Soundproof carpet

Abstract

To provide a soundproof carpet with excellent sound insulation performance. [Solution] The soundproof carpet 1 of the present invention comprises a soundproofing body 2, a tufted carpet 3, and an adhesive layer 4. The soundproofing body 2 is made of double raschel fabric with a weight of 300-600 g / m 2 The tufted carpet 3 has a thickness T of 5 to 10 mm. The tufted carpet 3 is placed on the soundproofing body 2. The adhesive layer 4 is interposed between the soundproofing body 2 and the tufted carpet 3. The soundproofing body 2 is recessed in the thickness direction from the surface facing the tufted carpet 3 and has multiple openings 5 ​​with an opening diameter of 1.0 to 5.0 mm.

Description

[Technical Field]

[0001] This invention relates to a soundproof carpet. [Background technology]

[0002] In apartment buildings and other multi-unit dwellings, vibrations caused by impact noise (floor impact noise) generated on the upper floors are transmitted to the lower floors, resulting in a problem of structure-borne sound transmission. Floor impact noise is generated by everyday sounds such as children running around, the use of vacuum cleaners and washing machines, the opening and closing of doors, pet barking, and the footsteps of large dogs.

[0003] To suppress the propagation of impact sounds, i.e., the generation of structure-borne sound, sound-insulating carpets have been proposed (see, for example, Patent Document 1). [Prior art documents] [Patent Documents]

[0004] [Patent Document 1] Japanese Utility Model Publication No. 5-63381 [Overview of the Initiative] [Problems that the invention aims to solve]

[0005] The soundproof carpet described in Patent Document 1 is made of various carpet materials such as woven carpets and embroidered carpets, with a cushioning material fixed to the back surface, which is an aggregate of elastic material pieces such as natural rubber pieces, synthetic rubber pieces, crushed waste tires, and cork pieces. It is thick, heavy, and hard. There is a need for a soundproof carpet that can suppress the generation of solid-borne sound while suppressing a decrease in the comfort level of the carpet. [Means for solving the problem]

[0006] The soundproof carpet of the present invention is made of double raschel fabric with a weight of 300-600 g / m². 2 The soundproofing material is 5-10mm thick, A tufted carpet is placed on the soundproofing body, The soundproofing material and the tufted carpet are interposed in an adhesive layer, The soundproofing material is characterized by having a plurality of openings that are recessed in the thickness direction from the surface facing the tufted carpet and have a diameter of 1.0 to 5.0 mm.

[0007] Furthermore, the soundproof carpet of the present invention has a number density of the multiple openings of 16,200 to 64,000 per square meter. 2 It is characterized by being such.

[0008] Furthermore, the soundproof carpet of the present invention is characterized in that the double raschel fabric is composed of polyester fibers, polyethylene fibers, or polypropylene fibers.

[0009] Furthermore, the soundproof carpet of the present invention is characterized in that the double raschel fabric is composed of monofilament, multifilament, or a mixture of monofilament and multifilament.

[0010] Furthermore, the soundproof carpet of the present invention is characterized in that the tufted carpet is a polypropylene tufted carpet, a nylon tufted carpet, or a polyester tufted carpet. [Effects of the Invention]

[0011] The soundproof carpet of the present invention can suppress the generation of structure-borne sound. Furthermore, the soundproof carpet of the present invention can suppress a decrease in the comfort level of the carpet. [Brief explanation of the drawing]

[0012] [Figure 1] This is a cross-sectional view of a soundproof carpet 1 according to one embodiment of the present invention. [Figure 2] Figure 1 is a plan view of the soundproofing material 2 of the soundproofing carpet 1, as seen from the surface 2a side. [Figure 3]It is a plan view of the soundproofing body 2 of the soundproof carpet 1 in FIG. 1 as seen from the back surface 2b side.

Embodiments for Carrying Out the Invention

[0013] Hereinafter, embodiments of the present invention will be described with reference to the drawings. In each drawing, the same or substantially the same elements and parts are denoted by the same reference numerals, and overlapping descriptions are omitted or simplified. Also, the drawings used in the following description are schematic, and the dimensional ratios, shapes, etc. on the drawings do not necessarily match the actual ones. In this specification, the notation "~" includes the numerical values at both ends thereof.

