JP6369846B2 - Rug cushion material - Google Patents

Description

  The present invention relates to a lug cushion laid indoors.

  In general, carpets made of a skin layer, a backing resin layer, and a backing layer such as tufted carpet, hook carpet, and nonwoven fabric are known. Carpets are laid in various facilities, home living rooms, children's rooms, etc., and are also used as insoles and partial lays, as well as interiors and used in places where people can relax in living spaces that are closely related to their lives. .

  These carpets include various carpets ranging from a thin carpet that is relatively easy to handle to a carpet that is thick and has excellent heat retention and cushioning properties. For example, the floor heating carpet of Patent Document 1 is known as a carpet laid on a floor to which floor heating has been applied. On the other hand, thin carpets are also widely used because they are relatively easy to handle.

  However, such a carpet with good cushioning has a volume and is not easy to handle. On the other hand, a relatively thin carpet has a feeling of bottoming, and it was difficult to say that it was comfortable particularly in a home laid to relax on the carpet. In addition, in apartment houses and the like, walking sounds and falling sounds transmitted downstairs may interfere with comfort as so-called noise.

JP-A-60-246880

  The present invention has been made in view of such a technical background, and has a cushioning material for rugs that is laid under a carpet that has an excellent cushioning property without a feeling of bottoming and that is excellent in sound insulation to the downstairs. The purpose is to provide.

  In order to achieve the above object, the present invention provides the following means.

An intermediate layer made of a cushioning material is laminated below the surface layer, and a back surface layer is laminated below the intermediate layer, and at least partially attaches a non-slip resin to the lower side of the back surface layer. And a protrusion formed by thermally foaming a thermally expandable microcapsule is provided on the surface of the anti-slip resin, and the cushion material is a polyurethane foam having a thickness in a range of 10 mm to 40 mm, and the surface layer and The back surface layer is made of a needle punched nonwoven fabric having a basis weight of 100 to 300 g / m ² made of polyester fiber, and the surface layer is subjected to an anti-slip treatment in which the fibers are partially melted to be granular. Rug cushioning material.

In the present invention,
  -The result of the light floor impact sound level reduction test for the flooring material was a performance grade ΔLL (I) -7. Also, a rug cushioning material was placed on the flooring floor, and a rug carpet for two tatami mats was placed on top of it.
  -The result of the light floor impact sound level reduction test of the flooring material was a performance grade ΔLL (I) -6 and passed. Also, when a rug cushioning material was placed on the flooring floor and the rug carpet for two tatami mats was placed on the flooring, it was comfortable without showing a feeling of bottoming and having excellent cushioning. Furthermore, although I tried to walk on it, there was no deviation between the rug cushioning material and the rug carpet.
  -The result of the light floor impact sound level reduction test of the flooring material was a performance grade ΔLL (I) -9 and passed. Moreover, when a rug cushioning material was placed on the flooring floor and the rug carpet for two tatami mats was placed on the flooring material, the cushioning material was considerably softer than Example 1 and the cushioning property was excellent and comfortable. Furthermore, although I tried to walk on it, there was no deviation between the rug cushioning material and the rug carpet.
  ・ When riding on the rug carpet and walking 10 times, the rug cushioning material did not shift from the floor or from the rug carpet. Further, the result of the light floor impact sound level reduction test of the flooring material was a performance grade ΔLL (I) -7 and passed. In addition, the cushion material for rugs was placed on the flooring floor, and when sitting on the rug carpet for 2 tatami mats, it was soft and comfortable, showing excellent cushioning properties. Furthermore, although I tried to walk on it, there was no deviation between the rug cushioning material and the rug carpet.

It is explanatory drawing which shows the cushion material for rugs concerning this invention.

  One embodiment of the lug cushion material according to the present invention will be described with reference to FIG. The rug cushioning material 1 according to the present invention is characterized in that an intermediate layer 3 made of a cushioning material is laminated below the surface layer 2 and a back surface layer 4 is laminated below the intermediate layer 3. And

In the present invention, the surface layer 2 and the back layer 4 are not particularly limited, but are preferably non-woven fabrics. As a nonwoven fabric, 1 type chosen from the group which consists of a needle punch nonwoven fabric, a spun bond nonwoven fabric, and a chemical bond nonwoven fabric is preferable, and the fabric weight of the said nonwoven fabric has preferable 100-300 g / m < ² >. By using non-woven fabric as the surface layer 2 and the back layer 4, sufficient surface strength and sufficient wear resistance can be obtained, and when applied to a rug cushion material, it is laid on the rug cushion material. The slipping of the carpet can be suppressed.

If the basis weight of the nonwoven fabric is less than 100 g / m ^2, it may be difficult to ensure sufficient wear resistance and surface strength. Even if it exceeds 300 g / m ² , not only is the effect of matching it poor, but there is also a risk of increasing the cost and weight, such being undesirable. By setting the basis weight of the nonwoven fabric within this range, the intermediate layer made of the cushion material is protected by the front surface layer and the back surface layer, and handling becomes easier.

