WO2021140448A1 - Multilayer mat - Google Patents

Multilayer mat Download PDF

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Publication number
WO2021140448A1
WO2021140448A1 PCT/IB2021/050072 IB2021050072W WO2021140448A1 WO 2021140448 A1 WO2021140448 A1 WO 2021140448A1 IB 2021050072 W IB2021050072 W IB 2021050072W WO 2021140448 A1 WO2021140448 A1 WO 2021140448A1
Authority
WO
WIPO (PCT)
Prior art keywords
layer
multilayer mat
mat
multilayer
mat according
Prior art date
Application number
PCT/IB2021/050072
Other languages
French (fr)
Inventor
Yeon Ung Bae
Ki Ho Jeong
Original Assignee
3M Innovative Properties Company
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 3M Innovative Properties Company filed Critical 3M Innovative Properties Company
Publication of WO2021140448A1 publication Critical patent/WO2021140448A1/en

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Classifications

    • 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
    • B32B25/00—Layered products comprising a layer of natural or synthetic rubber
    • B32B25/04—Layered products comprising a layer of natural or synthetic rubber comprising rubber as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B25/045—Layered products comprising a layer of natural or synthetic rubber comprising rubber as the main or only constituent of a layer, which is next to another layer of the same or of a different material of foam
    • 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
    • B32B25/00—Layered products comprising a layer of natural or synthetic rubber
    • B32B25/04—Layered products comprising a layer of natural or synthetic rubber comprising rubber as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B25/08—Layered products comprising a layer of natural or synthetic rubber comprising rubber as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
    • 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
    • B32B25/00—Layered products comprising a layer of natural or synthetic rubber
    • B32B25/16—Layered products comprising a layer of natural or synthetic rubber comprising polydienes homopolymers or poly-halodienes homopolymers
    • 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
    • B32B25/00—Layered products comprising a layer of natural or synthetic rubber
    • B32B25/18—Layered products comprising a layer of natural or synthetic rubber comprising butyl or halobutyl rubber
    • 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
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/06—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B27/065—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material of foam
    • 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
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/18—Layered products comprising a layer of synthetic resin characterised by the use of special additives
    • B32B27/20—Layered products comprising a layer of synthetic resin characterised by the use of special additives using fillers, pigments, thixotroping agents
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/30—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers
    • B32B27/306—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers comprising vinyl acetate or vinyl alcohol (co)polymers
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    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/32—Layered products comprising a layer of synthetic resin comprising polyolefins
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    • 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
    • B32B5/22—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 the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/32—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 the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed at least two layers being foamed and next to each other
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
    • B32B7/04—Interconnection of layers
    • B32B7/12—Interconnection of layers using interposed adhesives or interposed materials with bonding properties
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J9/00—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof
    • C08J9/0061—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof characterized by the use of several polymeric components
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
    • C08K3/00—Use of inorganic substances as compounding ingredients
    • C08K3/02—Elements
    • C08K3/04—Carbon
    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09J—ADHESIVES; NON-MECHANICAL ASPECTS OF ADHESIVE PROCESSES IN GENERAL; ADHESIVE PROCESSES NOT PROVIDED FOR ELSEWHERE; USE OF MATERIALS AS ADHESIVES
    • C09J123/00—Adhesives based on homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Adhesives based on derivatives of such polymers
    • C09J123/02—Adhesives based on homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Adhesives based on derivatives of such polymers not modified by chemical after-treatment
    • C09J123/18—Homopolymers or copolymers of hydrocarbons having four or more carbon atoms
    • C09J123/20—Homopolymers or copolymers of hydrocarbons having four or more carbon atoms having four to nine carbon atoms
    • C09J123/22—Copolymers of isobutene; Butyl rubber ; Homo- or copolymers of other iso-olefines
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/62—Insulation or other protection; Elements or use of specified material therefor
    • E04B1/74—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls
    • E04B1/82—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls specifically with respect to sound only
    • E04B1/84—Sound-absorbing elements
    • E04B1/8409—Sound-absorbing elements sheet-shaped
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F15/00—Flooring
    • E04F15/18—Separately-laid insulating layers; Other additional insulating measures; Floating floors
    • E04F15/20—Separately-laid insulating layers; Other additional insulating measures; Floating floors for sound insulation
    • E04F15/206—Layered panels for sound insulation
    • 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
    • B32B2250/00—Layers arrangement
    • B32B2250/03—3 layers
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B32B2250/00—Layers arrangement
    • B32B2250/04—4 layers
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    • B32B2250/00—Layers arrangement
    • B32B2250/05—5 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
    • B32B2264/00—Composition or properties of particles which form a particulate layer or are present as additives
    • B32B2264/10—Inorganic particles
    • B32B2264/102—Oxide or hydroxide
    • B32B2264/1027—Clay
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    • B32B2264/00—Composition or properties of particles which form a particulate layer or are present as additives
    • B32B2264/10—Inorganic particles
    • B32B2264/107—Ceramic
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    • B32B2264/201—Flat or platelet-shaped particles, e.g. flakes
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    • B32B2264/30—Particles characterised by physical dimension
    • B32B2264/308—Aspect ratio of particles
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    • B32B2266/00—Composition of foam
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    • B32B2270/00—Resin or rubber layer containing a blend of at least two different polymers
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    • B32B2307/10—Properties of the layers or laminate having particular acoustical properties
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Definitions

  • the present invention relates to a multilayer mat.
