JPH0543506B2 - - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a method for manufacturing a sound insulating base plate for construction, which has excellent sound insulating properties and involves directly applying a cement mortar layer on the surface side at a construction site.

[Prior art and purpose and structure of the present invention]

Conventionally, this kind of base board was made by applying and drying a mixture of non-vulcanized rubber liquid and aggregate to the surface of plywood to create a roping-like uneven surface (the former).
The latter method has been proposed by mixing cement with aggregate, charcoal, synthetic resin, MC, etc., and applying and drying it on the surface of plywood to create an uneven surface with yuzu skin steps.

However, in the former case, the non-vulcanized rubber itself, mortar, plaster, etc. do not adhere well to wall coating materials, and the surface of the aggregate is covered with a film of non-vulcanized rubber liquid, so it does not adhere well to wall coating materials. Poor adhesion makes it impossible to apply thick wall coatings.

Another drawback is that the wall coating material peels off after construction due to deterioration of the non-vulcanized rubber that is the main component over time.

In the latter case, the cement layer on the surface has a rough surface with yuzu skin steps, increasing the adhesion area with the wall coating material and improving its adhesion effect. Since charcoal, methylcellulose (MC), etc. are water-retaining substances,
Water permeability decreases, and water in the wall coating material penetrates into the cement layer.
It permeates through the plywood and reduces the amount of moisture at the interface with the cement layer, resulting in poor curing and reduced adhesion. In addition, the plywood absorbs moisture and expands due to the permeated moisture, causing warping, resulting in the wall coating material cracking or peeling off. There is also the problem that the plywood and underlying structural materials rot due to permeated moisture.

And the back side of both is not processed in any way,
The plywood expands due to moisture absorption from the back side, causing the plywood to warp, and the wall coating to crack and peel off due to rot.

In addition, neither of them includes any consideration for sound insulation performance, and the plywood generally used as wall materials is 3 to 12 mm thick, and its areal density is 1.5 to 6 mm.
The problem remains that the sound insulation is low at Kg/m ² .

On the other hand, as a method of increasing the sound insulation properties, a composite plywood in which plywood and a lead sheet with a high areal density are bonded is proposed as a method of increasing the areal density of the material.

However, this composite plywood is expensive because the lead sheet itself is expensive, and it is not used in general houses, but as a wall material for X-ray rooms such as hospitals that require radiation shielding effects rather than sound insulation effects. Only some of them are used.

It is an object of the present invention to solve the problems of conventional base plates and sound insulating plates. That is, the present invention forms front and back undercoat layers 2, 2a on the front and back surfaces of an inorganic or organic plate-like substrate 1, a base-side cement mortar layer 3 on the surface of the surface undercoat layer 2, and a heavy cement mortar layer 3 on the back surface of the back undercoat layer 2a. This relates to a sound-insulating base plate on which a sound-insulating coating layer 4 containing powdered material is formed.

The base plate of the present invention is intended to provide a mortar base plate having sufficient strength and excellent sound insulation properties due to the above structure.

The base plate manufacturing method of the present invention will be explained below.

(1) 1 is a plate-like substrate, which includes plywood, fiberboard, particle board, gypsum board, cement board, asbestos board,
It is composed of inorganic materials such as silicon plates, organic materials, or mixed composites of inorganic and organic materials.

(2) A sealer containing a mixture of synthetic resin, latex, or bituminous material, and inorganic powder if necessary, is applied to the front and back surfaces of the plate-shaped substrate 1 to form the front and back undercoat layers 2 and 2a.

As the synthetic resin, vinyl acetate resin, ethylene-vinyl acetate resin, vinyl chloride resin, acrylic resin, epoxy resin, alkyd resin, etc. are used, and as the latex, rubber latex, MBR, SBR, NBR, etc. are used. As the bituminous material, asphalt, tar, etc. are used, and preferably an emulsion type material is used.

As the inorganic powder, cement, slag, gypsum, charcoal, talc, clay, etc. are used.

By using an inorganic powder with a specific gravity of 1 or more, when used as a sound-insulating base plate, the front and back undercoat layers 2, 2a can be formed without lowering the specific gravity.

Synthetic resins, latex, bituminous materials, inorganic powders, etc. may be used alone or in combination.

Further, in the sealer, auxiliary agents such as a dispersant and a thickener may be added to and mixed with the synthetic resin, latex, or bituminous material as necessary.

By forming the front and back undercoat layers 2 and 2a, the surface of the plate-shaped substrate 1 is smoothed, and the adhesion of cement mortar and sound insulation paint applied later is improved.It also has waterproof performance and prevents moisture from entering the plate-shaped substrate. This prevents permeation, prevents warpage due to hygroscopic expansion of the substrate due to permeated moisture, and rot due to moisture absorption, and also controls outflow of extracted components such as scum due to moisture etc. from the plate-shaped substrate.

