JPH108592A - Vibration damping material - Google Patents

Abstract

PROBLEM TO BE SOLVED: To improve the laying workability of a vibration control material and improve the sound insulation property thereof against shock sound on a floor, by laminating a fiber nonwoven fabric layer having a specified face-weight, a sound insulation layer composed of a high specific gravity filler and a binder component, an open-cell foamed body layer, a sound insulation layer, and a fiber nonwoven fabric layer having a specified face-weight in this order. SOLUTION: A synthetic resin fiber nonwoven fabric layer by use of a nonwoven fabric with 15-80g/m<2> in face-weight is superposed as the uppermost layer of a vibration control and sound insulation material to increase the shock absorption property and the vibration control property. A high specific gravity filler like iron sand or silica sand is used in a powdery condition. An emulsified unvalcanized rubber is mixed therewith as a binder component. And it is laminated as a sound insulation layer. Further, an open cell foamed body layer increasing the sound insulation property and the shock absorptive property, and the above sound-insulation layer are superposed. A fiber nonwoven fabric applied with a nonwoven fabric of 120-450g/m<2> in face-weight is used as the lowermost layer. The positioning work at the execution is facilitated and the laying workability is improved by laminating the nonwoven fabric layer as the lowermost layer.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a vibration damping and sound insulating material used for sound insulation of houses and the like, and more particularly to a vibration damping and sound insulating material suitable for use on a floor of a house.

[0002]

2. Description of the Related Art In recent years, with the spread of wooden floors and the increase of multi-family houses, demands for preventing floor noise from being transmitted downstairs in apartment buildings and general single-family houses have been increasing. I have. As a vibration-damping and sound-insulating material suitable for improving the impact sound of floors, especially wooden floors, for example,
Japanese Patent Application Laid-Open No. 63-259595 discloses a sheet or the like obtained by adding a filler having a high specific gravity to rubber, and this sheet is usually used as a floor base material such as plywood. Wood flooring is constructed on this sheet.

[0003] Usually, when the above-mentioned sheet is constructed, an adhesive or a peg is used. However, from the viewpoint of cost reduction of man-hours and the adhesive at the time of construction, or floor noise reduction effect. Recently, laying construction, which is a construction method that does not use an adhesive that has been conventionally used for the construction of a floor covering material and a sound insulation material, has been reviewed. However, in the case of a laying construction, if the interface between the floor covering material and the sound insulating material is slippery, it takes a long construction time and sometimes causes floor noise. Therefore, in order to adopt this construction method, it was necessary to select a non-slip material as the sound insulating material.

[0004]

SUMMARY OF THE INVENTION The present invention has been made to solve the above-mentioned problems, and an object of the present invention is to provide a vibration-damping and sound-insulating material which is excellent in laying workability and also excellent in breaking off floor impact sound. To provide materials.

[0005]

The vibration-damping and sound-insulating material of the present invention comprises:
(A) a fibrous nonwoven fabric layer having a surface weight of 15 to 80 g / m ² ,
(B) a sound insulation layer composed of a high specific gravity filler and a binder component containing unvulcanized rubber as a main component, (C) an open-cell foam layer, (B) a high specific gravity filler, and a non-vulcanized rubber. A sound insulation layer comprising a binder component as a component, and (D) a fibrous nonwoven fabric layer having a surface weight of 120 to 450 g / m ² are laminated in this order.

[0006] In the vibration damping and sound insulating material of the present invention, the fibrous nonwoven fabric layer (A) is laminated on the uppermost layer. Examples of the nonwoven fabric used in the fibrous nonwoven fabric layer (A) include nonwoven fabrics of natural fibers and chemical fibers. Examples of the natural fiber include plant, mineral, and animal fibers, and examples include blankets, asbestos, and paper. Examples of the chemical fibers include synthetic fibers and inorganic fibers. Examples of the inorganic fibers include rock fibers, glass fibers, and metal fibers.

It is preferable to use a synthetic fiber non-woven fabric as the fiber non-woven fabric layer (A). The synthetic fiber nonwoven fabric refers to a synthetic fiber long-fiber nonwoven fabric produced from a synthetic fiber spinning step, a fiber web forming step, and a bonding step. Nylon, polyester, polyethylene, polypropylene and the like are suitably used as raw materials of the synthetic fibers. The material of the synthetic fiber nonwoven fabric is not particularly limited, but polyester, which is most widely used, has many achievements and is suitable.

