, the foamed sheet 100 is sectioned into upper and lower parts, with main cavities 522 formed in the upper part of the foamed sheet 100 such that the cavities 522 communicate with the upper surface of the foamed sheet 100 and a filler 622 is contained in the cavities 522 and is also integrated with a layer 722. Further, a plurality of additional cavities 524, which are different from the main cavities 522 filled with the filler 622, are formed in the lower part of the foamed sheet 100, and another filler 642, which is different from the material of both the filler 622 and the layer 722, is contained in the additional cavities 524. In the embodiment of FIG. 15, the additional cavities 524 are completely isolated from the layer 722, so that the filler 642 contained in the additional cavities 524 can be freely selected without limitation. Described in detail, the material of the filler 642 contained in the additional cavities 524 can be selected from a variety of resins, a variety of functional materials, a variety of liquids, such as a fire extinguishing agent, and a variety of gases, such as air.

[68] As described above, the present invention is characterized in that the shape, size and number of main cavities formed in the foamed sheet may be appropriately controlled, and a material, selected from a variety of materials according to the use and function thereof, may be contained in the cavities of the foamed sheet and may be layered on the surface of the foamed sheet so as to allow the functional mat to efficiently execute a desired function, and, further, another functional material may be contained in the additional cavities, which are isolated from both the main cavities and the layer.

[69] Further, similar to the embodiment of FIG. 7, the functional mat according to the present invention may be configured such that a plurality of protrusions 560 is formed on one or both surfaces of the foamed sheet having the cavities 522. An embodiment of the functional mat having the protrusions 560 is shown in FIG. 16. Further, similar to the embodiments shown in FIG. 8 and FIG. 9, at least one selected from the protrusions 560 may be provided with an additional cavity 562, which is different from the main cavities 522 formed in the foamed sheet. Further, at least one selected from the additional cavities 562 formed in the protrusions 560 may be filled with a filler 564 so as to execute a function the same as or similar to that of the layer and the filler contained in the main cavities 522. Further, a plurality of grooves 566 may be formed in at least one selected from the two surfaces of the foamed sheet, or a plurality of through holes 568 may be formed in the foamed sheet such that the through holes penetrate from one surface to an opposite surface of the foamed sheet. Embodiments having the grooves 566 or the through holes 568 are shown in FIG. 17 and FIG. 18, respectively. Most elements of the embodiments remain the same as those of the embodiments of FIG. 8 and FIG. 9, or may be adapted in the form of modified elements, and thus further explanation of the elements is deemed unnecessary.

[70] Further, yet another embodiment of the present invention is characterized in that a fire retardant layer is formed on the layer 700. The embodiment is intended to increase the fire resistance of the functional mat when a fire breaks out. This embodiment is different from the embodiment in which the fire retardant layer is formed on the surface of the foamed sheet. Further, a surface protective layer may be formed on the layer 700 or on the fire retardant layer so as to protect the layer 700 or the fire retardant layer from the environment. The structures and functions of the fire retardant layer and the surface protective layer are the same as those described above, and further explanation is thus deemed unnecessary.

[71] FIG. 19 and FIG. 20 are a perspective view and a sectional view of an embodiment which comprises a layer 700, a fire retardant layer 900 and a surface protective layer 800. In the drawings, the fire retardant layer and the surface protective layer are sequentially layered on the surface of the foamed sheet such that they have respective layers. However, it should be understood that the surface protective layer and the fire retardant layer of the present invention may be configured as an integrated single layer.

[72] Although the embodiments of the present invention have been disclosed for illustrative purposes, those skilled in the art will appreciate that various modifications, additions and substitutions are possible, without departing from the scope and spirit of the invention as disclosed in the accompanying claims.

Claims

[I] A functional mat, comprising: a foamed sheet provided therein with a plurality of cavities having desired shapes; and a filler contained in at least one selected from the cavities of the foamed sheet. [2] A functional mat, comprising: a foamed sheet provided therein with a plurality of cavities, with a hole formed in at least one selected from the cavities such that the hole communicates with at least one selected from surfaces of the foamed sheet; a filler contained in the plurality of cavities including the at least one cavity having the hole; and a layer formed from the same material as that of the filler on at least one surface of the foamed sheet through the hole such that the layer is integrated with the filler. [3] The functional mat according to claim 1 or 2, wherein the cavities of the foamed sheet communicate with each other. [4] The functional mat according to claim 1 or 2, wherein at least one surface of the foamed sheet is provided with a plurality of protrusions. [5] The functional mat according to claim 4, further comprising: a cavity formed in at least one of the protrusions. [6] The functional mat according to claim 5, wherein at least one selected from the cavities is filled with at least one filler selected from solids, liquids and gases. [7] The functional mat according to claim 1 or 2, wherein a plurality of grooves is formed in at least one surface of the foamed sheet, or a plurality of through holes is formed in the foamed sheet such that the through holes penetrate from one surface to an opposite surface of the foamed sheet. [8] The functional mat according to claim 1, wherein the filler comprises at least one material selected from solids, liquids and gases. [9] The functional mat according to claim 1 or 2, wherein at least one surface of the foamed sheet is provided with a fire retardant layer made of a fire retardant material. [10] The functional mat according to claim 7, wherein at least one surface of the foamed sheet is provided with a fire retardant layer made of a fire retardant material.

[I I] The functional mat according to claim 9, further comprising: a surface protective layer formed on the fire retardant layer.

[12] The functional mat according to claim 10, further comprising: a surface protective layer formed on the fire retardant layer.