  • dwelling houses include multi-family houses such as apartment, town houses, etc. or individual houses.
  • the multi-family house is a house type wherein several residents live in a single building.
  • a noise-prevention mat may be used when a building such as an apartment is constructed.
  • a problem of interlayer noise still occurs.
  • the government has also proposed a plurality of solutions to reduce interlayer noise. Accordingly, there is a need for a noise-prevention mat capable of efficiently preventing interlayer noise.
  • Embodiments of the present invention have been designed as taking notice of the above-mentioned grounds. Therefore, it is an object of the present invention to provide a multilayer mat that can efficiently reduce interlayer noise.
  • a multilayer mat including: an EVA layer containing ethylene vinyl acetate; a mat layer containing a porous material; and a foam layer containing at least polyvinyl chloride resin.
  • interlayer noise can be efficiently reduced.
  • FIG. l is a perspective cross-sectional view showing the multilayer mat according to a first embodiment of the present invention.
  • FIG. 2 is a front view of FIG. 1.
  • FIG. 3 is a perspective cross-sectional view showing the multilayer mat according to a third embodiment of the present invention.
  • FIG. 4 is a front view of FIG. 3.
  • FIG. 5 illustrates results of comparing measured impact sounds to densities of foam layers when impact was applied to each of the multilayer mat according to the first embodiment of the present invention and the multilayer mat according to a first comparative example, respectively.
  • FIG. 6 illustrates results of comparing measured impact sounds to densities of foam layers when impact was applied to each of the multilayer mat according to a second embodiment of the present invention and the multilayer mat according to a second comparative example, respectively.
  • FIG. 7 illustrates results of comparing measured impact sounds to densities of foam layers when impact was applied to each of the multilayer mat according to the third embodiment of the present invention and the multilayer mat according to a third comparative example, respectively.
  • upper and lower directions may be z-axis direction in FIG. 1, wherein the upper direction may be +z-axis direction.
  • the multilayer mat 1 may be used to reduce noise between floors of a building such as an apartment.
  • the multilayer mat 1 may be arranged on a concrete slab. Further, when the multilayer mat 1 is arranged on the concrete slab, a pipeline is installed on the multilayer mat 1, followed by mortar working to finish the structure. For instance, the multilayer mat 1 to cover the concrete slab may reduce noise and may be formed using a heat transfer material.
  • interlayer noise occurring between floors of a building may be divided into lightweight impact sound and heavyweight impact sound.
  • the lightweight impact sound may be a noise with small impact for a short term, such as dragging a table or chair, dropping small objects, etc.
  • the heavyweight impact sound may be a noise with large impact for a long term, generated when a person runs, or due to, hammering, dropping big objects, etc.
  • the multilayer mat 1 may include a foam layer 100, a mat layer 200, an adhesive layer 300 and an EVA layer 400. Further, the multilayer mat 1 may be formed by laminating the foam layer 100, the mat layer 200, the adhesive layer 300 and the EVA layer 400 sequentially in one direction.
  • the foam layer 100 may include a polyvinyl chloride resin.
  • the foam layer 100 may be arranged at the lowermost side of the multilayer mat 1. Further, the polyvinyl chloride resin of the foam layer 100 may have a closed cell foam structure. Since the polyvinyl chloride resin has a closed cell foam structure, the foam layer 100 may have high impact absorption while effectively reducing noise. Further, the foam layer 100 plays a role of heat-insulation material so as to minimize discharge of heat. Such a closed cell foam structure exhibits higher effects of noise attenuation in a low frequency domain rather than an open cell foam structure. Therefore, the foam layer 100 may efficiently attenuate vibration energy of heavy weight impact sound.
  • a density of the foam layer 100 may be not less than 130 kg/m 3 and not more than 178 kg/m 3 .
  • the mat layer 200 is made of a heat-insulation material and may greatly reduce discharge of heat.
  • the mat layer 200 may include a matrix 210 and first filler 220. Further, the mat layer 200 may be laminated on the foam layer 100. Meanwhile, the matrix 210 may contain a porous material, wherein the porous material may include expanded polystyrene. Further, the first filler 220 may be provided inside the matrix 210 and may further include graphite filler. For instance, the expanded polystyrene and the graphite filler in the mat layer 200 may be included in a ratio by weight (“weight ratio”) of 19.5:0.5 to 18.5:1.5. Further, the mat layer 200 may have a density of not less than 14 kg/m 3 and not more than 18 kg/m 3 .
  • the adhesive layer 300 is disposed between any two layers among the foam layer 100, the mat layer 200 and the EVA layer 400 and may adhere these two layers.
  • the adhesive layer 300 may include a material having viscosity and attenuate vibration of the heavyweight impact sound with the viscosity, thereby reducing the noise.
  • the adhesive layer 300 may include at least one among butyl rubber, polyisobutene, nanoclay filler, C5 resin and polybutene.