The method for producing the above synthetic fiber nonwoven fabric includes the following:
For example, a spun bond method, a melt flow method, a flash spinning method, a tow opening method, a burst fiber method, a film method and the like can be mentioned, and any method may be used.

The surface weight of the nonwoven fabric used in the fibrous nonwoven fabric layer (A) is limited to 15 to 80 g / m ² . When the surface weight is less than 15 g / m ² , the effect of reinforcing the sound insulating layer is low,
If the surface weight exceeds 80 g / m ² , the workability at the time of bonding and laminating the floor finish may be adversely affected.

[0010] The sound insulating layer (B) used in the present invention is formed of a high specific gravity filler and a binder component mainly composed of unvulcanized rubber.

The high specific gravity filler is preferably one having a specific gravity of 2 or more, more preferably 4 or more and 15 or less. If the specific gravity is less than 2, the vibration damping and sound insulating properties are reduced. Examples of such a high specific gravity filler include iron sand, iron powder, iron oxide, calcium carbonate, zircon sand, chromite sand, iron slag powder, silica sand, lead powder, tin oxide, zinc oxide, barium sulfate, iron sulfide, Mica, aluminum hydroxide, talc, clay and the like can be mentioned.

As the shape of the high specific gravity filler, any of powder, fibrous, scale-like and the like can be used, but powder is preferable from the viewpoint of mixing properties.

The particle size of the high specific gravity filler is 3 μm
２2 mm is preferable, and more preferably 5 to 500 μm. If the particle size is less than 3 μm, the bulk specific gravity becomes too small, and it becomes difficult to mix a large amount of the high specific gravity filler, so that it is difficult to obtain a sheet having a high specific gravity, and the vibration damping property is high. It may be difficult to obtain a sound insulating material. Further, if the particle size exceeds 2 mm, uniform mixing becomes difficult, so that the performance of the vibration damping and sound insulating material tends to be uneven, and the bulk specific gravity becomes too large, so that a large amount of high specific gravity filler is mixed. May be difficult.

The non-vulcanized rubber includes natural rubber, SB
Rubbers that have not been vulcanized, such as R (styrene-butadiene rubber), NBR (nitrile rubber), CR (chloroprene rubber), BR (butadiene rubber), and IR (isoprene rubber). Among them, those emulsified are preferable from the viewpoint of vibration damping and sound insulating material production, for example,
SBR emulsions, NBR emulsions and the like are preferably used.

In the sound insulating layer (B), the proportion of the high specific gravity filler is preferably 85 to 99.5% by weight, more preferably 95 to 99% by weight. If the ratio of the high specific gravity filler is less than 85% by weight, it becomes difficult to obtain a high specific gravity filled sound insulating material having excellent impact sound insulation performance. On the other hand, when the content exceeds 99.5% by weight, it becomes difficult to uniformly mix with the unvulcanized rubber as the binder component.

The amount of the above-mentioned unvulcanized rubber (solid content conversion)
Is 0.5 to 15 with respect to 100 weight of the high specific gravity filler.
It is preferably 1 part by weight, more preferably 1 to 5 parts by weight. If the compounding amount of the unvulcanized rubber is less than 0.5 parts by weight, the high specific gravity filler is not sufficiently held by the unvulcanized rubber, and the strength of the obtained vibration damping sound insulating material is reduced. On the other hand, when the compounding amount of the unvulcanized rubber exceeds 15 parts by weight, the obtained vibration damping and sound insulating material has reduced vibration damping and sound insulating properties.

The sound insulating layer (B) may contain a processing aid such as a gelling agent and a thickening agent and a pigment. Examples of the gelling agent include urethane prepolymers, and examples of the thickener include methylcellulose. Further, a plasticizer such as DOP (dioctyl phthalate) may be used in order to adjust the viscosity of the non-vulcanized rubber or the gelling agent used as the binder.

