JPH0649362B2 - Method of manufacturing elastic sheet - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION [Industrial field of application] The present invention relates to a floor of a house, particularly an apartment house, for example, a reinforced concrete floor slab cast in situ, a factory-produced PC floor slab, a lightweight concrete floor slab, and an aerated concrete floor. Various cushioning effects are required, including cushioning materials used to obtain excellent soundproofing effect when applied to floors formed on floor slabs used as upper and lower floors such as wooden floor slabs. The present invention relates to a method for producing an elastic sheet applicable to various uses, particularly an elastic sheet composed of small pieces of bonded elastic body.

[Prior art] As flooring materials for houses, tatami mats, carpets, carpets, wooden flooring materials, cushion flooring materials, etc. are used.
Of these, wood flooring has a high effect of suppressing mites and mold,
It is a floor material that is easy to clean and has a feeling of cleanliness, is a natural material and has a bright and high-class feel.The cushion floor material is adhered to floors around water, such as kitchens, toilets, washrooms, bathrooms, etc. It is used by pasting it with an agent. Both wooden floor materials and cushion floor materials are excellent floor materials, but they are inferior in sound insulation performance against so-called lightweight floor impact sounds such as chair dragging noise, dropping of spoons and knives, walking noise of slippers and sandals, etc. Therefore, there is a problem of noise complaints on the upper and lower floors. As for wooden floor materials, various wooden soundproof floor materials with improved sound insulation performance against this lightweight floor impact sound have been proposed.Generally, sound insulation sheets such as vibration damping sheets, sound insulation sheets, and cushioning sheets are integrated. Target. Materials such as vinyl chloride resin, ethylene-vinyl acetate copolymer resin, asphalt, and butyl rubber are generally known as damping sheets and sound insulation sheets, and foamed plastics and foamed rubbers are used as cushioning sheets. Sheets made of various fibers are used. However, in the case of the vibration control sheet and the sound insulation sheet, although the sound insulation performance against the light weight floor impact sound is improved to some extent, it is still insufficient. In addition, the one using the cushioning sheet has a large strain amount when a load is applied, and when walking,
There is a feeling of discomfort, not only causes fatigue and discomfort,
Especially when installing a heavy object such as a piano or a refrigerator, the amount of distortion is too large, so it is complicated to prepare a floorboard orthogonal to the longitudinal direction of the floor material and install it on it. The recovery of the amount of strain when unloading is insufficient, and the sound insulation performance against light floor impact sound is not sufficient.

On the other hand, the cushion floor material itself has a foam layer, and has some sound insulation performance,
In particular, the sound insulation performance against light-weight floor impact sound is not always sufficient, and in particular, in recent years, the sound insulation performance against light-weight floor impact sound has been remarkably improved in wooden floor materials. It has been done.

In order to solve the above-mentioned problems, the inventors of the present invention have a floor material satisfying a high sound insulation performance against a light-weight floor impact sound, in particular, a wood-based floor material, a sheet material made of a bonded elastic body piece as a cushioning material for a cushion floor material. I have already proposed (Japanese Patent Application 1-
No. 68769, Japanese Patent Application No. 1-103249, Japanese Patent Application No. 1-301672), in order to obtain excellent sound insulation performance, elastic small pieces are further scattered on at least one surface of the sheet material made of the combined elastic small pieces. It is preferable to have a configuration, and as this manufacturing method, the elastic body pieces to which the adhesive is attached are scattered or cast on the substrate subjected to the release treatment and accumulated in a sheet shape,
A method of lightly pressing with a pressure roller or a pressure plate to adjust to a desired thickness has been shown, but this method has a problem in productivity. As a method for producing this type of sheet material with high productivity, various methods are conceivable, but as a molding method with good productivity, which does not require much pressure,
There is a doctor blade method. However, in general, the doctor blade method is widely used as a method for shaping a liquid material, but it is not always suitable as a method for forming an aggregate of small pieces, which is the object of the present invention. That is, when the aggregate raw material of the elastic body pieces is regulated by the doctor knife and the thickness is adjusted, unlike the liquid body material, the elastic body pieces do not always flow uniformly and smoothly in the traveling direction,
There are small pieces that are slow compared to the progressing speed of the entire elastic small piece raw material. Then, the elastic pieces are restricted by the small pieces, and as a result, there are few or no elastic small pieces in the vicinity of the small pieces, and a uniform elastic sheet cannot be obtained. Although such an elastic sheet is excellent in sound insulation performance, it does not have sufficient strain resistance to a heavy load.