[0014] FIG. 1 is a cross-sectional view of a soundproof carpet 1 according to an embodiment of the present invention, FIG. 2 is a plan view of the soundproofing body 2 of the soundproof carpet 1 in FIG. 1 as seen from the front surface 2a side, and FIG. 3 is a plan view of the soundproofing body 2 of the soundproof carpet 1 in FIG. 1 as seen from the back surface 2b side.

[0015] As shown in FIG. 1, the soundproof carpet 1 according to an embodiment of the present invention includes a soundproofing body 2, a tufted carpet 3, and an adhesive layer 4.

[0016] The soundproofing body 2 is composed of a double raschel fabric and has a front surface 2a and a back surface 2b. The soundproofing body 2 may be composed of synthetic fibers such as polyester fiber, polyethylene fiber, polypropylene fiber, nylon fiber, and polytrimethylene terephthalate fiber. The basis weight of the soundproofing body 2 is 180~1200 g / m 2 and preferably 330~1000 g / m 2 The thickness T of the soundproofing body 2 is 5~10 mm.

[0017] The tufted carpet 3 is arranged on the surface 2a of the soundproofing body 2. As shown in Figure 1, the tufted carpet 3 includes a base material 33 in which pile yarns 32 are tufted (implanted) onto a base fabric 31, and a backing layer 34 located on the back surface of the base material 33. The pile yarns 32 are made of, for example, polypropylene fibers, nylon fibers, polyester fibers, etc. The base fabric 31 may be a woven, knitted, or nonwoven fabric made of polypropylene fibers, nylon fibers, polyester fibers, etc. The backing layer 34 is made of, for example, rubber latex, resin, etc.

[0018] The adhesive layer 4 is interposed between the soundproofing body 2 and the tufted carpet 3, and adheres the soundproofing body 2 and the tufted carpet 3 together. The adhesive layer 4 may be, for example, a polyethylene sheet.

[0019] As shown in Figure 2, the soundproofing body 2 has a plurality of openings 5 ​​that are recessed in the thickness direction from the surface 2a on the tufted carpet 3 side. The opening diameter (equivalent circle diameter) of the plurality of openings 5 ​​on the surface 2a is 1.0 to 5.0 mm. A portion of the adhesive layer 4 is contained within each opening 5. The shape of the openings 5 ​​on the surface 2a of the soundproofing body 2 may be, for example, circular, elliptical, polygonal, or other shapes.

[0020] The soundproof carpet 1 is used with the back surface 2b of the soundproofing body 2 facing or in contact with the floor surface. Everyday noises generated on the upper floor create impact noise in the tufted carpet 3. The impact noise generated in the tufted carpet 3 is transmitted to the soundproofing body 2, and energy is lost due to friction between the fibers constituting the soundproofing body 2, the viscosity of the air present inside the soundproofing body 2, etc. In this way, the soundproof carpet 1 can suppress the propagation of impact noise and suppress the generation of structure-borne sound.

[0021] Soundproof carpet 1 has a soundproofing material 2 with a weight of 300-600 g / m². 2Therefore, since the thickness T is 5 to 10 mm, it can suppress the generation of solid-borne sound, while also providing appropriate cushioning and suppressing a decrease in comfort as a carpet (for example, the occurrence of a feeling of touching the floor or instability when walking).

[0022] In the soundproof carpet 1, since the soundproofing body 2 has multiple openings 5, at least a portion of the adhesive layer 4 enters each opening 5, and the soundproofing body 2 and the tufted carpet 3 are firmly bonded together. As a result, impact sound generated in the tufted carpet 3 is efficiently propagated to the soundproofing body 2, and energy is lost in the soundproofing body 2. Therefore, the soundproof carpet 1 can efficiently suppress the generation of structure-borne sound. Furthermore, since the opening diameters of the multiple openings 5 ​​in the soundproof carpet 1 are 1.0 to 5.0 mm, the bond between the soundproofing body 2 and the tufted carpet 3 can be strengthened while minimizing the substantial reduction in the thickness T of the soundproofing body 2.