  • the butyl rubber in the adhesive layer 300 has a high loss coefficient in order to attenuate vibration energy of heavy weight impact sound transferred to the adhesive layer 300.
  • butyl rubber, polyisobutene, nanoclay filler, C5 resin and polybutene in the adhesive layer 300 may be included in a weight ratio of 4:3:6:2:5.
  • the EVA layer 400 may attenuate vibration of heavy weight impact sound transferred from the outside. That is, the EVA layer 400 may attenuate vibration energy of the heavyweight impact sound, thereby reducing noise.
  • the EVA layer 400 may include a base part 410 and second filler 420.
  • the EVA layer 400 may be laminated on the adhesive layer 300.
  • the base part 410 may contain ethylene vinyl acetate.
  • the second filler 420 may be provided inside the base part 410 and may attenuate vibration energy of heavyweight impact sound transferred to the EVA layer 400. That is, the vibration energy of the heavyweight impact sound transferred to the EVA layer 400 may be attenuated while passing a boundary between the base part 410 and the second filler 420.
  • the filler 420 may include kaolin filler in a plate shape.
  • the kaolin filler may be formed to have an aspect ratio of not less than 80 and not more than 100.
  • the foam layer 100 in the first embodiment may not include acrylonitrile-butadiene rubber.
  • the foam layer 100 may further include a rubber material such as acrylonitrile-butadiene rubber.
  • the foam layer 100 may be called a rubber layer since rubber is contained.
  • FIGS. 3 and 4 the second and third embodiments of the present invention will be described. In the description of the second and third embodiments, differences as compared to the above embodiment will be mostly described while the same description and reference numerals of the above embodiment are cited.
  • the foam layer 100 may further include a rubber material.
  • the rubber material in the foam layer 100 may include acrylonitrile-butadiene rubber. Further, the acrylonitrile- butadiene rubber and polyvinyl chloride resin in the foam layer 100 may be included in a weight ratio of 2.5:7.5 to 3.5:6.5.
  • the foam layer 100 containing the acrylonitrile- butadiene rubber may have a density of not less than 150 kg/m 3 and not more than 230 kg/m 3 .
  • the adhesive layer 300 may include a first adhesive layer 310 and a second adhesive layer 320.
  • the first adhesive layer 310 may include at least one among butyl rubber, polyisobutene, nanoclay filler, C5 resin and polybutene.
  • the first adhesive layer 310 may be disposed between the mat layer 200 and the EVA layer 400.
  • the second adhesive layer 320 may include at least one among butyl rubber, polyisobutene, nanoclay filler, C5 resin and polybutene.
  • the second adhesive layer 320 may be disposed between the foam layer 100 and the mat layer 200.
  • the multilayer mat 1 according to the third embodiment of the present invention may be formed by laminating the foam layer 100, the second adhesive layer 320, the mat layer 200, the first adhesive layer 310 and the EVA layer sequentially in one direction.
  • Table in FIG. 5 shows results of comparing impact sounds due to impact applied to a floor surface, measured when the multilayer mat 1 according to the first embodiment of the present invention was installed on the floor surface and when the mat according to a first comparative example was installed on the floor surface, respectively.
  • experiments were implemented to measure two types of impact sounds (heavyweight impact sound and lightweight impact sound), and such two types of impact sounds to altered densities of the foam layer 100 were illustrated as experimental results (the experiment was implemented twice according to the first embodiment, and the densities of the foam layer 100 in the experiments were 130 kg/m 3 and 170 kg/m 3 , respectively).
  • the multilayer mat 1 according to the first embodiment and the mat according to the first comparative example are substantially the same in terms of components and constitutional layers, but are different in density of the foam layer 100 (according to the first comparative example, the experiment was implemented twice and the densities of the foam layer 100 were 120 kg/m 3 and 180 kg/m 3 , respectively).
  • the heavyweight impact sound was measured using a bang machine, while the lightweight impact sound was measured through a tap machine.
  • the multilayer mat 1 according to the first embodiment of the present invention has a measured impact sound value (dB) lower than that of the mat according to the first comparative example, in terms of the heavyweight impact sound and even the lightweight impact sound.
  • measurement of relatively lower impact sound values means that the impact sound measured when the same impact is applied was reduced, thereby more desirably shielding noise. Accordingly, the multilayer mat 1 according to the first embodiment may efficiently reduce interlayer noise more than the mat according to the first comparative example.
  • Table in FIG. 6 shows results of comparing impact sounds due to impact applied to a floor surface, measured when the multilayer mat 1 according to the second embodiment of the present invention was installed on the floor surface and when the mat according to a second comparative example was installed on the floor surface, respectively.
  • experiments were implemented to measure two types of impact sounds (heavyweight impact sound and lightweight impact sound), and such two types of impact sounds to altered densities of the foam layer 100 were illustrated as experimental results (the experiment was implemented three (3) times according to the second embodiment, and the densities of the foam layer 100 in the experiments were 150 kg/m 3 , 190 kg/m 3 and 230 kg/m 3 , respectively).
