Floor impact sound reducing flooring, floor impact sound reducing sheets, and floor impact sound reducing mats

Abstract

To provide a floor impact sound reduction floor, a floor impact sound reduction sheet and a floor impact sound reduction mat which are capable of reduction heavy weight floor impact sound.SOLUTION: A floor impact sound reduction sheet comprises a cushion, a sheet, and an adhesive layer for bonding the cushion and the sheet, wherein the cushion is a laminate of foam sheets, and the thickness of the cushion is 40 mm to 80 mm inclusive.SELECTED DRAWING: Figure 1

Description

Technical Field

[0001] The present invention relates to a floor impact sound reduction floor, a floor impact sound reduction sheet, and a floor impact sound reduction mat that can reduce floor impact sound, particularly heavy floor impact sound.

Background Art

[0002] In apartment houses, suppression of floor impact sound transmitted from the upper floor to the lower floor is required. Floor impact sound includes lightweight floor impact sound and heavy floor impact sound. Lightweight floor impact sound can be reduced by laying a finishing material with cushioning properties on the surface such as a carpet on the floor. On the other hand, it is difficult to reduce heavy floor impact sound even by laying a finishing material on the floor. This is because heavy floor impact sound is mainly determined by the thickness of the concrete floor. Therefore, in order to suppress heavy floor impact sound, it is important to plan a thick concrete floor at the time of building design. In already constructed apartment houses, since it is impossible to change the concrete floor, after the construction of the concrete floor, when improvement of heavy floor impact sound is necessary, there is a method of constructing an anti-vibration floating floor on the concrete floor. However, the anti-vibration floating floor is very expensive, and since it has a large mass, reinforcement work may be required in some cases. Furthermore, it is also difficult to perform work to change the floor finishing material in a housing environment where residents are already living.

[0003] As a simple countermeasure against floor impact sound that can be carried out even after starting to live, there is a method of laying a commercially available children's play mat on the finished floor (see Patent Document 1). However, most commercially available play mats are effective for lightweight floor impact sound, but cannot reduce heavy floor impact sound. Mats using a foam material having an effect of reducing heavy floor impact sound are also commercially available. However, such mats using a foam material have a problem that since the surface is soft, when receiving a large impact load due to human jumping etc., sagging occurs and the performance of reducing heavy floor impact sound deteriorates.

[0004] Incidentally, some children with intellectual disabilities or developmental disorders habitually jump around, and as they grow, the force of their impacts increases. Families with such children often cover the entire room with foam mats to cope with this, but since these need to be replaced when they wear out and their performance deteriorates, it is a significant financial burden. Furthermore, many of these foam materials have surfaces that are red, blue, yellow, light blue, pink, etc., which reduces their aesthetic appeal compared to finished flooring materials such as hardwood. [Prior art documents] [Patent Documents]

[0005] [Patent Document 1] Japanese Patent Publication No. 2002-276135 [Overview of the Initiative] [Problems that the invention aims to solve]

[0006] The object of this invention is to provide floor impact sound reducing floor, floor impact sound reducing sheet, and floor impact sound reducing mat that can reduce heavy floor impact noise. [Means for solving the problem]

[0007] The means for solving the problems of the present invention are as follows. 1. A floor impact sound reducing floor characterized by having a cushion layer consisting of multiple cushioning materials laid on an existing floor, one or more sheet layers consisting of long sheets, and an adhesive layer that bonds the cushion layer and the sheet layers together. 2. The floor impact sound reducing floor according to 1, characterized in that the cushion layer is a laminate of foam sheets. 3. The floor impact sound reducing floor according to 1. or 2., characterized in that the sheet layer has a tensile strength of 2 mm or more when the tensile strength is measured using a dumbbell-shaped No. 2 test specimen specified in JIS K6251, and the smaller of the elongation at break or yield is 80 N or more, and the tensile strength at break or yield, whichever is smaller the elongation. 4. A floor impact sound reducing sheet characterized by comprising a cushion, a sheet, and an adhesive layer for bonding the cushion and the sheet together. 5. It comprises two or more floor impact sound reduction sheets as described in 4. and a cover sheet that encloses the floor impact sound reduction sheets. The cover sheet comprises two or more bag-shaped portions, each capable of containing one of the floor impact sound reduction sheets, and connecting portions that connect the bag-shaped portions. A floor impact sound reduction mat characterized by being able to be folded using the aforementioned connecting portion as an axis. [Effects of the Invention]