The urethane prepolymer used as the above-mentioned gelling agent is a prepolymer containing an NCO group at a terminal obtained by reacting a polyol with a polyisocyanate, and reacts with water to form a crosslinked product.

Examples of the polyol include polyoxyalkylene polyols such as polyethylene glycol and polypropylene glycol; polyester polyols, polycaprolactone polyols, dimer acid ester polyols, polycarbonate polyols, butadiene polyols, acrylic polyols, ethylene-vinyl acetate copolymers And chloroprene polyol.

Examples of the polyisocyanate include tolylene diisocyanate (TDI), diphenylmethane diisocyanate (MDI), polymethylene polyphenyl isocyanate (C-MDI), hexamethylene diisocyanate, xylylene diisocyanate (X
DI), isophorone diisocyanate, hydrogenated XD
I, hydrogenated MDI and the like.

The urethane prepolymer is preferably hydrophilic in consideration of dispersibility in an aqueous slurry. As the polyol component, for example, polyethylene glycol and polypropylene glycol are contained in a molar ratio of 85:15, and as the isocyanate component, tolylene diisocyanate (TDI) and / or diphenylmethane diisocyanate (MDI) are contained.
Prepolymers having a terminal NCO ratio of about 5 mol% are preferred.

The molecular weight of the urethane prepolymer is usually from 8 × 10 ^{2 to} 3 × 1 (weight average molecular weight (Mw)).
0 ^4, more preferably 2 × 10 ³ ~2 × 10
⁴ The number average molecular weight (Mn) is 5 × 1
0 ² to 1 × 10 ⁴ , more preferably 8 × 10 4
^{It is 2} to 8 × 10 ³ .

The weight ratio of the unvulcanized rubber to the urethane prepolymer (crosslinked product) in the binder component is as follows:
5: 1 to 0.5: 1 is preferred, more preferably 3: 1.
１1: 1. When the weight ratio of the unvulcanized rubber is less than 0.5: 1, the vibration control performance of the unvulcanized rubber becomes insufficient. Insufficient ability to prevent deformation.

The sound insulation layer (B) can be manufactured according to the following steps (1) to (4). A step of preparing an aqueous slurry containing a high specific gravity filler and an emulsion of unvulcanized rubber; A step of applying and laminating the aqueous slurry on a fibrous nonwoven fabric or an open-cell foam sheet. A step of drying and removing water in the aqueous slurry.

In the above process, a mixer having a stirring blade, a screw mixer, or the like can be used for mixing the high specific gravity filler and the emulsion of the unvulcanized rubber. The amount of water to be added is preferably 20 to 40 parts by weight, more preferably 10 to 40 parts by weight based on 100 parts by weight of the high specific gravity filler.
２５25 parts by weight.

In the above step, the aqueous slurry may be formed into a sheet by coating or laminating on a fibrous nonwoven fabric or an open-cell foam sheet, or by using an extruder, spray coating, or the like. Further, it can be formed into a desired shape (usually a sheet shape) by press molding, cast molding or the like. As a base material to which the aqueous slurry is applied, a wood panel such as plywood, a gypsum board, or the like may be used.

In the aqueous slurry formed or applied in the above step, the NCO group of the urethane prepolymer reacts with water to form a crosslinked product by a urea bond, thereby causing gelation. In this reaction, CO ₂ gas is generated, so that the reaction product slurry contains CO ₂ bubbles.
This reaction is represented by the following formula (1). 2R (NCO) ₂ + H ₂ O → OCN-R- (NHCONH) -R-NCO + CO ₂ .. (1) Since this reaction usually takes place at normal temperature, it does not require any particular heating. May be heated.

In the above step, the drying method includes:
A normal heating method can be used, and examples thereof include a method using a hot-air heating furnace, a heating plate, and the like.

The material of the open-cell foam used in the open-cell foam layer (C) used in the present invention is not particularly limited, but the most general-purpose flexible polyurethane foam has many achievements as an impact cushioning material. It is suitable. In general,
Foams are mainly classified into two types: closed-cell foams represented by polyethylene foams, polystyrene foams and the like, and open-cell foams represented by flexible polyurethane foams and the like.