[Specific Means for Solving Problems] The present inventors arrived at the present invention as a result of earnest studies on a method for efficiently producing a cushioning material having excellent sound insulation performance and strain resistance against heavy load. It was done.

That is, the present invention continuously supplies an adhesive agent and a small piece of elastic material on a substrate that moves in the horizontal direction, and possesses at least two lowest points of approximately the same level, and between the lowest points and the lowest points. Is a method for manufacturing an elastic sheet, which is characterized in that it passes through a weir that does not have a substantial open portion.

The method of the present invention belongs to a category of molding methods generally called a doctor blade method, and is characterized by the construction of a weir, and specific examples will be described below with reference to the drawings.

FIG. 1 is a schematic view showing an example of an apparatus for carrying out the method of the present invention. The elastic piece 2 in the hopper 1 is preliminarily coated with an adhesive, and the base material 3 is placed on the support base 4. As the sheet moves horizontally to the left, it is discharged from the lower supply port of the hopper 1 and moves to the left together with the substrate 3. 5
Is a doctor knife, 6 is a fixed roll,
The lowest points 7, 7'of each are supported so as to be substantially equidistant from the support base 4. In this example, the lowest points 7 and 7'of substantially the same level are formed by separate weirs, that is, the doctor knife 5 and the roll 6, but they do not necessarily have to be separate, for example, shown in FIG. You may use the doctor knife which integrally has the weir which has two lowest points of such a cross-sectional shape. In FIG. 1, the elastic piece 2 passes while being regulated by the lowest point 7 of the doctor knife 5, and then is regulated by the lowest point 7'of the roll 6 and moves leftward with a constant thickness. Here, the doctor knife 5 and the roll 6 are in contact with each other, and the extra elastic piece 2 stays in the space formed by the contact point 8 and the lowest points 7 and 7 '. The doctor knife 5 and the roll 6 do not have to be in strict contact with each other, but may be in close proximity to each other so that the elastic body piece does not come out. In the case of such a structure, that is, in the case of a weir having one lowest point or a weir having two lowest points, the elastic sheet is not elastic. It is easy to make a part where there is no body piece, that is, a part with a hole. The reason for this is that the doctor knife 5 and the roll 6 both have slippery surfaces, but as a result of the elastic piece 2 not flowing smoothly, holes can be formed. In the configuration of the present invention, the extra elastic piece is present in the space, and
In the figure, since a force is exerted in the lower left direction, the force is pushed below the lowest point 7 ', and a uniform elastic sheet can be obtained.

The surface of the weir is preferably made slippery at least in the vicinity of the lowest point, and it is also preferable to increase the surface smoothness and additionally take a means for improving lubricity, for example, applying a lubricant.

The roll 6 is basically of a fixed type, but it is also preferable to rotate the roll 6 as appropriate in order to avoid the inconvenience caused by the adhesion of the elastic small pieces to the surface and enable continuous production for a long time.

Although not shown, the elastic sheet that has passed through the roll 6 is introduced into an oven and dried to dry the adhesive. The elastic sheet obtained by the method of the present invention is obtained as a substantially uniform bonded elastic body aggregate, but the surface (the surface opposite to the base material) is stochastically different from other parts due to the particle size of the elastic piece. It is configured such that more protruding elastic body pieces are scattered.