[0008] The floor impact sound reducing floor, floor impact sound reducing sheet, and floor impact sound reducing mat (hereinafter also simply referred to as reduction floor, reduction sheet, and reduction mat, respectively) of the present invention can reduce heavy floor impact noise. The lowering floor of the present invention can be easily installed in existing buildings. Because the lowering floor of the present invention can be installed in a short time, it places less burden on residents during installation. The noise-reducing floor of the present invention, in which the cushioning layer is a laminate of foam sheets, can further reduce heavy floor impact noise. The noise-reducing floor of the present invention is resistant to sagging, thus reducing the frequency of replacement. The noise-reducing floor of the present invention, using a sheet layer in which the smaller of the elongation at break or yield elongation measured using a dumbbell-shaped No. 2 test piece specified in JIS K6251 is 2 mm or more, and the tensile strength at break or yield (the smaller elongation) is 80 N or more, is extremely resistant to sagging because the sheet layer is resistant to deformation and has excellent repairability after deformation. The noise-reducing floor of the present invention, in which the sheet layer is equipped with a printed layer, has excellent design. The reduction sheet and reduction mat of the present invention are easy to install and store, so they can be installed only when and where needed, and stored away when guests are present. [Brief explanation of the drawing]

[0009] [Figure 1] A partial cross-sectional perspective view of a floor impact sound reducing floor, which is the first embodiment of the present invention. [Figure 2]A partial cross-sectional perspective view of a floor impact sound reducing floor, which is a second embodiment of the present invention. [Figure 3] A schematic diagram of a cover sheet, which is one embodiment used in the floor impact sound reduction mat of the present invention. [Figure 4] A diagram showing the relationship between tensile force and displacement in Experiment 2. [Figure 5] This figure shows the relationship between the number of repeated loading cycles and the rate of height reduction in Experiment 3. [Modes for carrying out the invention]

[0010] "Floor sound reduction flooring" The floor impact sound reduction floor of the present invention will be described according to its embodiments. Figure 1 shows a partial cross-sectional perspective view of a floor impact sound reducing floor, which is the first embodiment of the present invention. The floor impact sound reducing floor 1, which is the first embodiment, has a cushion layer 2 consisting of nine cushioning materials 21 laid on an existing floor, a single sheet layer 3 consisting of two long sheets 31, and an adhesive layer (not shown) that bonds the cushion layer 2 and the sheet layer 3.

[0011] • Cushion layer In the sound-reducing floor of the present invention, the cushion layer consists of multiple cushioning materials laid on the existing floor. The laid cushioning materials can be fixed to adjacent cushioning materials with adhesive tape, adhesive, etc. In the first embodiment, the floor impact sound reducing floor 1, the cushioning material 21 consists of a laminate of foam sheets. The material of the cushioning material used in this invention is not particularly limited as long as it absorbs impact and reduces floor impact noise, but foam is preferred, for example. Foam has excellent impact noise reduction performance and deformation recovery performance. Polyethylene foam, polyurethane foam, polystyrene foam, etc. can be used as the foam, and among these, polyethylene foam is preferred because it has an excellent balance between impact noise reduction performance and strength, and is also inexpensive.

[0012] In the floor impact sound reduction floor of the present invention, the cushioning material can be a single layer or a laminate, but the cushioning material is preferably a laminate. The cushioning material made of a laminate is superior in the performance of reducing floor impact sound compared to a single-layer cushioning material having the same total thickness and material. Furthermore, the cushioning material made of a laminate can adjust the frequency band and the reduction performance for reducing impact sound by adjusting the elasticity, thickness, etc. of each layer.

[0013] The thicker the cushioning material, the more excellent the effect of reducing the weighted floor impact sound (63 Hz). However, as it gets thicker, problems such as increased weight, increased tendency to sag, and a large step with the part where the reduction floor is not laid, making it difficult to live, become more significant. Therefore, it is preferably 20 mm or more and 100 mm or less, and more preferably 40 mm or more and 80 mm or less. When the cushioning material is made of a laminate, the thickness of one layer is preferably 5 mm or more and 10 mm or less, and the thicknesses of each layer may be the same or different.

