JPH02115452A - Multi-layer type composite soundproof floor material - Google Patents

Abstract

PURPOSE:To improve the soundproof property by laminating a wooden surface material, a vinyl chloride resin foaming body with a rugged pattern on the surface, a bed plate, and a vinyl chloride resin foaming body with a rugged pattern on the surface in this order from the above and laminating a nonwoven fabric at the lowermost layer. CONSTITUTION:Four layers of a wooden surface material 1, a vinyl chloride resin foaming body 2 with a rugged pattern on the surface, a bed plate 3, and a vinyl chloride resin foaming body 4 with a rugged pattern on the surface are laminated from the above. A nonwoven fabric is laminated below the vinyl chloride resin foaming body 4 at the lowermost layer to form a soundproof floor material.

Description

[Detailed description of the invention] [Industrial application field] The present invention relates to a composite soundproof flooring material.

Wood-based flooring is a product that has been rapidly increasing in demand in recent years, as it has been praised for its cleanliness and luxury as an alternative to carpets and carpets that were previously used in condominiums and public housing due to dust mite pollution. .

[Prior Art] Conventionally, wood-based composite soundproof floor materials have been proposed in which one or more layers of wood floor members and various types of cushioning materials are laminated. However, these soundproof flooring materials have insufficient durability against objects such as refrigerators that have a large load per unit area, and the feeling of walking on them as a wooden floor. As a result of our investigation, we found that in order to satisfy soundproofing, durability, and walking sensation, it is sufficient to create a small gap between the wooden floor member and the cushioning material.

There are methods to create this void, such as cutting the wooden flooring material or cushioning material, but considering productivity, such as the ability to apply existing lines and enable continuous production, it is necessary to The best method is to coat it with a sol of a resin compound, foam-mold it in a heated foaming furnace, and then emboss it to make a cushioning material.

As the base material, flame-retardant paper or paper having release properties such as process paper is usually used. However, there were still problems with the adhesion between the flooring material and the concrete slab. That is, using flame-retardant paper as the base material so that the adhesive surface of the flooring material to the slab becomes the flame-retardant paper surface, the paper is not moisture resistant, so there are concerns about long-term durability. On the other hand, if process paper is used and the paper is peeled off after molding so that the adhesive surface to the flooring slab becomes the vinyl chloride resin surface, epoxy-based adhesives, which are currently commonly used for direct installation, can be used. The adhesive could not adhere to concrete slabs unless treated with a primer.

[Problems to be Solved by the Invention] The purpose of the present invention is to create a composite soundproof flooring material with excellent soundproofing properties, durability, etc. using vinyl chloride resin foam without changing the existing production line or construction method. It is about providing.

[Means for Solving the Problems] In view of the above-mentioned current situation, the present inventors have conducted extensive studies and have completed the present invention.

That is, the present invention uses a wooden surface material from above and an uneven pattern on the surface.
4 layers of vinyl chloride resin foam, a base plate, and a vinyl chloride resin foam with an uneven pattern on the surface, or a base plate and a vinyl chloride resin foam with an uneven pattern on the surface as a lower layer, respectively. This invention relates to a multi-layered composite soundproof flooring material consisting of six or more layers in which one or more layers are alternately laminated, characterized in that a nonwoven fabric is laminated on the lower surface of the bottom layer of vinyl chloride resin foam.

[Effect] The present invention will be explained in detail below.

In the present invention, it is desirable to use polyvinyl chloride paste resin as a raw material for the foam having an uneven pattern on its surface, which is used as a cushioning material.

As the polyvinyl chloride paste resin, for example, vinyl chloride homopolymer obtained by emulsion polymerization method, vinyl chloride/
Examples include copolymers such as vinyl acetate copolymers. Furthermore, for the purpose of lowering the sol viscosity of the polyvinyl chloride paste resin, it is also possible to use a blend resin for polyvinyl chloride paste or a vinyl chloride resin produced by a normal suspension polymerization method.

To give an example of the manufacturing method for the bottom layer cushioning material, first of all, a plasticizer such as DOP (di-2-ethylhexyl phthalate) and a blowing agent such as azodicarbonamide are added to the polyvinyl chloride paste resin. Mix appropriate amounts and further add inorganic fillers, stabilizers, flame retardants, etc. as necessary, mix and stir with a mixer to obtain a sol, and then apply the sol thinly onto a nonwoven fabric base material. Examples include a method in which embossing is performed after foam molding using a heat foam molding machine used to manufacture wallpaper and flooring materials.

The uneven pattern on the surface can be any pattern,
Examples include patterns such as a houndstooth check pattern and a polka dot pattern. Further, from the viewpoint of soundproofing, it is preferable that the height difference between the unevenness is 0.2 or more.

Further, the area ratio between the four parts and the convex parts is preferably in the range of 50:5.0 to 5:95 from the standpoint of soundproofing and durability.

The nonwoven fabric used here is not limited to material or area weight, as long as it has heat resistance against the heating temperature and the sol does not seep out to the back side, but the cross-sectional shape of the fibers is elliptical. 1] 30 g/rr
A nonwoven fabric having a rating of r1 or more is preferable because it has a high effect of preventing the sol from seeping out from the back side.

In addition, the middle layer cushioning material may be manufactured using the same manufacturing method as the bottom layer cushioning material, but it may also be one that uses a releasable base material as in the past and is peeled off after molding. good.