The material of the elastic piece used in the present invention is rubber,
Examples thereof include cork, and these can be used alone or as a mixture. In the case of a rubber material, it has an appropriate compression elastic modulus and an appropriate mechanical loss coefficient to insulate vibration transmission due to a lightweight floor impact, and a high sound insulation performance against a lightweight floor impact sound is obtained. It is excellent in recovering the amount of strain when a heavy object such as a refrigerator or a refrigerator is installed for a long period of time and then unloaded. In the case of cork, although the compression strain recovery power is slightly inferior to that of the rubber material, high sound insulation performance can be obtained, and particularly, the walking feeling is excellent, and it may be appropriately used according to the purpose.

As long as there is no special use regulation, the material of the elastic piece does not matter as long as it has excessive strength and elasticity, and a generally known rubber material such as NR (natural rubber), SBR (styrene / butadiene rubber), CR (chloroprene rubber), NBR (acrylonitrile / butadiene rubber), BR (butadiene rubber),
IR (isoprene rubber), IIR (butyl rubber), AC
M (acrylic rubber), EPM, EPDM (ethylene / propylene rubber), NIR (nitrile / isoprene rubber), T (polysulfide rubber), MBR (methacrylate / butadiene rubber), VP (butadiene / styrene / vinyl-pyridine), CSM (chlorosulfonated polyethylene), EVA (ethylene / vinyl acetate copolymer), U
(Urethane rubber), CO / ECD (epochlorohydrin rubber), CM (chlorinated polyethylene), Q (silicone rubber), etc., preferably NR, SBR having a suitable compression elastic modulus and a suitable mechanical loss coefficient. , CR, IR are used. In consideration of economic efficiency, tires, generally rubber pieces obtained by crushing and crushing waste tires, small pieces of miscellaneous rubber such as molding burrs produced during rubber molding, metal powder, mineral powder, inorganic powder, ceramic powder, plastic powder, wood powder, Fiber pieces, rice meal, seed meal, soybean meal, rice husks, rice husks, buckwheat husks, buckwheat noodles, small pieces formed by solidifying rubber, etc. with rubber, and other rubber molded articles or rubber pieces crushed and crushed waste are also preferable . Various states such as vulcanization and semi-vulcanization can be selected as the rubber material, but a vulcanized material is preferable in consideration of long-term retention of compressive strain recovery force.

The cork is obtained by crushing bark of cork oak (called cork) whose main production areas are Portugal and Spain, and may be generally used for stoppers, gaskets, shoe soles and the like.

Further, although the elastic small pieces are mainly unfoamed ones, foamed ones may be mixed depending on the required performance.

The adhesive for the elastic piece is not particularly limited, but is determined in consideration of the type of elastic body used. For example, when rubber is used as the elastic piece, a rubber adhesive is naturally preferable. The type of rubber does not matter as long as it has rubber elasticity as long as there is no special use regulation, like the material of the rubber pieces, and it is generally well known NR, SBR, CR, NBR, BR, IR,
IIR, ACM, MBR, U, VP and the like are used, and more preferably, NR, SBR, CR and IR having an appropriate compression elastic modulus and an appropriate mechanical loss coefficient are used. Further, as the rubber-based adhesive, it is preferable to use it in a latex form because it is easy to handle, and a crosslinking agent, an antibacterial agent, a flame retardant, an antiaging agent,
Pigments and the like can be added as required. When a cork material is used, a rubber-based adhesive is used similarly to the rubber material, but a mixture of a urea-based adhesive and a melamine-based adhesive with a curing agent for the adhesive is added to the rubber-based adhesive. You may use it. The amount of adhesive used is 10 elastic pieces.
5 to 60 parts by weight, preferably 10 parts by weight, based on 0 parts by weight
Add about 55 parts by weight, and knead using a kneading machine generally used for wetting the surface of the elastic piece with an adhesive, such as a universal stirring kneading machine or a kneader.

If the solid content of the adhesive is less than 5 parts by weight, it is difficult to sufficiently wet the surface of the elastic body pieces, and the elastic body pieces are not sufficiently bonded to each other. On the other hand, if the amount exceeds 60 parts by weight, the excess amount that does not contribute to the mutual binding of the elastic body pieces increases, which is economically disadvantageous.