  • the multilayer mat 1 according to the second embodiment and the mat according to the second comparative example are substantially the same in terms of components and constitutional layers, but are different in density of the foam layer 100 (according to the second comparative example, the experiment was implemented twice and the densities of the foam layer 100 were 130 kg/m 3 and 250 kg/m 3 , respectively).
  • the multilayer mat 1 according to the second embodiment of the present invention has a measured impact sound value (dB) lower than that of the mat according to the second comparative example, in terms of the heavyweight impact sound and even the lightweight impact sound. Accordingly, the multilayer mat 1 according to the second embodiment may efficiently reduce interlayer noise more than the mat according to the second comparative example.
  • Table in FIG. 7 shows results of comparing impact sounds due to impact applied to a floor surface, measured when the multilayer mat 1 according to the third embodiment of the present invention was installed on the floor surface and when the mat according to a third comparative example was installed on the floor surface, respectively (the experiment was implemented three (3) times according to the third embodiment, and the densities of the foam layer 100 in the experiments were 150 kg/m 3 , 190 kg/m 3 and 230 kg/m 3 , respectively).
  • the multilayer mat 1 according to the third embodiment and the mat according to the third comparative example are substantially the same in terms of components and constitutional layers, but are different in density of the foam layer 100 (according to the third comparative example, the experiment was implemented twice and the densities of the foam layer 100 were 130 kg/m 3 and 250 kg/m 3 , respectively).
  • the multilayer mat 1 according to the third embodiment of the present invention has a measured impact sound value (dB) lower than that of the mat according to the third comparative example, in terms of the heavyweight impact sound and even the lightweight impact sound. Accordingly, the multilayer mat 1 according to the third embodiment may efficiently reduce interlayer noise more than the mat according to the third comparative example.
  • Item l is a multilayer mat, including: an EVA layer containing ethylene vinyl acetate; a mat layer containing a porous material; and a foam layer containing at least polyvinyl chloride resin.
  • Item 2 is the multilayer mat, further including an adhesive layer disposed between any two layers among the foam layer, the mat layer and the EVA layer, which contains butyl rubber.
  • Item 3 is the multilayer mat, wherein the foam layer, the mat layer and the EVA layer are sequentially laminated in one direction.
  • Item 4 is the multilayer mat, wherein the polyvinyl chloride resin contained in the foam layer has a closed cell foam structure.
  • Item 5 is the multilayer mat, wherein the foam layer further includes a rubber material consisting of acrylonitrile-butadiene rubber.
  • Item 6 is the multilayer mat, wherein the foam layer has a density of not less than 150 kg/m 3 and not more than 230 kg/m 3 .
  • Item 7 is the multilayer mat, wherein the acrylonitrile-butadiene rubber and the polyvinyl chloride resin in the foam layer are included in a ratio by weight (“weight ratio”) of 2.5:7.5 to 3.5:6.5.
  • Item 8 is the multilayer mat, further including: a first adhesive layer containing butyl rubber; and a second adhesive layer containing butyl rubber, wherein the foam layer, the second adhesive layer, the mat layer, the first adhesive layer and the EVA layer are sequentially laminated in one direction.
  • Item 9 is the multilayer mat, wherein the mat layer includes: a matrix containing the porous material; and first filler provided inside the matrix, wherein the porous material includes expanded polystyrene.
  • Item 10 is the multilayer mat, wherein the first filler includes graphite filler.
  • Item 11 is the multilayer mat, wherein the expanded polystyrene and the graphite filler in the mat layer are included in a weight ratio of 19.5:0.5 to 18.5:1.5.
  • Item 12 is the multilayer mat, wherein the mat layer has a density of not less than
  • Item 13 is the multilayer mat, wherein the EVA layer includes: a base part containing ethylenevinyl acetate; and second filler provided in the base part, wherein the second filler includes kaolin filler having a plate shape.
  • Item 14 is the multilayer mat, wherein the kaolin filler is formed to have an aspect ratio of not less than 80 and not more than 100.
  • Item 15 is the multilayer mat according to item 2, wherein the adhesive layer further includes at least one among polyisobutene, nanclay filler, C5 resin and polybutene.
  • Item 16 is the multilayer mat, wherein the butyl rubber, the polyisobutene, the nanoclay filler, C5 resin and the polybutene in the adhesive layer are included in a weight ratio of 4:3:6:2:5.
  • Item 17 is the multilayer mat, wherein the foam layer does not include acrylonitrile-butadiene rubber and has a density of not less than 130 kg/m 3 and not more than 178 kg/m 3 .
  • the present invention has described by means of specific embodiments. However, these embodiments are introduced only for illustrative purpose, and the present invention is not particularly limited thereto and should be construed as including the widest range within the basic spirit and scope of the invention described in the present specification. Those skilled in the art may implement patterns in undefined forms by combination/substitution of the embodiments described above, which are also within the scope of the present invention. In addition, it is to be understood that those skilled in the art may easily alter or modify the aforementioned embodiments on the basis of the present specification, and such alterations or modifications are also within the scope of the present invention.

Abstract

The present invention relates a multilayer mat. More particularly, according to one embodiment of the present invention, there may be provided a multilayer mat, including: an EVA layer containing ethylene vinyl acetate; a mat layer containing a porous material; and a foam layer containing at least polyvinyl chloride resin.