[0014] ·Sheet layer In the reduction floor of the present invention, one or more sheet layers are made of a long sheet, and the lowermost sheet layer is bonded to a plurality of cushioning materials. By bonding the long sheet to a plurality of cushioning materials, the displacement of the cushioning materials can be prevented. In the reduction floor 1 which is the first embodiment, the long sheet 31 is one layer, the width is 1.5 times that of the cushioning material 21, the length is 3 times that of the cushioning material 21, it has an area equivalent to 4.5 sheets of the cushioning material 21, and is bonded to 6 sheets of the cushioning material 21. The sheet layer can be used without particularly limiting the material used for the floor surface material. For example, vinyl chloride, polypropylene, ethylene-vinyl alcohol copolymer, etc. can be used. Also, these sheets can contain fiber materials such as glass fiber and polymer fiber. Note that vinyl chloride is most commonly used as the floor surface material. Also, when the sheet layer is the uppermost layer, it is preferably printed with a wood grain pattern or the like.

[0015] Since the sheet layer is less deformable than the cushion layer, by adhering the sheet layer to the surface of the cushion layer, the amount of deformation of the cushion layer can be reduced. Further, although the deformed sheet layer has self-repairability to return to its original shape, as the sheet layer is restored to its shape, the cushion layer adhered to the sheet layer can also return to its original shape, so the reduction floor of the present invention is less likely to sag.

[0016] Here, a long sheet used for architectural purposes is generally about 1.8 m wide. Since the long sheet is narrow compared to the dimensions of the room, in order to install the reduction floor of the present invention over a large area, as shown in FIG. 1, it is necessary to join the widthwise ends of the long sheet by an adhesive, welding, or the like. Since the joints between the long sheets are inferior in strength compared to the non-jointed portions, if a large force is applied when a child jumps on the joint, the joint may peel off or break.

[0017] FIG. 2 shows a partial cross-sectional perspective view of a floor impact sound reduction floor which is a second embodiment of the present invention. The floor impact sound reduction floor 10 which is a second embodiment has a sheet layer 3-2 on the sheet layer 3, and has the same configuration as the reduction floor 1 which is a first embodiment, except that the long sheet 31-2 constituting the sheet layer 3-2 is laminated so that the longitudinal direction is orthogonal to the long sheet 31.

[0018] As shown in the second embodiment, by laminating two or more sheet layers so that the longitudinal directions of the long sheets constituting each sheet layer are different, breakage of the joints can be prevented. Alternatively, breakage of the joints can be prevented by laminating so that the joints do not overlap even if the longitudinal directions are the same. When laminating so that the longitudinal directions are the same and the joints do not overlap, it is preferable that the joints of the upper and lower sheet layers are separated by 5 cm or more in the horizontal direction, and more preferably 10 cm or more. When laminating two or more sheet layers, it is preferable from the viewpoint of preventing breakage of the joints of the outermost sheet layer to use, as at least one of the long sheets constituting the lower sheet layer, a sheet containing a fiber material. In the lowering floor of the present invention, one or more sheet layers are sufficient, but if multiple sheet layers are provided, two layers are preferable from the viewpoint of ease of installation. However, if the width of the long sheet is sufficient to install the lowering floor of the present invention in a corridor or part of a room, one sheet layer is sufficient.

[0019] In the present invention, it is preferable that at least one sheet layer of the reduced floor has a tensile strength of 2 mm or more for the smaller of the elongation at break or yield elongation when measured using a dumbbell-shaped No. 2 test specimen specified in JIS K6251, and that the tensile strength at the break or yield point of the smaller elongation is 80 N or more. If the smaller of the elongation at break or yield elongation is less than 2 mm, the sheet layer is prone to tearing during deformation or to wrinkling without returning to its original shape after being stretched. Also, if the tensile stress at this 2 mm elongation is less than 80 N, the restorative force is insufficient, and the cushion layer is prone to sagging. It is more preferable that the smaller of the elongation at break or yield elongation is 3 mm or more, and even more preferable that it is 5 mm or more. Furthermore, it is more preferable that the tensile stress at this 2 mm elongation is 100 N or more, and even more preferable that it is 120 N or more.

[0020] ·Adhesive layer The adhesive layer adheres the cushion layer and the sheet layer. If there are two or more sheet layers, the adhesive layer also adheres between each sheet layer. The adhesive layer can be any material that can firmly bond the cushion layer and the sheet layer; pressure-sensitive adhesives, heat-sensitive adhesives, adhesives, double-sided adhesive tapes, etc., can be used. In this case, it is preferable that the adhesive surface of the sheet layer has fine irregularities such as embossing, as this increases the adhesive strength. Furthermore, the adhesive layer only needs to be able to uniformly bond the cushion layer and the sheet layer, and can be applied to the entire surface or in a pattern of dots or lines. When applied in a pattern, the adhesive area is preferably 50% or more of the entire surface, and more preferably 60% or more.