Here, the distinction between the closed-cell foam and the open-cell foam is not clearly defined, but is usually determined by measuring the closed-cell rate, and the closed-cell foam having a low closed-cell rate, that is, open-cell foam, Those with a high rate are referred to as open-cell foams. The closed cell rate is a percentage by volume of closed cells (complete bubbles in which foam cells are not communicated) existing in the entire volume, and is, for example, ASTM D2.
It can be measured according to 856.

In the open cell foam layer (C), when the open cell ratio is high, air can freely flow inside the foam, so that sound absorption and shock absorption are increased, and compression set is considered to be reduced. . Conversely, an increase in the closed cell ratio causes a decrease in shock absorption and an increase in compression set. Therefore, the open cell rate of the open cell foam layer (C) is preferably 20% by volume or less.

The above-mentioned open-cell foam layer (C) usually contains
A sheet-like foam is used, and a polyurethane foam is generally used as the foam. The thickness of the open-cell foam layer (C) is preferably 1 to 5 mm. If it is less than 1 mm, the shock absorption is poor, and if it exceeds 5 mm, the walking sensation is reduced when the vibration damping and sound insulating material is installed under the floor material.

In the vibration damping and sound insulating material of the present invention, a fiber nonwoven fabric layer (D) is laminated on the lowermost layer. The fibrous nonwoven fabric (D) is not particularly limited, and nonwoven fabrics similar to those used for the fibrous nonwoven fabric layer (A) can be used. However, the most commonly used polyester nonwoven fabric has been used in many cases. preferable.

[0034] As a surface weight of the nonwoven fabric used for the fibrous nonwoven fabric layer (D) is limited to 120~450g / m ^2, preferably 150 and 400 / m ^2. When the surface weight is less than 120 g / m ^2, there is a problem in the reinforcing effect of the sound insulation layer and the workability, and when the surface weight exceeds 450 g / m ² , the thickness becomes too thick and the handleability including the workability deteriorates. .

As described above, the vibration damping and sound insulating material of the present invention
A fiber non-woven fabric layer (A) is provided on the uppermost layer, a fiber non-woven fabric layer (D) is provided on the lowermost layer, and a sound insulation layer (B) is laminated inside each of the layers (A) and (D). It is composed of a laminate having a five-layer structure in which a body layer (C) is arranged.

The thickness of the vibration damping and sound insulating material is preferably 2 to 15 mm, more preferably 3 to 10 mm. If the thickness is less than 2 mm, it is difficult to manufacture, and if it exceeds 15 mm, the vibration-damping and sound-insulating material itself becomes too heavy, resulting in poor workability.

When the vibration-damping and sound-insulating material of the present invention is used as a vibration-damping and sound-insulating flooring material, the vibration-damping and sound-insulating material is laminated on at least one or both sides of the wooden layer, or the two vibration-damping and sound-insulating materials are made of wood. It is used by being laminated in a sandwich shape between layers. When used as a flooring material, the vibration-damping and sound-insulating material is generally used in the state of a sandwich between the floor base material and the floor finishing material. When used as a floor finish, it is preferably laminated on the upper surface of the layer and the lower surface of the wooden layer.

The term "wood layer" as used herein means a wood panel usually used for a floor structure such as a floor covering material or a floor finishing material of a house. Examples of such a woody layer include floor base materials such as plywood, particle board, OSB (oriented strand board), and MDF (mid density fiber) board; and floor finish materials such as parquet flooring material.

When the vibration-damping and sound-insulating material is used as a sandwich between a floor covering material and a floor finishing material such as a parquet flooring material, it is usually laminated by an adhesive. For bonding,
Normally, a solvent-based adhesive is used, so if the open-cell foam layer into which the adhesive easily penetrates has a problem in construction, it is better to laminate sound insulation layers on both sides of the open-cell foam layer one by one. preferable. If the open-cell foam layer is laminated in an exposed state, not only is it difficult to apply the adhesive, but also the permeated adhesive greatly reduces the original cushioning property of the open-cell foam layer.