Description

MULTILAYER MAT
Technical Field
The present invention relates to a multilayer mat.
Background
In general, dwelling houses include multi-family houses such as apartment, town houses, etc. or individual houses. Among those, the multi-family house is a house type wherein several residents live in a single building. Substantially, about 77% of Korean populations live in the multi-family houses such as apartments, townhouses, etc.
As such, since more than half of Korean populations (or households) live in the multi-family houses such as apartments, townhouses, etc., various noises may occur during living. Causes of the noises in multi -family houses may include people’s walking, opening and closing of doors, moving of utensils or furniture, operation or stopping of equipment, or the like. Further, when impact occurs in a floor of the multi-family house, solid transmission sound caused by the impact may be conveyed to all directions, thus vibrating the surface of a building structure. In addition, this sound is transferred into air transmission sound that may be recognized as a noise when heard by surrounding people.
In order to prevent noise occurring in the multi-family house, a noise-prevention mat may be used when a building such as an apartment is constructed. However, although such a noise-prevention mat is used, a problem of interlayer noise still occurs. Recently, there is very often a quarrel between neighbors due to interlayer noise, and the government has also proposed a plurality of solutions to reduce interlayer noise. Accordingly, there is a need for a noise-prevention mat capable of efficiently preventing interlayer noise.
Summary
Technical Problem to be Solved
Embodiments of the present invention have been designed as taking notice of the above-mentioned grounds. Therefore, it is an object of the present invention to provide a multilayer mat that can efficiently reduce interlayer noise.
Technical Solution
According to one aspect of the present invention, there is provided a multilayer mat, including: an EVA layer containing ethylene vinyl acetate; a mat layer containing a porous material; and a foam layer containing at least polyvinyl chloride resin. Effects of Invention
According to the embodiments of the present invention, interlayer noise can be efficiently reduced.
Brief Description of the Drawings
FIG. l is a perspective cross-sectional view showing the multilayer mat according to a first embodiment of the present invention.
FIG. 2 is a front view of FIG. 1.
FIG. 3 is a perspective cross-sectional view showing the multilayer mat according to a third embodiment of the present invention.
FIG. 4 is a front view of FIG. 3.
FIG. 5 illustrates results of comparing measured impact sounds to densities of foam layers when impact was applied to each of the multilayer mat according to the first embodiment of the present invention and the multilayer mat according to a first comparative example, respectively.
FIG. 6 illustrates results of comparing measured impact sounds to densities of foam layers when impact was applied to each of the multilayer mat according to a second embodiment of the present invention and the multilayer mat according to a second comparative example, respectively.
FIG. 7 illustrates results of comparing measured impact sounds to densities of foam layers when impact was applied to each of the multilayer mat according to the third embodiment of the present invention and the multilayer mat according to a third comparative example, respectively.
Detailed Description
Hereinafter, concrete embodiments to realize the spirit of the present invention will be described in detail with reference to accompanying drawings.
Further, in the following description, a detailed description of related arts, known configurations or functions will be omitted when it is determined that the gist of the present invention may be blurred by the same.
It is to be understood that, when an element is referred to as being “laminated” or “arranged” on or “contacting” to another element, it may not only be directly laminated or arranged on or contact to the other element, but also, other elements may be present therebetween. Further, terms and phrases used in this specification are merely for purpose of describing specific embodiments, and they should not be construed as limiting the present invention. A singular term also includes multiple expressions, unless explicitly stated otherwise.
It will also be understood that the terms “top”, “bottom”, “left”, “right”, etc. are used in the specification for clarity with reference to the drawings and, if a direction of the corresponding subject is altered, the above expressions may also be changed. For the same reason, with reference to the accompanying drawings, some elements have been exaggerated, omitted or schematically illustrated, and the dimension of each element does not definitely reflect a real size of the same.
Further, the terms including an ordinal number such as first, second, etc. are used to explain various elements, but the corresponding elements are not particularly limited by the same. Such terms are merely used for purpose of distinguishing an element from other elements.
The terms “include” or “comprise” described herein should be construed to define a specific feature, area, integer, step, action, element and/or component, but not exclude existence or addition of other specific features, area, integers, steps, actions, elements and/or components.
Meanwhile, in the present text, upper and lower directions may be z-axis direction in FIG. 1, wherein the upper direction may be +z-axis direction.
Hereinafter, referring to the figures, concrete configurations of a multilayer mat 1 according to the first embodiment of the present invention will be described in detail.
Hereinafter, referring to FIGS. 1 and 2, the multilayer mat 1 according to the first embodiment of the present invention may be used to reduce noise between floors of a building such as an apartment. The multilayer mat 1 may be arranged on a concrete slab. Further, when the multilayer mat 1 is arranged on the concrete slab, a pipeline is installed on the multilayer mat 1, followed by mortar working to finish the structure. For instance, the multilayer mat 1 to cover the concrete slab may reduce noise and may be formed using a heat transfer material.