[0021] The impact sound-reducing floor of the present invention is lightweight, both in terms of the cushioning material and the sheet layer, so no structural reinforcement is required for installation. The impact sound-reducing floor of the present invention can be installed simply by laying multiple sheets of cushioning material on the existing floor to form a cushion layer, and then attaching a long sheet to this cushion layer to form a sheet layer. No special equipment is required for installation, and it can be installed quickly by a small number of people. When the impact sound-reducing floor of the present invention is installed in a residence after occupancy, the residents do not need to move out for a short period of time. Both the cushioning material and the long sheet can be carried in by hand. The cushioning material and the long sheet are made of soft material, so they are less likely to be damaged even if they bump into walls or furniture during transport.

[0022] "Floor impact sound reduction sheet" The floor impact sound reduction sheet of the present invention comprises a cushion, a sheet, and an adhesive layer for bonding the cushion and the sheet together. The floor impact sound reduction sheet of the present invention is equivalent in size to one cushioning material of the floor impact sound reduction floor of the present invention described above, and materials equivalent to those used for the cushion, sheet, and adhesive layer of the floor impact sound reduction floor can be used.

[0023] "Floor impact sound reduction mat" A floor impact sound reduction mat can be created by enclosing two or more of the above-mentioned floor impact sound reduction sheets in a cover sheet that has a bag-like section capable of enclosing each floor impact sound reduction sheet and a connecting section that connects these bag-like sections. Figure 3 shows a schematic diagram of a cover sheet according to one embodiment. The cover sheet 4 shown in Figure 2 has three bag-shaped parts 41 and two connecting parts 42 that connect the bag-shaped parts 41, and can be folded around the connecting parts 42 as axes. In the cover sheet 4 shown in Figure 2, the connecting parts 42 are arranged alternately at the top and bottom, so it can be folded like a folding screen. In the present invention, the number of bag-shaped parts of the cover sheet is not particularly limited, but it is preferable that there be two to four bag-shaped parts from the viewpoint of handling. [Examples]

[0024] Experiment 1: Impact Sound Reduction Experiment "Example 1" A test specimen was obtained by bonding a commercially available sheet 1 (made of polyvinyl chloride: 2 mm thick) to a laminated polyethylene mat (40 mm thick) consisting of a laminate of 5 mm thick polyethylene foam using an acrylic adhesive. Example 2 A test specimen was obtained in the same manner as in Example 1, except that the thickness of the laminated polyethylene mat was set to 50 mm. "Example 3" A test specimen was obtained in the same manner as in Example 1, except that the thickness of the laminated polyethylene mat was set to 80 mm.

[0025] "Comparative Example 1" Only the laminated polyethylene mat from Example 1 was used as the test specimen. "Comparative Example 2" Only single, unlaminated polyethylene mats with a thickness of 40 mm were used as test specimens.

[0026] "Comparative Example 3" A test specimen was obtained in the same manner as in Example 1, except that sheet 1 was replaced with a commercially available sheet 2 (made of polyvinyl chloride: 0.8 mm thick). "Comparative Example 4" A test specimen was obtained in the same manner as in Example 1, except that sheet 1 was replaced with a commercially available sheet 3 (made of polyvinyl chloride: 2.3 mm thick).

[0027] The levels of heavy impact sound were measured using an impact source (tire) with impact force characteristics (1) according to JIS A1418-2:2000, both with and without each test specimen placed on a concrete floor. The reduction in heavy impact sound was determined from the difference between these measurements. The shape changes of the test specimens before and after the test were also visually confirmed. Table 1 shows the results for each 1 / 3 octave band, specifically for the 50Hz to 80Hz range, which is important for heavy impact sound. [Table 1]

[0028] ·result Examples 1-3 confirmed that increasing the thickness of the cushioning layer improved the performance in reducing heavy floor impact noise. Furthermore, no changes were observed in the shape of the test specimens before and after the tests in Examples 1-3. Comparative Examples 1 and 2 confirmed that a laminated cushioning layer exhibited superior performance in reducing heavy floor impact noise. In Comparative Examples 1 and 2, indentations were observed in the test specimens (cushioning layer only) after the test. Example 1 and Comparative Example 3 had almost equivalent performance in reducing heavy floor impact noise. However, deformation was observed in the sheet layer of the specimen in Comparative Example 3 after the test. In Comparative Example 4, the sheet layer of the test specimen tore after being struck just once with the impact source, making it impossible to measure the heavy floor impact sound.