By forming the front and back undercoat layers 2 and 2a, even when the surface of the plate-shaped substrate 1 is porous, voids (air pockets) in the surface recesses are eliminated, the generation of air bubbles is prevented, and cement mortar, sound-insulating paint, and the plate-shaped substrate substantially increases the adhesion area.

(3) Apply cement mortar, which is a mixture of synthetic resin, latex, or bituminous material, and inorganic powder or lightweight aggregate as necessary, to the surface of the surface undercoat layer 2 to form the base cement mortar layer 3. .

Synthetic resins include vinyl acetate resin, ethylene-vinyl acetate resin, vinyl chloride resin, acrylic resin, epoxy resin, alkyd resin, etc. Latexes include rubber latex, MBR, SBR, NBR, etc.
Use. As bituminous materials, sphalt,
Tar or the like is used, preferably an emulsion type.

As the inorganic powder, hydraulic cements such as Portland cement, blast furnace cement, silica cement, flyash cement, and alumina cement, slag, and gypsum are used. As the lightweight aggregate to be mixed as necessary, volcanic sand, perlite, vermiculite, foamed synthetic resin particles, etc. are used.

The surface of the base-side cement mortar layer 3 may be a smooth surface (FIG. 1) or an uneven surface. (Fig. 2) Synthetic resin, latex, or bituminous material is added to the cement mortar layer 3 on the base side. The adhesion force is improved by the intermolecular attraction effect, and the bond is firmly fixed.

(4) On the back side of the backing undercoat layer 2a, a sound insulating paint made of a mixture of synthetic resin, latex, or bituminous material, heavy material powder with a specific gravity of 4 or more, and inorganic powder as necessary is applied to provide sound insulating properties. Coating layer 4 is formed.

As the synthetic resin, vinyl acetate resin, ethylene-vinyl acetate resin, vinyl chloride resin, acrylic resin, epoxy resin, alkyd resin, etc. are used, and as the latex, rubber latex, MBR, SBR, NBR, etc. are used. As the bituminous material, asphalt, tar, etc. are used, and preferably an emulsion type material is used.

Heavy substance powders with a specific gravity of 4 or more include iron powder, iron sand powder, lead powder, lead alloy powder, zinc powder, tin, copper powder, iron oxide, copper oxide, zinc oxide, lead oxide, titanium oxide, antimony oxide, and oxide. Metals, metal oxides or sulfides, ore powders such as bismuth, cadmium oxide, tungsten oxide, tin oxide, tantalum oxide, manganese oxide, molybdenum oxide, silver oxide, zirconium oxide, lead sulfide, iron sulfide, zinc sulfide, ore powder etc. These heavy substance powders may be used alone or in combination.

The heavy material powder used has a particle size of 2 mm or less. Alternatively, scaly pieces may be used. If the particle size is 2 mm or more, uniform stirring becomes difficult when mixing with synthetic resin, latex, or bituminous material.

Furthermore, the rigidity of the sound-insulating coating layer 4 increases, and the coincidence effect shifts to the low-frequency side, resulting in a decrease in the sound-insulating effect for low frequencies.

Cement, slag, gypsum, charcoal, talc, clay, etc. are used as the inorganic powder.If the inorganic powder has a specific gravity of 1 or more and is used as a sound insulating base plate, the sound insulating coating layer 4 can be used without lowering the specific gravity. is formed.

Inorganic powder adjusts the structural viscosity of sound insulation paint,
Improves the transferability to the surface of the undercoat layer 2a of the plate-shaped substrate. In particular, when coating with a roll coater, spreader, etc., the transfer properties from the coating roll surface are improved, allowing thick coating of the sound-insulating coating.

Furthermore, in the case of application using a flow coater, spray (lishin gun), etc., the sound insulating paint itself needs to have fluidity, and mixing of inorganic powder is not necessarily required.

Synthetic resin, latex, or bituminous material is used as the sound-insulating paint, and the sound-insulating paint is made of a synthetic resin, latex, or bituminous material, and the backing is coated by an intermolecular attractive force generated between the synthetic resin, latex, or bituminous material forming the undercoat layer 2a. The undercoat layer 2a and the sound-insulating paint are firmly fixed and integrated.

Thus, the desired sound-insulating base plate can be obtained by the method of the present invention.

(5) When installing the sound insulating base plate, the pillars of the house,
The sound insulating coating layer 4 provided on the back surface of the sound insulating base board is fixed onto the base structure materials such as studs and rims by nailing so as to be in contact therewith.

Next, in the case of interior walls, after applying an intermediate coating layer 5 such as plaster or cement mortar on the base-side cement mortar layer provided on the surface of the sound-insulating base plate, a wall coating such as Kyoto wall, sand wall, fiber wall, etc. Apply the material.

In addition, in the case of exterior walls, the intermediate coating layer 5 such as cement mortar is applied directly, or after the mortar has been undercoated, a wall coating material such as decorative cement mortar or resin paint is applied by troweling, gun spraying, etc. Configure.