  Although it does not specifically limit as a raw material which comprises a nonwoven fabric, A polyester fiber, a polypropylene fiber, nylon fiber, etc. can be mentioned. Among these, a needle punch nonwoven fabric or a spunbond nonwoven fabric made of polyester fiber or polypropylene fiber is more preferable.

  It is preferable that the non-slip resin 5 is partially fixed to the lower side of the back layer 4. Examples of the anti-slip resin 5 include, but are not limited to, styrene / butadiene rubber (SBR), vinyl chloride (PVC), ethylene vinyl acetate copolymer (EVA), methyl methacrylate / butadiene rubber (MBR), and acrylic resin. It is formed by applying the coating on the lower side of the back layer 4 by a coating method using a knife, a roll or the like or a printing method using a screen, and then heating.

The anti-slip resin 5 may be fixed to the entire surface of the back layer 4 or may be partial. It is preferably partial, and for example, it is preferably formed by applying in a dot shape. Furthermore, you may combine designs, such as a dot shape and a pattern. By doing in this way, even if it lays the cushion material for rugs on floors, such as a tatami mat and flooring, it can prevent slipping.
Furthermore, a heat-expandable microcapsule may be blended with the anti-slip resin 5, and by doing so, it can be foamed during heating to further form a protrusion.

  In the present invention, the intermediate layer 3 made of the cushion material is not particularly limited. For example, polyethylene foam and urethane foam can be used. By doing in this way, while exhibiting the outstanding cushioning property, it is excellent in the sound-insulating property to a downstairs. Among these, a polyurethane foam having a thickness in the range of 10 mm to 40 mm is preferable. If the thickness is less than 10 mm, although there is cushioning property, there is a possibility of feeling a bottoming, which is not preferable in terms of sound insulation. Even if the thickness exceeds 40 mm, although the sound insulation is excellent, the entire lug cushioning material becomes thick, which may be difficult to handle.

The polyurethane foam may be a known one, and is not particularly limited, but the polyurethane foam is preferably 16D to 40D (D is the density of urethane, Kg / m ³ ).

  Furthermore, in the present invention, the surface layer 2 is preferably subjected to an anti-slip treatment. The slip prevention with the carpet can be improved, and the displacement of the carpet can be prevented. As the anti-slip treatment applied to the surface layer 2, for example, the fiber on the surface of the surface layer 2 is heated by applying a flame of a gas burner, so that the fiber partially melts and becomes granular and imparts anti-slip properties. be able to. Further, for example, a vinyl chloride resin, an acrylic resin, or the like can be applied to the nonwoven fabric of the surface layer 2 by a known method such as a printing method, a spray method, a coating method, or a dip method. The coating may be performed on the entire surface layer 2, or may be partially or partially applied.

  In the present invention, a design may be applied to the surface layer 2 of the lug cushion material. For applying the design, a known method such as rotary printing, flat screen printing, ink jet printing, or thermal transfer film can be used for the surface layer. In addition, a design property can be improved by giving the above-mentioned design as the surface layer 2 using the nonwoven fabric using the fiber dyed with cotton. Further, not only a dye design with a dye but also a print design with a pigment or a resin may be imparted to the surface layer 2.

  In the present invention, the intermediate layer 3 made of a cushioning material is laminated on the lower side of the surface layer 2 and the back surface layer 4 is laminated and integrated on the lower side. For example, styrene-butadiene rubber (SBR) It can be integrated by applying an adhesive made of a resin selected from a polymer (EVA), methyl methacrylate / butadiene rubber (MBR), an acrylic resin and the like by a known method between the layers, and by dry bonding. it can. In addition, the intermediate layer 3 made of a cushion material is bonded to a material having heat melting properties such as urethane foam by melting one surface of the urethane foam by a flame such as a gas burner and simultaneously laminating and pressing the surface layer 2. Further, the opposite surface of the urethane foam is melted in the same manner, and at the same time, the back surface layer 4 is laminated and pressure bonded, whereby the surface layer 2, the intermediate layer 3, and the back surface layer 4 can be firmly bonded and integrated.

  Further, the lug cushion material of the present invention may be subjected to overlock processing, tape processing, or hem processing on the peripheral portion to prevent fraying and adjust the appearance.

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

<Example 1>
On one side of a needle punched nonwoven fabric made of polyester fiber having a basis weight of 200 g / m ^2, a vinyl chloride resin is printed in a dot shape to a size of about 2 mm in diameter using a screen (wet application amount 90 g / m ² ), and then the temperature is 150 Drying at 5 ° C. for 5 minutes formed an anti-slip resin 5. Next, one surface of a urethane foam having a density of 18D and a thickness of 15 mm was melted by a gas burner and simultaneously laminated and adhered to the opposite side of the surface of the back surface layer 4 on which the anti-slip resin 5 was formed. Thereafter, the other surface of the urethane foam was melted in the same manner, and a polyester fiber basis weight 200 g / m ² needle punched nonwoven fabric was laminated and adhered. The rug cushion material thus obtained was cut into a size of 170 cm in length and 170 cm in width, and taped to the peripheral edge portion to prevent fraying of the rug cushion material. The result of the light floor impact sound level reduction test of the flooring material was a performance grade ΔLL (I) -7. Also, a rug cushioning material was placed on the flooring floor, and a rug carpet for two tatami mats was placed on top of it.