The elastic sheet obtained by the method of the present invention is an assembly of elastic small pieces, and since the surface is not pressed by a means such as a press, the surface opposite to the substrate is stochastically different from other surfaces. The elastic small pieces further protruding from the part are scattered and distributed.

The base material 3 used in the present invention is not particularly limited, but the strength is sufficient for placing and moving the elastic body pieces, and it depends on the kind of the adhesive agent. A material that has heat resistance against it is selected, and a non-woven fabric or a woven fabric can be used as a material that is easy to handle and has a suitable surface roughness for mounting elastic small pieces and moving integrally. , As the material, synthetic resin such as nylon, polyester, acrylic, polyurethane, polyethylene, polypropylene, inorganic fiber such as glass fiber,
Natural fibers such as cotton and hemp can be used.

Further, a non-woven fabric or a woven fabric can be integrally provided on the surface opposite to the base material 3 by means such as adhesion, and adhesion with other materials can be performed more reliably depending on the application.

The elastic cushioning material of the present invention is not limited in thickness unless otherwise specified, but is usually 1 to 20 mm, preferably 2 to
It is selected in the range of 12 mm. If it is less than 1 mm, it is difficult to form the elastic cushioning material, and if it exceeds 20 mm, it is not only economically disadvantageous, but also the construction target is limited, which is not preferable. The average system of elastic strips used depends on the desired thickness of the elastic diameter cushioning material and is typically no more than 80% of the thickness of the cushioning material. For example, when the thickness of the cushioning material is 8 mm, it is preferable to select the elastic piece having an average diameter of 6.4 mm or less.

In the method of the present invention, the movement of the base material 3 may be carried out by winding the product after drying the adhesive, moving the both ends of the base material 3 while applying tension with a take-up machine, or by fixing the support base 4. Instead, by using a conveyor belt, the base material itself may be moved without applying tension. Further, the base material may be preliminarily impregnated with an adhesive in order to better adhere to the elastic body piece.

Hereinafter, the present invention will be described in detail with reference to Examples.

Example 1 Using the apparatus shown in FIG. 1, as an adhesive to 100 parts by weight of a rubber piece having a diameter of 3 to 5 mm (trade name: rubber powder A, crushed tire product, manufactured by Kansai Environmental Development Co., Ltd.) Chloroprene rubber latex (trade name: Denka Chloroprene LM
-60, solid content 60%, manufactured by Denki Kagaku Kogyo Co., Ltd. as solid content
Add 13 parts by weight, knead for 5 minutes with a universal stirring kneader, put into hopper 1, and pre-impregnated with the adhesive width 1530 mm
The continuous polyester non-woven fabric (surface weight of 30 g / m ² , manufactured by Nippon Lutra Building Co., Ltd.) was used as a substrate and was passed through a drying furnace (not shown) at a winding speed of 1.5 m / min.
The support base 4 is a flat steel plate having a width of 1750 mm and a length of 750 mm, and the distance between the lower supply port of the hopper 1 and the support base 4 is 50 mm. The doctor knife 5 is made of steel and has a width of 17
The thickness is 00 mm and the thickness is 9 mm, and the angle is 20 ° with respect to the support 4. The roll 6 is a pipe made of 100 mmφ steel, and a release sheet is attached to the surfaces of the doctor knife 5 and the roll 6 in order to suppress the adhesion of the elastic piece 2. Further, the gaps between the doctor knife 5, the roll 6 and the support base 4 are 9 mm and 8 mm, respectively, and the doctor knife 5 and the roll 6 are in contact with each other. Using this device, continuous molding was carried out, and the molded product was allowed to stay in a drying oven having an average temperature of 120 ° C. for 20 minutes to cure the adhesive and obtain a molded sheet. This product has an average thickness of 8 mm and a weight per unit area of 2.
It was 5 Kg / m ² , and protrusions (average protrusion length of about 3 mm) due to small rubber pieces (rubber powder A) were scattered and distributed on one surface.