In the vibration damping and sound insulating material, the fiber nonwoven fabric layer (A) takes into consideration non-adhesion work with the particle board, and the synthetic fiber nonwoven fabric layer (D) takes into account adhesion work with the flooring material. Selected. Further, by providing the open-cell foam layer (C), the impact force generated on the floor surface is reduced due to the low elastic modulus of the foam layer, and the effect of cushioning can be obtained. Since the cells are open cells, the effect of sound absorption and vibration suppression can be exerted by friction when air moves. The sound insulating layer (B) has a high specific gravity and thus has excellent sound insulating properties against other sound sources, and further has a large loss coefficient and thus has excellent vibration damping performance.

As described above, the vibration-damping and sound-insulating material of the present invention has a five-layer structure, so that a synergistic effect is exhibited and the sound-insulating material has high overall sound insulating performance.

(Function) In the vibration-damping and sound-insulating material of the present invention, a fiber nonwoven fabric layer (D) having a surface weight of 120 to 450 g / m ^{2 in} the lowermost layer
By using, slipping hardly occurs on the floor surface of a particle board or the like, positioning can be easily performed when laying on the floor surface, and floor noise does not easily occur in terms of surface weight. Furthermore, since it is laminated with a wooden layer at the time of construction, vibration damping and sound insulating properties are high in the sense of damping properties and cushioning against impact.

Further, since the fibrous nonwoven fabric layer (A) is laminated on the uppermost layer of the above-mentioned vibration damping and sound insulating material, the adhesive application property is good, the cushioning property and the vibration damping property are provided, and the sound absorbing and damping property is provided. Since it can exhibit the effect of vibration damping, it is particularly effective as a sound insulating material for wooden flooring materials.

[0044]

DESCRIPTION OF THE PREFERRED EMBODIMENTS Hereinafter, embodiments of the present invention will be described in detail. Note that the present invention is not limited to these embodiments at all, and various modifications are possible.

(Example 1) 1) Fiber nonwoven fabric layer (A): Spunbond polyester nonwoven fabric ("6301A" manufactured by Toyobo Co., Ltd., surface weight 30 g / m2)
² ) used. 2) Sound insulation layer (B): iron sand (specific gravity 4.
6, 750 parts by weight of carboxy-modified SBR emulsion ("JSR-0619" manufactured by Nippon Synthetic Rubber Co., Ltd., specific gravity 1.0, solid content 48) as a non-vulcanized rubber
20% by weight (solid content: 9.6 parts by weight), methylcellulose (Shin-Etsu Chemical Co., Ltd. “Metroze 90”)
SH30000 ”), 0.5 part by weight of a gelling agent (water-crosslinkable urethane prepolymer), and 3.8 parts by weight of water and 100 parts by weight of water were stirred and mixed using a stirring blade to prepare a mixed slurry.

3) Open-cell foam layer (C): A flexible polyurethane foam sheet ("Soflan ether foam 360s" manufactured by Toyo Tire & Rubber Co., Ltd. West Japan, 2.5 mm-thick open-cell foam) was used. 4) Fiber non-woven fabric layer (D): Spunbond polyester non-woven fabric ("Borans 4161N" manufactured by Toyobo Co., Ltd., surface weight 1)
65 g / m ² ).

[Preparation of vibration-damping and sound-insulating material] The mixed slurry was applied to a nonwoven fabric layer (D) laid on release paper ("SJA70A" manufactured by San-A Chemical Co., Ltd.) using a mold and a knife coater. Coated to 2mm, sound insulation layer (B)
Was formed. Further, the open-cell foam layer (C) was placed on the slurry and lightly compressed to be laminated. further,
On the open-cell foam layer (C), the mixed slurry was applied to a thickness of 1.5 mm using a mold and a knife coater to form a sound insulation layer (B). Finally, the fiber nonwoven fabric layer (A) was laminated thereon to obtain a laminate having a five-layer structure.

The laminate was dried in a drying chamber maintained at 50 ° C. for 24 hours to obtain a vibration damping and sound insulating material. The obtained vibration damping and sound insulating material is integrated without moisture evaporation and delamination, has an overall thickness of 7.5 mm, an overall weight of 7.4 kg / m ² , and has a material configuration of the sound insulating layer (B). It was 98% by weight of iron sand and 2% by weight of a binder component.