<Example 2>
In Example 1, a rug cushioning material was obtained in the same manner as in Example 1 except that polyurethane foam having a thickness of 12 mm was used. The result of the light floor impact sound level reduction test of the flooring material was a pass in performance grade ΔLL (I) -6. Also, when a rug cushioning material was placed on the flooring floor and the rug carpet for two tatami mats was placed on the flooring, it was comfortable without showing a feeling of bottoming and having excellent cushioning. Furthermore, although I tried to walk on it, there was no deviation between the rug cushioning material and the rug carpet.

<Example 3>
A rug cushioning material was obtained in the same manner as in Example 1 except that polyurethane foam having a thickness of 35 mm was used. The result of the light floor impact sound level reduction test of the flooring material was a performance grade ΔLL (I) -9 and passed. Moreover, when a rug cushioning material was placed on the flooring floor and the rug carpet for two tatami mats was placed on the flooring material, the cushioning material was considerably softer than Example 1 and the cushioning property was excellent and comfortable. Furthermore, although I tried to walk on it, there was no deviation between the rug cushioning material and the rug carpet.

<Example 4>
In Example 1, as the anti-slip treatment on the surface of the surface layer 2, the fibers on the surface of the surface layer 2 were heated by applying a flame of a gas burner, and the fibers were partially melted and granulated to give anti-slip properties. A rug cushioning material was obtained in the same manner as in Example 1. Even when riding on the rug carpet and reciprocating 10 times, the rug cushioning material did not shift from the floor or from the rug carpet. Further, the result of the light floor impact sound level reduction test of the flooring material was a performance grade ΔLL (I) -7 and passed. In addition, the cushion material for rugs was placed on the flooring floor, and when sitting on the rug carpet for 2 tatami mats, it was soft and comfortable, showing excellent cushioning properties. Furthermore, although I tried to walk on it, there was no deviation between the rug cushioning material and the rug carpet.

<Comparative Example 1>
In Example 1, the surface layer 2 and the back surface layer 4 were laminated and integrated using an ethylene vinyl acetate copolymer (EVA) emulsion as an adhesive without using the urethane foam intermediate layer 3 having a thickness of 12 mm. A cushioning material was obtained in the same manner as in Example 1. The result of the light floor impact sound level reduction test of the flooring material was a failure in performance grade ΔLL (I) -4. In addition, when this cushion material was placed on the flooring floor and the rug carpet for 2 tatami mats was placed on it, it was difficult to say that there was a feeling of bottoming and cushioning.

<Comparative example 2>
Example 1 except that the same non-woven fabric as the surface layer 2 was used instead of the urethane foam having a thickness of 15 mm, and an ethylene vinyl acetate copolymer (EVA) emulsion was used as an adhesive and laminated and integrated. A cushion material was obtained in the same manner. The result of the light floor impact sound level reduction test of the flooring material was a failure in performance grade ΔLL (I) -5. In addition, when this cushion material was put on the flooring floor and it sat down on the place where the rug carpet for 2 tatami mats was piled up, the feeling of bottoming was remarkable like comparative example 1, and it was hard to say that there was cushioning properties. .

  The rug cushioning material of Examples 1 to 4 of the present invention can be used by placing the rug cushioning material on the flooring floor and overlapping the rug carpet thereon, and is excellent in sound insulation to the downstairs and excellent cushioning. It was sexual and comfortable.

  On the other hand, the cushion materials of Comparative Examples 1 and 2 have a remarkable bottoming feeling and were hardly said to have cushioning properties.

  Moreover, the impact sound of the obtained lug cushion material was evaluated based on the following test.

<Light floor impact sound level reduction test evaluation method for flooring>
The lug cushioning material is laid on the flooring of the performance grade ΔLL (I) -4, measured using a standard lightweight impact source (tapping machine) based on JIS A 1440-1, and the sound insulation to the downstairs It was evaluated. A performance grade ΔLL (I) −6 or higher was considered acceptable.

  The rug cushioning material of the present invention is excellent in sound insulation to the downstairs and has an excellent cushioning property without a feeling of bottoming, and is therefore used as a rug cushioning material laid under a carpet.

DESCRIPTION OF SYMBOLS 1 ... Cushioning material for rugs 2 ... Surface layer 3 ... Intermediate layer 4 ... Back layer 5 ... Anti-slip resin

Claims (1)

An intermediate layer made of a cushioning material is laminated below the surface layer, and a back surface layer is laminated below the intermediate layer, and at least partially attaches a non-slip resin to the lower side of the back surface layer. And a protrusion formed by thermally foaming a thermally expandable microcapsule is provided on the surface of the anti-slip resin, and the cushion material is a polyurethane foam having a thickness in a range of 10 mm to 40 mm, and the surface layer and The back surface layer is made of a needle punched nonwoven fabric having a basis weight of 100 to 300 g / m ² made of polyester fiber, and the surface layer is subjected to an anti-slip treatment in which the fibers are partially melted to be granular. Rug cushioning material.

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