[0029] Experiment 2: Tensile Test The tensile strength of sheets 1-3 used in Experiment 1, and another commercially available sheet 4 (made of polyvinyl chloride: 2 mm thick), was measured. The measurement involved cutting sheets into dumbbell-shaped No. 2 shapes as specified in JIS K6251, and then stretching them at a tensile speed of 100 mm / min using a benchtop precision universal testing machine (manufactured by Shimadzu Corporation, device name Autograph AGS-X 5kN) to measure the tensile strength relative to the elongation. The measurement results are shown in Table 2 and Figure 4. [Table 2]

[0030] ·result Sheet 2 exhibits a large displacement under tensile force. This is likely why deformation occurred in Experiment 1. Sheet 3 had a yield elongation of 1.2 mm and a tensile strength of 68.1 N at yield. It is thought that Sheet 3 tore in Experiment 1 because of its low yield elongation. Sheet 4 is stronger than Sheet 1 and is expected to have the same resistance to deformation as Sheet 1.

[0031] Experiment 3: Sagging Test "Comparative Example 5" Only the laminated polyethylene mat from Example 2 was used as the test specimen. "Comparative Example 6" A test specimen was obtained in the same manner as in Example 2, except that the laminated polyethylene mat and sheet 1 were not bonded together.

[0032] The repeated compressive residual strain was determined in accordance with JIS K6400-4. Specifically, a 500mm x 500mm test specimen was repeatedly subjected to a 500N force using a 100mm diameter pressure bar 60 times per minute, and the decrease in height (thickness) at the point of application compared to before application was measured. The same measurements were also performed on the test specimens obtained in Example 2 and Comparative Example 3. The results are shown in Figure 5.

[0033] ·result Example 2 of the present invention was found to be less prone to height reduction and sagging even when subjected to repeated loads, compared to Comparative Examples 3, 5, and 6. In particular, it was confirmed from Example 2 and Comparative Example 6 that bonding the sheet layer and the cushion layer makes it less prone to height reduction, i.e., less prone to sagging. [Explanation of Symbols]

[0034] 1.10 Floor impact sound reduction floor 2 Cushioning layer 21 Cushioning material 3,3-2 Sheet Layer 31,31-2 Long sheet 4 Cover Sheets 41 Pouch 42 Connecting part

Claims

1. It comprises a cushion, a sheet, and an adhesive layer for bonding the cushion and the sheet. The cushion is a laminate of polyethylene foam with a thickness of 5 mm to 10 mm that has cushioning properties. The thickness of the cushion is 40 mm or more and 80 mm or less. The aforementioned sheet, when its tensile strength is measured using a dumbbell-shaped No. 2 test specimen as specified in JIS K6251, has a fracture elongation or yield elongation of 2 mm or more (whichever is smaller), and the tensile strength at fracture or yield (whichever is smaller) is 80 N or more. A floor impact sound reduction sheet characterized by being laid on top of an existing floor, independently of the existing floor.

2. It comprises two or more floor impact sound reduction sheets and a cover sheet that encloses the floor impact sound reduction sheets. The floor impact sound reducing sheet comprises a cushion, a sheet, and an adhesive layer that adheres the cushion and the sheet together. The cushion is a laminate of polyethylene foam with a thickness of 5 mm to 10 mm that has cushioning properties. The thickness of the cushion is 40 mm or more and 80 mm or less. The aforementioned sheet, when its tensile strength is measured using a dumbbell-shaped No. 2 test specimen as specified in JIS K6251, has a fracture elongation or yield elongation of 2 mm or more (whichever is smaller), and the tensile strength at fracture or yield (whichever is smaller) is 80 N or more. The cover sheet comprises two or more bag-shaped portions, each capable of containing one of the floor impact sound reduction sheets, and connecting portions that connect the bag-shaped portions. It can be folded around the aforementioned connecting part as an axis. A floor impact sound reduction mat characterized by being laid on top of an existing floor, independently of the existing floor.

Images