Example 2 In the same manner as in Example 1, 30 parts by weight and 70 parts by weight of rubber pieces (manufactured by Kansai Environmental Development Co., Ltd.) having diameters of 3 to 5 mm (rubber powder A) and 1 to 3 mm (rubber powder B), respectively. Of 100 parts by weight of natural rubber latex graft-polymerized with methyl methacrylate as an adhesive (trade name: MG-2
5, solid content 51%, manufactured by Nanyo Kasei Co., Ltd. solid content was added by 10 parts by weight, and raw materials were mixed and molded. The obtained sheet had a thickness of about 8 mm and a surface weight of 2.7 kg / m ² , and one side had a protruding portion (average protruding length of about 2) due to rubber pieces (rubber powders A and B).
mm) were scatteredly distributed.

Comparative Example 1 Molding was performed in the same manner as in Example 1 except that the apparatus without the roll 6 in FIG. 1 was used. The resulting sheet has an average thickness of 9 mm and a weight per unit area of 1.5.
It was Kg / m ² , and there were 150 holes / m ^{2 on} average. The size of the holes was about 5 to 15 mmφ.

Comparative Example 2 Molding was performed in the same manner as in Example 2 except that the roll 6 and the doctor knife 5 in FIG. The resulting sheet has an average thickness of 8 m.
The weight per unit area in m is 1.7 Kg / m ² , and the average
There were holes of 100 pieces / m ² . The size of the hole is 3-10 mm
It was about φ.

With respect to the materials obtained in Examples 1 and 2 and Comparative Examples 1 and 2, the sound insulation performance against light-weight floor impact sound and the flexural resistance when loading heavy objects were compared and examined.

In order to measure these performances, as a wood-based flooring material laminated with the elastic sheets of Examples 1 and 2 and Comparative Examples 1 and 2, a natural oak name wood veneer having a thickness of about 1 mm was used as a base plate as a base plate. And a plywood with a thickness of 6.3 mm, and a thickness of 1
mm foamed chloroprene rubber sheet is interposed, and after being bonded and integrated with these water-based vinyl urethane adhesives, actual processing and back splitting processing (groove width 2 mm, groove depth 4 m
m) with a total thickness of about 8.3 mm and a width of 75 mm was commonly used. A urethane adhesive was used to bond the elastic sheet to the wooden floor material, and an epoxy adhesive was used to bond the elastic sheet to the reinforced concrete floor slab with a thickness of about 150 mm. The sound insulation performance was measured according to "Measurement method of floor impact sound level at building site, JISA-1418", and the lightweight floor impact sound level L _L number (dB) was obtained. this
A lower L _L number indicates that the floor material or floor structure has excellent sound insulation performance against light-weight floor impact sound. This result is the first
Shown in the table.

On the other hand, the strain resistance when loading a heavy load is that when a wooden floor material and a cushioning material are laminated and integrated, and a 75 mm square test piece is subjected to an evenly distributed load by a compression tester and the strain amount becomes 1 mm. The load (ton / m ² ) was calculated. The larger this load is, the less the distortion is. The results are shown in Table 1.

[Effects of the Invention] The elastic sheet obtained by the production method of the present invention is excellent in sound insulation performance against light-weight floor impact sound, and is used for various floor components, vibration insulation materials for motors and compressors, or artificial grass and pavement. It is also useful as a base material for wood, and is particularly useful as a floor material for soundproofing in apartment houses and the like.

[Brief description of drawings]

FIG. 1 is a schematic view showing an example of an apparatus for carrying out the manufacturing method of the present invention. FIG. 2 is a schematic view showing an example of another weir used in the method of the present invention. 1 ... Hopper, 2 ... Elastic small piece, 3 ... Base material 4 ... Support stand, 5 ... Doctor knife 6 ... Roll, 7,7 '... Bottom point, 8 ... Contact point

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Claims (1)

[Claims] 1. An adhesive agent and a small piece of elastic material are continuously supplied onto a base material that moves in a horizontal direction, and at least two lowest points at approximately the same level are owned, and between the lowest points and the lowest points. A method for manufacturing an elastic sheet, which comprises passing through a weir that does not substantially have an open portion.