In this way, the wall coating material can be applied directly onto the sound insulating base plate using the method of the present invention, thereby shortening the construction period.

(Example) On the surface of a 9 mm thick plywood board, a sealer containing 100 parts by weight of MBR, 70 parts by weight of Charcoal and 5 parts by weight of water was applied using a roll coater and forced drying in a drying oven to form an undercoat layer. (Coating film thickness;
0.05mm). Next, the substrate was turned over, and a sealer having the same composition was applied to the back surface using a roll coater, and then forced drying in a drying oven to form an undercoat layer (film thickness: 0.05 mm).

5 parts by weight of synthetic resin emulsion and cement 50 with a specific gravity of 1.05 are applied to the surface of the dry undercoat layer on the surface side.
A cement mortar containing 45 parts by weight of sand, 45 parts by weight of sand, and 35 parts by weight of water was applied using a roll coater and forcedly dried in a drying oven to form a base-side cement mortar layer (film thickness: 2.5 mm).

Next, the substrate was turned over, and 100 parts by weight of iron powder with a specific gravity of 4.8 and a particle size of 500μ was applied to the surface of the undercoat layer on the back side.
A sound insulation coating (film thickness of 1
mm) to obtain a sound insulating base plate.

[Actions and effects of the present invention]

The effects of the present invention are summarized as follows.

Since the wall coating material is completely adhered to the plate-like substrate 1 via the base cement mortar layer and the surface undercoat layer 2, the wall coating material will not crack or peel off.

The plate-shaped substrate 1 has front and back undercoat layers 2, 2a on the front and back sides.
is formed, so that moisture from the outside is prevented from permeating into the substrate 1 after the wall coating material is applied.
Further, there is no occurrence of warping of the plate-like substrate 1 due to expansion due to moisture absorption or decay due to moisture absorption.

A sound insulating coating layer is formed on the back surface, and in addition to improving sound insulating properties, the sound insulating properties are further improved by the base-side cement mortar layer 3 on the front surface and the wall coating material applied later.

The sound-insulating coating layer 4 has a high areal density by mixing heavy substance powder with a specific gravity of 4 or more, and the rigidity of the medium of synthetic resin, latex, or bituminous material increases due to its elasticity when solidified. It is declining. Therefore, the sound insulation based on the weight law is improved, the coincidence effect is shifted to the high frequency side, and the sound insulation effect is further improved.

By mixing heavy substance powder with a specific gravity of 4 or more into the sound-insulating coating layer 4, after construction of the base plate of the present invention,
The areal density of the sound-insulating coating layer 4 can be made higher than the areal density of the intermediate coating layer 5 such as cement mortar applied to the surface thereof.

After construction of the base material, the intermediate coating layer 5 such as cement mortar applied to the surface thereof is generally a cement mortar with a cement:sand mixing ratio of 1:3, and its specific gravity is around 2.1, or it is hard. Plaster also has approximately the same specific gravity, so in order to increase the specific gravity of the sound insulating paint, it can be easily obtained by using a heavy substance powder with a specific gravity of 4 or more. If a material with a specific gravity lower than 4 is used, the amount of heavy substance powder added increases to form a sound-insulating coating layer with a surface density higher than that of the intermediate coating layer 5, and the strength of the sound-insulating coating layer decreases significantly. Put it away. Further, in order to maintain the strength, the areal density of the sound insulating coating layer decreases, and in order to obtain the same sound insulating effect, it is necessary to form the sound insulating coating layer thicker, which is not preferable.

In other words, by adding heavy substance powder with a specific gravity of 4 or more,
Further, in order to reduce the rigidity under the condition that the areal density is higher than that of the intermediate coating layer 5, other synthetic resins, latexes, or bituminous materials may be added.

[Brief explanation of the drawing]

Figure 1: Cross-sectional view when the surface of the sound insulating base plate is made smooth by the method of the present invention, Figure 2: Cross-sectional view when the surface is similarly roughened, 1: Substrate, 2: Surface undercoat layer, 2a: Back undercoat layer, 3: Base side cement mortar layer, 4: Sound insulation coating layer, 5: Intermediate coating layer.

Claims (1)

[Scope of Claims] 1. In a construction base board on which a surface cement mortar layer is directly laminated at a construction site, synthetic resin,
Alternatively, a sealer made of latex or bituminous material mixed with inorganic powder as necessary is applied to form the front and back undercoat layers 2, 2a, and synthetic resin, latex, or bituminous material is applied on top of the surface undercoat layer 2. and cement mortar mixed with inorganic powder is applied to form the base-side cement mortar layer 3, and on the back side of the undercoat layer 2a, synthetic resin, latex, or bituminous material and a heavy substance with a specific gravity of 4 or more are applied. A method for producing a sound insulating base board, characterized in that a sound insulating paint layer 4 is formed by applying a sound insulating paint mixed with powder. 2. The method for manufacturing a base plate according to claim 1, wherein an inorganic powder is mixed in the front and back undercoat layers 2, 2a.