Meanwhile, interlayer noise occurring between floors of a building may be divided into lightweight impact sound and heavyweight impact sound. For instance, the lightweight impact sound may be a noise with small impact for a short term, such as dragging a table or chair, dropping small objects, etc. On the other hand, the heavyweight impact sound may be a noise with large impact for a long term, generated when a person runs, or due to, hammering, dropping big objects, etc. The multilayer mat 1 may include a foam layer 100, a mat layer 200, an adhesive layer 300 and an EVA layer 400. Further, the multilayer mat 1 may be formed by laminating the foam layer 100, the mat layer 200, the adhesive layer 300 and the EVA layer 400 sequentially in one direction.
The foam layer 100 may include a polyvinyl chloride resin. The foam layer 100 may be arranged at the lowermost side of the multilayer mat 1. Further, the polyvinyl chloride resin of the foam layer 100 may have a closed cell foam structure. Since the polyvinyl chloride resin has a closed cell foam structure, the foam layer 100 may have high impact absorption while effectively reducing noise. Further, the foam layer 100 plays a role of heat-insulation material so as to minimize discharge of heat. Such a closed cell foam structure exhibits higher effects of noise attenuation in a low frequency domain rather than an open cell foam structure. Therefore, the foam layer 100 may efficiently attenuate vibration energy of heavy weight impact sound. A density of the foam layer 100 may be not less than 130 kg/m3 and not more than 178 kg/m3.
The mat layer 200 is made of a heat-insulation material and may greatly reduce discharge of heat. The mat layer 200 may include a matrix 210 and first filler 220. Further, the mat layer 200 may be laminated on the foam layer 100. Meanwhile, the matrix 210 may contain a porous material, wherein the porous material may include expanded polystyrene. Further, the first filler 220 may be provided inside the matrix 210 and may further include graphite filler. For instance, the expanded polystyrene and the graphite filler in the mat layer 200 may be included in a ratio by weight (“weight ratio”) of 19.5:0.5 to 18.5:1.5. Further, the mat layer 200 may have a density of not less than 14 kg/m3 and not more than 18 kg/m3.
The adhesive layer 300 is disposed between any two layers among the foam layer 100, the mat layer 200 and the EVA layer 400 and may adhere these two layers. The adhesive layer 300 may include a material having viscosity and attenuate vibration of the heavyweight impact sound with the viscosity, thereby reducing the noise. The adhesive layer 300 may include at least one among butyl rubber, polyisobutene, nanoclay filler, C5 resin and polybutene. Specifically, the butyl rubber in the adhesive layer 300 has a high loss coefficient in order to attenuate vibration energy of heavy weight impact sound transferred to the adhesive layer 300. For instance, butyl rubber, polyisobutene, nanoclay filler, C5 resin and polybutene in the adhesive layer 300 may be included in a weight ratio of 4:3:6:2:5.
The EVA layer 400 may attenuate vibration of heavy weight impact sound transferred from the outside. That is, the EVA layer 400 may attenuate vibration energy of the heavyweight impact sound, thereby reducing noise. Further, the EVA layer 400 may include a base part 410 and second filler 420. The EVA layer 400 may be laminated on the adhesive layer 300. In this case, the base part 410 may contain ethylene vinyl acetate. Further, the second filler 420 may be provided inside the base part 410 and may attenuate vibration energy of heavyweight impact sound transferred to the EVA layer 400. That is, the vibration energy of the heavyweight impact sound transferred to the EVA layer 400 may be attenuated while passing a boundary between the base part 410 and the second filler 420. The filler 420 may include kaolin filler in a plate shape. For example, the kaolin filler may be formed to have an aspect ratio of not less than 80 and not more than 100.
Meanwhile, the foam layer 100 in the first embodiment may not include acrylonitrile-butadiene rubber. However, according to second and third embodiments of the present invention, the foam layer 100 may further include a rubber material such as acrylonitrile-butadiene rubber. In this case, the foam layer 100 may be called a rubber layer since rubber is contained. Hereinafter, referring to FIGS. 3 and 4, the second and third embodiments of the present invention will be described. In the description of the second and third embodiments, differences as compared to the above embodiment will be mostly described while the same description and reference numerals of the above embodiment are cited.
The foam layer 100 may further include a rubber material. The rubber material in the foam layer 100 may include acrylonitrile-butadiene rubber. Further, the acrylonitrile- butadiene rubber and polyvinyl chloride resin in the foam layer 100 may be included in a weight ratio of 2.5:7.5 to 3.5:6.5. The foam layer 100 containing the acrylonitrile- butadiene rubber may have a density of not less than 150 kg/m3 and not more than 230 kg/m3.
In addition to the configurations as described above, according to the third embodiment of the present invention, the adhesive layer 300 may include a first adhesive layer 310 and a second adhesive layer 320. The first adhesive layer 310 may include at least one among butyl rubber, polyisobutene, nanoclay filler, C5 resin and polybutene. The first adhesive layer 310 may be disposed between the mat layer 200 and the EVA layer 400.
The second adhesive layer 320 may include at least one among butyl rubber, polyisobutene, nanoclay filler, C5 resin and polybutene. The second adhesive layer 320 may be disposed between the foam layer 100 and the mat layer 200.
The multilayer mat 1 according to the third embodiment of the present invention may be formed by laminating the foam layer 100, the second adhesive layer 320, the mat layer 200, the first adhesive layer 310 and the EVA layer sequentially in one direction.