[0023] If the diameter of the opening 5 is less than 1.0 mm, impact sounds generated in the tufted carpet 3 are more likely to be reflected off the surface 2a of the soundproofing body 2, making it difficult for them to propagate into the interior of the soundproofing body 2. If the diameter of the opening 5 exceeds 5.0 mm, the soundproofing body 2 and the tufted carpet 3 may not be sufficiently firmly bonded, making it difficult for impact sounds to be efficiently propagated to the soundproofing body 2. Also, if the diameter of the opening 5 exceeds 5.0 mm, the effective thickness T of the soundproofing body 2 decreases, making it difficult for the soundproofing body 2 to suppress the propagation of impact sounds, and the comfort of the soundproofing carpet 1 is more likely to decrease.

[0024] The number density of the multiple openings 5 ​​on the surface 2a of the soundproofing material 2 is 16,200 to 64,000 per square meter. 2 This is acceptable. In this case, the generation of solid-borne sound can be efficiently suppressed, and the decrease in comfort of the soundproof carpet 1 can be suppressed.

[0025] The number density of the multiple openings 5 ​​is 16,200 per m². 2If it is less than this value, the impact sound generated in the tufted carpet 3 is likely to be reflected on the surface 2a of the soundproof body 2 and is less likely to be propagated inside the soundproof body 2. The number density of the plurality of openings 5 is 64,000 pieces / m 2 If it exceeds this value, the soundproof body 2 and the tufted carpet 3 are not sufficiently firmly bonded, and the impact sound may not be efficiently propagated to the soundproof body 2. Also, when the number density of the plurality of openings 5 exceeds 64,000 pieces / m 2 If it exceeds this value, the substantial thickness T of the soundproof body 2 decreases, making it difficult for the soundproof body 2 to suppress the propagation of the impact sound, or the comfort of the soundproof carpet 1 is likely to deteriorate.

[0026] The soundproof body 2 may be composed of synthetic fibers with a relatively high elastic modulus, such as polyester fibers, polyethylene fibers, and polypropylene fibers. In this case, it is possible to suppress the generation of structure-borne sound while suppressing the deterioration of the comfort of the soundproof carpet 1.

[0027] The soundproof body 2 may be composed of monofilaments, multifilaments, or a mixed yarn of monofilaments and multifilaments. The soundproof body 2 may be composed of monofilaments with a relatively high elastic modulus. In this case, it is possible to suppress the generation of structure-borne sound while suppressing the deterioration of the comfort of the soundproof carpet 1.

[0028] The fineness of the fibers constituting the soundproof body 2 is 30 to 900 dTex, preferably 30 to 200 dTex, and more preferably 30 to 90 dTex.

[0029] As shown in Figure 1, the soundproofing body 2 has a three-dimensional structure including a surface layer 6 including a surface 2a, a back layer 7 including a back surface 2b, and a bonding layer 8 that connects the surface layer 6 and the back layer 7. The surface layer 6, the back layer 7, and the bonding layer 8 may be composed of the same fibers (i.e., the same fiber material, the same fiber structure, and the same fineness), or at least two of them may be composed of different fibers. In this case, by appropriately changing the combination of fibers that make up the surface layer 6, the back layer 7, and the bonding layer 8, the basis weight, thickness T, etc. of the soundproofing body 2 can be freely controlled, making it possible to provide a soundproofing carpet 1 that meets the required specifications.

[0030] A non-slip surface 9 may be provided on the back surface 2b of the soundproofing body 2. The non-slip surface 9 is formed, for example, by adhering synthetic resin to the back surface 2b of the soundproofing body 2 in a granular, linear, grid-like shape. The non-slip surface 9 can be formed, for example, by applying and drying synthetic resin to the back surface 2b of the soundproofing body 2 using a roll coater or the like.