The foam produced in the manner described above is laminated with a wooden surface material and a base plate so that the nonwoven fabric surface is the lowest layer to obtain a multilayer composite soundproof flooring material. At this time, the uneven patterns of the upper layer foam and the lower layer foam may be superimposed in any manner, but it is preferable that the four parts and the convex parts of both layers completely overlap each other. In addition, water-based emulsion type adhesives such as EVA-based adhesives are used for adhesion of the foam laminated between the wooden surface material and the base plate, and for adhesion between the base plate and the foam layer below, from the viewpoint of ease of handling. Adhesive adhesive is preferred. On the other hand, a conventional epoxy adhesive can be used to bond the lowermost layer made of the nonwoven fabric surface to the concrete slab surface.

[Examples] The present invention will be described below based on Examples, but the present invention is not limited by these Examples.

(Example 1) Polyvinyl chloride paste resin (manufactured by Tosoh Corporation, trade name "Ryuron Paste 725J") 1001r [based on Okibe, 60ffiQ parts of phthalic acid plasticizer (manufactured by Kao Corporation, trade name "Vinicizer J"), Azodicarbonamide foaming agent (manufactured by Hydration Kasei Kogyo Co., Ltd., trade name: “Vinihole AC#3MJ”)
)3ff! Quantity: 1 part of stabilizer (manufactured by Adeka Argus Co., Ltd., trade name: rFL-21J), 1 part of mica (manufactured by Kuraray Co., Ltd., trade name: "Sujirite Mica 40SJ") 10f
The flffi part is mixed and stirred in a mixer to form a sol, and the cross section of the fiber is circular and the basis weight is 100g/
rr? Non-woven fabric (manufactured by Unitika, product name r7100)
0WsOJ) to a thickness of 0.7 mm and heated at 200°C for 3 minutes and 40 seconds, the diameter of the convex portion as shown in Figures 1(a) and (b) was 10 m5. A foam was obtained by embossing so that the center distance was 401 cm and the difference in thickness between the convex part and the four parts was 1 mm. Using two layers of this foam, as shown in Figure 2, from the top, the EVA is made of wood surface material, foam, base plate, and foam so that the upper and lower convex parts are in the same position.
A multi-layered composite flooring material was obtained by laminating a composite flooring material using a adhesive (manufactured by Konishi Co., Ltd., trade name: rcVc3105J).

(Example 2) The same sol as in Example 1 was used as a nonwoven fabric (manufactured by Unitika, trade name: r
20557FLVJ) to a thickness of 0.7 mm and processed in the same manner as in Example 1 to obtain a multilayer composite soundproof flooring material.

(Example 3) The same sol as in Example 1 was applied to a nonwoven fabric (manufactured by Unitika, trade name: R70250WS OJ) whose fibers have a circular cross section and a thickness of 25 tr/rtf (manufactured by Unitika, trade name: r70250WS OJ) with a thickness of 0.7
After drying at 60°C for 3 hours, apply again for 4 hours and perform the same processing as in Example 1 to obtain a multi-layered composite soundproof flooring material. I got it. went. The results are shown in Table 1.

(Comparative Example 1) The same sol as in Example 1 was applied to a flameproof paper to a thickness of 0.7n+, and the same processing as in Example 1 was carried out to obtain a multilayer composite soundproof flooring material.

Table 1 (Comparative Example 2) The same sol as in Example 1 was applied to process paper to a thickness of 0.7 mm, heated at a temperature of 200°C for 3 minutes and 40 seconds, and then embossing was performed in the same manner as in Example 1. A multi-layer composite soundproof flooring material was obtained.

(Immersion peeling #i test) The flooring material shown in each example was attached to a 9 mm thick concrete plate with epoxy adhesive (manufactured by Konishi Co., Ltd., product name: rE350R).
J) and immersed in boiling water for 4 hours (contact test) according to the JAS Standard Class 1 immersion peel test.
The concrete jig shown in Figure 4 was glued to the top and bottom surfaces of this flooring material using an epoxy adhesive (manufactured by Konishi Co., Ltd., trade name: rE350RJ), and the tensile speed was measured using a tensile tester. A tensile test was conducted at 1/sec. Table 2 shows the results of the maximum breaking load around the adhesive area between the convex portion of the bottom layer and the wooden floor member at this time.

2nd Decoration A conventional type of wood floor made of a temporary layer of 2 mm thick polyethylene foam was pasted onto a 150 am thick concrete slab with double-sided tape over a 900 m+s square area using a tapping machine to create a lightweight floor. Impact sound was measured. The hitting points of the tapping machine were set so that the central hammer of the tapping machine hit the center of the flooring construction area, and all the hammer hitting points were diagonal. The results showed that the conventional type of directly connected wood floor was rated L-70, while all the others were rated L-50.

[Effects of the Invention] As is clear from the above description, according to the present invention, a multi-layered composite soundproof flooring material with excellent soundproofing performance, productivity, and workability can be manufactured.

(Floor impact sound test) Flooring material and thickness of 10■■ shown in each example

[Brief explanation of drawings]

FIG. 1(a) is a top view of the foam according to the present invention. Further, FIG. 1(b) is a side view of the foam according to the present invention. FIG. 2 is a side view of a multilayer composite soundproof flooring material according to the present invention. 1...Wood surface material 2...Foam 3...Bedboard 4...Foam Figure 3 is a perspective view of the multilayer composite soundproof flooring material of the present invention seen from above. FIG. 4 is a diagram of a jig used for the tensile test in the present invention. Figure 1 (a) (b) Figure 2

Claims (1)

[Claims] (1) Four layers from top to bottom: wood surface material, vinyl chloride resin foam with an uneven pattern on the surface, base plate, and vinyl chloride resin foam with an uneven pattern on the surface, or a base plate below that, and an uneven surface. A flooring material consisting of six or more layers in which one or more layers of polyvinyl chloride resin foam having a pattern are laminated alternately in that order, characterized in that a nonwoven fabric is laminated on the lower surface of the lowest layer of vinyl chloride resin foam. Multi-layer composite soundproof flooring material.