Example 2 As the fiber nonwoven fabric layer (D),
Except for using a spunbond polyester nonwoven fabric (“Borans 4421N” manufactured by Toyobo Co., Ltd., surface weight 420 g / m ² ), the entire thickness was 10 m in the same manner as in Example 1.
m and a total weight of 7.8 kg / m ² .

Example 3 As the fiber nonwoven fabric layer (D),
Except for using a spunbond polyester nonwoven fabric (“Borans 4301N” manufactured by Toyobo Co., Ltd., surface weight: 300 g / m ² ), the overall thickness was 8.8 m in the same manner as in Example 1.
m and a total weight of 7.6 kg / m ² .

Example 4 A spunbond polyester nonwoven fabric ("H67" manufactured by Toyobo Co., Ltd.) was used as the fiber nonwoven fabric layer (D).
01A "and a surface weight of 70 g / m ² ), and a vibration damping material having a total thickness of 7.6 mm and a total weight of 7.5 kg / m ² was obtained in the same manner as in Example 1.

(Comparative Example 1) As the fiber nonwoven fabric layer (D),
Spunbond polyester nonwoven fabric (Toyobo “H6
501A "and a surface weight of 50 g / m ² ), and a vibration damping material having a total thickness of 6.2 mm and a total weight of 7.2 kg / m ² was obtained in the same manner as in Example 1.

(Comparative Example 2) As the fiber nonwoven fabric layer (D),
Except for using a polyester fiber non-woven fabric (surface weight: 550 g / m ² ), a total thickness of 1
A vibration damping sound insulating material having a thickness of 1.2 mm and a total weight of 8.0 kg / m ² was obtained.

Comparative Example 3 A synthetic fiber nonwoven fabric layer (A) was used.
And polyester fiber non-woven fabric (area weight 10 g / m ^Two)
Used, as fiber non-woven fabric layer (D), spunbond poly
Ester nonwoven fabric (Toyobo “6301A”, surface weight
30g / m^TwoSame as Example 1 except that
The total thickness is 6.2 mm and the total weight is 7.2 kg / m
^TwoThe vibration damping sound insulation material was obtained.

The following evaluations were performed on the vibration-damping and sound-insulating materials obtained in the above Examples and Comparative Examples, and the results are shown in Table 1. (1) Workability The above vibration-damping and sound-insulating material is cut into a size of 910 mm x 455 mm, and is laid without glue on a particle board in a 6-tatami Western-style room on the second floor of "2U Home" manufactured by Sekisui Chemical Co., Ltd. After that, an adhesive for wood flooring ("Sekisui Bond" manufactured by Sekisui Chemical Co., Ltd., aqueous one-pack type)
Non-thinner) is applied with a special applicator, and a flooring material (width 300 mm x length 1800 mm) is laminated by bonding.
The construction time per 1m ² required for this construction was measured. (2) Floor Noise Whether the floor noise occurred when a person walked on the flooring material on which the vibration damping sound insulating material was bonded and laminated was judged by hearing.

[0056]

[Table 1]

[0057]

The vibration-damping and sound-insulating material of the present invention is as described above, and the synthetic fiber nonwoven fabric layer is laminated on the uppermost layer.
It can provide cushioning and vibration damping properties, and exhibit sound absorbing and vibration damping effects. In addition, by having a sound insulating layer with a high specific gravity, it is excellent in sound insulation and has a large loss coefficient, so it is excellent in vibration damping performance. Provides extremely excellent sound insulation performance.

The lowermost layer has a surface weight of 120 to 450 g /
Since m ² of non-woven fabric are laminated, slip hardly occurs on particle board, it is possible to easily perform the positioning at the time of construction, excellent in laying workability placed, excellent adhesion and flooring floor It is difficult for noise to occur.

Claims (1)

[Claims] (A) a fiber nonwoven fabric layer having a surface weight of 15 to 80 g / m ² , (B) a sound insulation layer comprising a high specific gravity filler and a binder component containing non-vulcanized rubber as a main component, ) open-cell foam layer, (B) and high specific gravity filler, non-vulcanized rubber sound insulation layer comprising a binder component consisting mainly of, and (D) surface weight fibrous nonwoven layer of 120~450g / m ² Are laminated in this order.