[0031] The synthetic resin used for the anti-slip material 9 may be, but is not limited to, polyvinyl chloride resin (PVC), styrene-butadiene rubber (SBR), nitrile rubber (NBR), methyl methacrylate-butadiene rubber (MBR), ethylene vinyl acetate copolymer, acrylic resin, polyethylene resin, polyethylene terephthalate resin, etc.

[0032] The anti-slip material 9 may be in the form of minute granules with an average diameter of 0.5 to 3 mm, preferably 1.0 to 2.5 mm, and more preferably 1.5 to 2 mm. When the anti-slip material 9 is in the form of granules, 8 to 12 pieces / cm² can be placed on the back surface 2b of the soundproofing material 2. 2 Preferably 6-8 pieces / cm 2 More preferably 4-6 pieces / cm 2 They may be formed at the following number density. [Examples]

[0033] The present invention will be specifically described below based on the following examples. However, the present invention is not limited to the examples described below.

[0034] <Preparation of test specimens and comparison specimens> Using 83dTex polyester filament (drawn yarn) as the front and back yarns, and 33dTex polyester filament (FDY yarn) as the middle yarn, and knitting on a double raschel machine (manufactured by Karl Mayer), the fabric weight is 530-590g / m. 2 A double raschel fabric was produced. Polyvinyl chloride resin was applied to one side of the produced double raschel fabric using a roll coater device so that it was scattered in granular form, and then dried to produce a soundproofing body 2 made of double raschel fabric with an anti-slip surface 9 formed on the back surface 2b.

[0035] The soundproofing material 2 that was created has 17 warp threads / cm 2 × 10 weft threads / cm 2 The anti-slip surface 9 had a height of 0.3 mm, and the spacing between adjacent anti-slip surfaces 9 was 10 mm.

[0036] The fabricated soundproofing material 2 was cut to a size of 100 cm x 100 cm, and tufted carpet 3 of the same size was bonded to it with adhesive layer 4 to create test specimens 1 to 9 of the example. Comparative specimens 1 to 3 were also prepared as comparative examples.

[0037] Test specimens 1-3 were classified as tufted carpet 3, with a basis weight of 530 g / m². 2 The test specimens used are polypropylene tufted carpets. Test specimens 1 to 3 have different thicknesses T of soundproofing material 2. Test specimen 1 has a thickness T of 5 mm, test specimen 2 has a thickness T of 8 mm, and test specimen 3 has a thickness T of 10 mm. Test specimens 1 to 3 have an opening diameter of opening 5 of 1.0 to 5.0 mm. Comparison specimen 1 is a known soundproofing felt (weight 200 g / m²). 2 It is made by laminating the above-mentioned polypropylene tufted carpet onto a 3.0mm thick base.

[0038] Test specimens 4-6 were classified as tufted carpet 3, with a basis weight of 1700 g / m². 2The test specimens used are nylon tufted carpet. Test specimens 4 to 6 have different thicknesses T of soundproofing material 2. Test specimen 4 has a thickness T of 5 mm, test specimen 5 has a thickness T of 8 mm, and test specimen 6 has a thickness T of 10 mm. Test specimens 4 to 6 have an opening diameter of opening 5 of 1.0 to 5.0 mm. Comparison specimen 2 is a known soundproofing felt (weight 200 g / m 2 It is made by laminating the above-mentioned nylon tufted carpet onto a 3.0mm thick base.

[0039] Test specimens 7-9 were classified as tufted carpet 3, with a basis weight of 550 g / m². 2 The test specimens used are polyester tufted carpet. Test specimens 7 to 9 have different thicknesses T of soundproofing material 2. Test specimen 7 has a thickness T of 5 mm, test specimen 8 has a thickness T of 8 mm, and test specimen 9 has a thickness T of 10 mm. Test specimens 7 to 9 have an opening diameter of opening 5 of 1.0 to 5.0 mm. Comparison specimen 3 is a known soundproofing felt (weight 200 g / m 2 It is made by laminating the above-mentioned polyester tufted carpet onto a 3.0mm thick base.