Hereinafter, functional effects of the multilayer mat 1 having the above configurations will be described.
Table in FIG. 5 shows results of comparing impact sounds due to impact applied to a floor surface, measured when the multilayer mat 1 according to the first embodiment of the present invention was installed on the floor surface and when the mat according to a first comparative example was installed on the floor surface, respectively. Herein, experiments were implemented to measure two types of impact sounds (heavyweight impact sound and lightweight impact sound), and such two types of impact sounds to altered densities of the foam layer 100 were illustrated as experimental results (the experiment was implemented twice according to the first embodiment, and the densities of the foam layer 100 in the experiments were 130 kg/m3 and 170 kg/m3, respectively).
In this regard, the multilayer mat 1 according to the first embodiment and the mat according to the first comparative example are substantially the same in terms of components and constitutional layers, but are different in density of the foam layer 100 (according to the first comparative example, the experiment was implemented twice and the densities of the foam layer 100 were 120 kg/m3 and 180 kg/m3, respectively). Among such two types of impact sounds as described above, the heavyweight impact sound was measured using a bang machine, while the lightweight impact sound was measured through a tap machine.
Referring to FIG. 5, the multilayer mat 1 according to the first embodiment of the present invention has a measured impact sound value (dB) lower than that of the mat according to the first comparative example, in terms of the heavyweight impact sound and even the lightweight impact sound. As such, measurement of relatively lower impact sound values means that the impact sound measured when the same impact is applied was reduced, thereby more desirably shielding noise. Accordingly, the multilayer mat 1 according to the first embodiment may efficiently reduce interlayer noise more than the mat according to the first comparative example.
Table in FIG. 6 shows results of comparing impact sounds due to impact applied to a floor surface, measured when the multilayer mat 1 according to the second embodiment of the present invention was installed on the floor surface and when the mat according to a second comparative example was installed on the floor surface, respectively. Herein, experiments were implemented to measure two types of impact sounds (heavyweight impact sound and lightweight impact sound), and such two types of impact sounds to altered densities of the foam layer 100 were illustrated as experimental results (the experiment was implemented three (3) times according to the second embodiment, and the densities of the foam layer 100 in the experiments were 150 kg/m3, 190 kg/m3 and 230 kg/m3, respectively).
In this regard, the multilayer mat 1 according to the second embodiment and the mat according to the second comparative example are substantially the same in terms of components and constitutional layers, but are different in density of the foam layer 100 (according to the second comparative example, the experiment was implemented twice and the densities of the foam layer 100 were 130 kg/m3 and 250 kg/m3, respectively).
Referring to FIG. 6, the multilayer mat 1 according to the second embodiment of the present invention has a measured impact sound value (dB) lower than that of the mat according to the second comparative example, in terms of the heavyweight impact sound and even the lightweight impact sound. Accordingly, the multilayer mat 1 according to the second embodiment may efficiently reduce interlayer noise more than the mat according to the second comparative example.
Table in FIG. 7 shows results of comparing impact sounds due to impact applied to a floor surface, measured when the multilayer mat 1 according to the third embodiment of the present invention was installed on the floor surface and when the mat according to a third comparative example was installed on the floor surface, respectively (the experiment was implemented three (3) times according to the third embodiment, and the densities of the foam layer 100 in the experiments were 150 kg/m3, 190 kg/m3 and 230 kg/m3, respectively). In this regard, the multilayer mat 1 according to the third embodiment and the mat according to the third comparative example are substantially the same in terms of components and constitutional layers, but are different in density of the foam layer 100 (according to the third comparative example, the experiment was implemented twice and the densities of the foam layer 100 were 130 kg/m3 and 250 kg/m3, respectively).
Referring to FIG. 7, the multilayer mat 1 according to the third embodiment of the present invention has a measured impact sound value (dB) lower than that of the mat according to the third comparative example, in terms of the heavyweight impact sound and even the lightweight impact sound. Accordingly, the multilayer mat 1 according to the third embodiment may efficiently reduce interlayer noise more than the mat according to the third comparative example.
The embodiments of the present invention are listed as follows.
Item l is a multilayer mat, including: an EVA layer containing ethylene vinyl acetate; a mat layer containing a porous material; and a foam layer containing at least polyvinyl chloride resin.
Item 2 is the multilayer mat, further including an adhesive layer disposed between any two layers among the foam layer, the mat layer and the EVA layer, which contains butyl rubber.
Item 3 is the multilayer mat, wherein the foam layer, the mat layer and the EVA layer are sequentially laminated in one direction.
Item 4 is the multilayer mat, wherein the polyvinyl chloride resin contained in the foam layer has a closed cell foam structure.
Item 5 is the multilayer mat, wherein the foam layer further includes a rubber material consisting of acrylonitrile-butadiene rubber.
Item 6 is the multilayer mat, wherein the foam layer has a density of not less than 150 kg/m3 and not more than 230 kg/m3.
Item 7 is the multilayer mat, wherein the acrylonitrile-butadiene rubber and the polyvinyl chloride resin in the foam layer are included in a ratio by weight (“weight ratio”) of 2.5:7.5 to 3.5:6.5.