[0040] <Soundproofing Test> Lightweight floor impact sound measurements were performed on a floor surface with flooring material laid on a concrete slab using a tapping machine (FI-01A model, manufactured by Rion Co., Ltd.) with test specimens 1-9 and comparison specimens 1-3 to measure the sound insulation effect of test specimens 1-9 and comparison specimens 1-3. Specifically, five cylindrical steel hammers with a mass of 500g and a diameter of 30mm, simulating everyday walking and impact sounds, were placed at 100mm intervals and dropped from a height of 40mm at 0.1-second intervals to generate impact sounds. The generated impact sounds were used as the reference curve in the standard frequency characteristics of sound insulation grades related to floor impact sound levels, and the floor impact sound level (dB) values ​​shown at each frequency were read from this reference curve. The floor impact sound level reduction amount (dB) was calculated by subtracting the floor impact sound level (dB) value with a test specimen or comparison specimen from the floor impact sound level (dB) value without a test specimen or comparison specimen.

[0041] <Evaluation Results> Based on the floor impact sound level reduction (dB) of test specimens 1-9 and comparison specimens 1-3, the performance grade (ΔLL grade) of test specimens 1-9 and comparison specimens 1-3 was evaluated. The results are shown in Table 1.

[0042] [Table 1]

[0043] As is clear from Table 1, test specimens 1-9 showed a greater reduction in floor impact sound level (dB) compared to comparison specimens 1-3, and their performance grades in the ΔLL scale were equivalent to ΔLL(I)-6 to 8. In the ΔLL scale, the highest level of sound insulation for floors is ΔLL(I)-6, which indicates that everyday sounds from the upper floor are virtually inaudible to the lower floor. Therefore, test specimens 1-9 have sufficient sound insulation performance for use in apartment buildings.

[0044] Although embodiments of the present invention have been described in detail above, the present invention is not limited to the embodiments described above, and various modifications and improvements are possible without departing from the spirit of the invention. For example, the soundproof carpet 1 may be implemented as a tile carpet. The soundproofing body 2 is not limited to being combined with the tufted carpet 3, but may be combined with other carpets such as plain weave carpets or circular knit carpets. [Explanation of Symbols]

[0045] 1. Soundproof carpet 2 Soundproofing 2a surface 2b Back side 3 Tufted Carpet 31 Base fabric 32 Pile yarn 33 Base material 34 backing layers 4 Adhesive layer 5 Openings 6 Surface layer 7. Back layer 8 Connector layer 9. Anti-slip

Claims

1. Made from double raschel fabric, with a weight of 300-600 g / m ２ The soundproofing material is 5 to 10 mm thick, A tufted carpet is placed on the soundproofing body, The soundproofing material and the tufted carpet are interposed in an adhesive layer, The soundproofing body has a plurality of openings that are recessed in the thickness direction from the first surface on the tufted carpet side, The soundproof carpet is characterized in that the plurality of openings have an opening diameter of 1.0 to 5.0 mm and terminate inside the soundproofing body.

2. The number density of the aforementioned multiple openings is 16,200 to 64,000 per square meter. ２ The soundproof carpet according to claim 1, characterized in that it is the same as described in claim 1.

3. The soundproof carpet according to claim 1 or 2, characterized in that the double raschel fabric is composed of polyester fibers, polyethylene fibers, or polypropylene fibers.

4. The soundproof carpet according to claim 1 or 2, characterized in that the double raschel fabric is composed of monofilament, multifilament, or a mixture of monofilament and multifilament.

5. The soundproof carpet according to claim 1 or 2, characterized in that the tufted carpet is a polypropylene tufted carpet, a nylon tufted carpet, or a polyester tufted carpet.

6. The soundproofing body has a three-dimensional structure including a surface layer including the first surface, a back surface layer including a second surface opposite to the first surface, and a connecting layer that connects the surface layer and the back surface layer, The soundproof carpet according to claim 1 or 2, characterized in that the opening terminates on the surface of the bonding layer that is on the surface layer side.

7. The soundproof carpet according to claim 6, characterized in that the fibers constituting the surface layer and the fibers constituting the bonding layer are the same.

8. The soundproof carpet according to claim 6, characterized in that the fibers constituting the surface layer and the fibers constituting the bonding layer are different.

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