Item 8 is the multilayer mat, further including: a first adhesive layer containing butyl rubber; and a second adhesive layer containing butyl rubber, wherein the foam layer, the second adhesive layer, the mat layer, the first adhesive layer and the EVA layer are sequentially laminated in one direction.
Item 9 is the multilayer mat, wherein the mat layer includes: a matrix containing the porous material; and first filler provided inside the matrix, wherein the porous material includes expanded polystyrene.
Item 10 is the multilayer mat, wherein the first filler includes graphite filler.
Item 11 is the multilayer mat, wherein the expanded polystyrene and the graphite filler in the mat layer are included in a weight ratio of 19.5:0.5 to 18.5:1.5.
Item 12 is the multilayer mat, wherein the mat layer has a density of not less than
14 kg/m3 and not more than 18 kg/m3.
Item 13 is the multilayer mat, wherein the EVA layer includes: a base part containing ethylenevinyl acetate; and second filler provided in the base part, wherein the second filler includes kaolin filler having a plate shape.
Item 14 is the multilayer mat, wherein the kaolin filler is formed to have an aspect ratio of not less than 80 and not more than 100.
Item 15 is the multilayer mat according to item 2, wherein the adhesive layer further includes at least one among polyisobutene, nanclay filler, C5 resin and polybutene.
Item 16 is the multilayer mat, wherein the butyl rubber, the polyisobutene, the nanoclay filler, C5 resin and the polybutene in the adhesive layer are included in a weight ratio of 4:3:6:2:5.
Item 17 is the multilayer mat, wherein the foam layer does not include acrylonitrile-butadiene rubber and has a density of not less than 130 kg/m3 and not more than 178 kg/m3.
As described above, the present invention has described by means of specific embodiments. However, these embodiments are introduced only for illustrative purpose, and the present invention is not particularly limited thereto and should be construed as including the widest range within the basic spirit and scope of the invention described in the present specification. Those skilled in the art may implement patterns in undefined forms by combination/substitution of the embodiments described above, which are also within the scope of the present invention. In addition, it is to be understood that those skilled in the art may easily alter or modify the aforementioned embodiments on the basis of the present specification, and such alterations or modifications are also within the scope of the present invention.

Claims

What is claimed is:
1. A multilayer mat, comprising: an EVA layer including ethylene vinyl acetate; a mat layer including a porous material; and a foam layer including at least polyvinyl chloride resin.
2. The multilayer mat according to claim 1, further comprising: an adhesive layer disposed between any two layers among the foam layer, the mat layer and the EVA layer, which includes butyl rubber.
3. The multilayer mat according to claim 2, wherein the foam layer, the mat layer and the EVA layer are sequentially laminated in one direction.
4. The multilayer mat according to claim 1, wherein the polyvinyl chloride resin included in the foam layer has a closed cell foam structure.
5. The multilayer mat according to claim 1, wherein the foam layer further includes a rubber material consisting of acrylonitrile-butadiene rubber.
6. The multilayer mat according to claim 5, wherein the foam layer has a density of not less than 150 kg/m3 and not more than 230 kg/m3.
7. The multilayer mat according to claim 5, wherein the acrylonitrile-butadiene rubber and the polyvinyl chloride resin in the foam layer are included in a ratio by weight (“weight ratio”) of 2.5:7.5 to 3.5:6.5.
8. The multilayer mat according to claim 6, further comprising: a first adhesive layer including butyl rubber; and a second adhesive layer including butyl rubber, wherein the foam layer, the second adhesive layer, the mat layer, the first adhesive layer and the EVA layer are sequentially laminated in one direction.
9. The multilayer mat according to claim 1, wherein the mat layer includes: a matrix containing the porous material; and first filler provided inside the matrix, wherein the porous material includes expanded polystyrene.
10. The multilayer mat according to claim 9, wherein the first filler includes graphite filler.
11. The multilayer mat according to claim 10, wherein the expanded polystyrene and the graphite filler in the mat layer are included in a weight ratio of 19.5:0.5 to 18.5:1.5.
12. The multilayer mat according to claim 1, wherein the mat layer has a density of not less than 14 kg/m3 and not more than 18 kg/m3.
13. The multilayer mat according to claim 1, wherein the EVA layer includes: a base part containing ethylene vinyl acetate; and second filler provided in the base part, wherein the second filler includes kaolin filler having a plate shape.
14. The multilayer mat according to claim 13, wherein the kaolin filler is formed to have an aspect ratio of not less than 80 and not more than 100.
15. The multilayer mat according to claim 2, wherein the adhesive layer further includes at least one among polyisobutene, nanclay filler, C5 resin and polybutene.
16. The multilayer mat according to claim 15, wherein the butyl rubber, the polyisobutene, the nanoclay filler, C5 resin and the polybutene in the adhesive layer are included in a weight ratio of 4:3:6:2:5.
17. The multilayer mat according to claim 1, wherein the foam layer does not include acrylonitrile-butadiene rubber and has a density of not less than 130 kg/m3 and not more than 178 kg/m3.
PCT/IB2021/050072 2020-01-07 2021-01-06 Multilayer mat WO2021140448A1 (en)

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