JP2001049846A - Soundproof flooring - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide soundproof flooring having high sound insulating efficiency notwithstanding that there is no occurrence of crack, flooring joint section pushing-up, joint gap or the like, without the expansion, contraction to be caused by temperature variation the like. SOLUTION: In soundproofing flooring laminated in the order of surface facing plate, plate-like body and hard resin foam from the surface side, linear coefficient of expansion of the material constituting the plate-like body is-8 to 8*10-6/ deg.C, the rear of the plate-like body having a shape in the case of the constituting the soundproof flooring is mounted on concrete, and flexural rigidity of the plate-like body is at most 30MPa .cm4 when load is applied from the surface side of the plate-like body.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a soundproof flooring material, and more particularly to a soundproofing flooring material suitably used for a heating floor.

[0002]

2. Description of the Related Art Conventionally, as a heating floor material used in an apartment house, a floor heating panel having a heating means buried on the back side of a surface material has been used. However, conventional floor heating panels do not consider soundproofing, and are susceptible to sound due to impact, and are likely to transmit the sound of life downstairs, that is, the sound of walking and falling objects. Was. Therefore, there is a problem that it cannot be directly attached to a floor slab, and in an apartment house, it is inconvenient to perform a heating function on floor materials.

Therefore, as a method for solving the above-mentioned problems, a soundproofing material is attached to the backside of a heating panel formed by disposing heating means on the backside of the surface material, and a cushion is provided on the backside of the soundproofing material. A floor heating panel to which a material is adhered has been proposed (JP-A-2-61435).

[0004] However, as apparent from the drawing, the floor heating panel is provided in a concave portion formed on the back surface of the surface material.
The heating means is fitted on the back side of the surface material such that the heating plate and the film heater serving as the heating means are arranged.

[0005]

Generally, plywood is generally used as the surface material. In this case, since the plywood has a high coefficient of linear expansion, when it is used for a floor heating panel, the space between the grains gradually expands due to expansion and shrinkage due to heat, and thus fine cracks often occur on the surface.

[0006] On the other hand, in the case of ordinary flooring materials (without heating means), when plywood is used, in addition to the temperature change due to the seasonal change between summer and winter, the humidity change due to wet-dryness is also caused. In some cases, fine cracks as described above were generated. When wood fiberboard is used in place of plywood, cracks as described above are reduced, but expansion and contraction of the board itself causes the floor material to be pushed up when the board is stretched, and when the board is shrunk, the floor is shrunk. There has been a problem that glazing of the material connecting portion occurs.

[0007] The present invention solves the above-mentioned problems, and has a small expansion and contraction due to a temperature change, etc.
It is an object of the present invention to provide a soundproof flooring material having high soundproofing performance despite no occurrence of eyes or the like.

[0008]

The sound-insulating flooring material according to claim 1 (hereinafter referred to as "the present invention") comprises a surface decorative plate, a plate-like body, and a hard resin foam laminated in this order from the surface side. Wherein the material constituting the plate-like body has a linear expansion coefficient of −8 to 8 × 10 ⁻⁶ / ° C., and has a plate-like shape when constituting the sound-insulating floor material. When the body is placed on concrete with the back side of the plate-like body and a load is applied from the front side of the plate-like body, the plate-like body has a flexural rigidity of 30 MPa · cm ⁴ or less.

[0009] The surface decorative board used in the present invention comprises:
It is used to decorate the surface of the flooring material and enhance the design, and as the material, for example, a wooden veneer, a printing paper, a decorative plastic sheet, or the like is used.

[0010] The linear expansion coefficient of the plate-like body used in the present invention is too large or too small. Since problems such as thrusting and blinding occur, the linear expansion coefficient measured in accordance with JIS is -8 to 8
It is limited to × 10 ⁻⁶ / ° C. and is preferably closer to 0, but the linear expansion coefficient of a plate-like body that can be usually used for a soundproof flooring material is 1 × 10 ⁻⁸
３3 × 10 ⁻⁶ / ° C.

Bending rigidity of the plate used in the present invention
If the sound is too large, the soundproofing performance will decrease.
The plate-like body in the shape of
Place on a cleat and apply a load from the surface of the plate
Flexural rigidity of the plate-shaped body at the time of^Fourless than
Limited and too small makes it difficult for the plate to hold its own weight
Which makes it difficult to handle soundproof flooring.
And 10MPa · cm ^FourPreferably
New

The plate is not particularly limited as long as it satisfies the above conditions, and the linear expansion coefficient of the plate is -8 to
It can be selected as appropriate by selecting a material having a density of 8 × 10 ⁻⁶ / ° C. and changing the thickness and shape of the plate to a flexural rigidity of 30 MPa · cm ⁴ or less. However, flooring materials used in recent years usually have a thickness of 12 to 16 mm due to a demand for barrier-free. As a result, the thickness and the shape of the plate-like body may be restricted, and therefore, as described in claim 2, the plate-like body is composed of a synthetic resin and a filler. Preferably, it does not substantially melt and does not dissolve in the synthetic resin.

Examples of the synthetic resin include a phenolic resin, an epoxy resin, an unsaturated polyester resin,
Thermosetting resins such as urethane resins, polyolefin resins, polyvinyl chloride resins, ethylene-vinyl acetate resins, thermoplastic polyester resins, acrylic resins, and thermoplastic resins such as polycarbonate resins. These may be used alone or in combination of two or more.

Examples of the filler which does not substantially melt at the molding temperature of the synthetic resin and does not dissolve in the synthetic resin include the following. Fibrous material: inorganic fiber such as glass fiber and carbon fiber; organic fiber such as aramid fiber; natural fiber such as wood fiber, kenaf, cotton, hemp etc. Granular material: granule such as glass beads and shirasu balloon; Powders such as glass powder, activated carbon, and aluminum hydroxide Needles: potassium titanate, etc. Plates: mica, etc. These may be used alone or in combination of two or more.

In particular, as set forth in claim 3, the synthetic resin is preferably a polyolefin-based resin, and the filler may be a powdery or substantially non-melting material at the molding temperature of the polyolefin-based resin. Preferably, the filler is made of a granular material of a woody material, the amount of which is 5 to 95% of the material constituting the plate-like body.
More preferably, it is% by weight.

The above-mentioned plate-like body may be a flat plate, but in order to secure a necessary thickness as a floor material, it is usually 2 to 8 mm.
Is required. In that case, the bending rigidity of the plate
In order to reduce the pressure to 30 MPa · cm ⁴ or less, it is preferable that a concave groove extending in an arbitrary direction is provided on the back surface of the plate-like body. By doing so, it is possible to further reduce the bending stiffness of the hard plate-like body and to further improve the soundproofing. The shape of the concave groove is usually formed in a U-shape, a V-shape, a U-shape, etc., the groove width is about 1.5 to 2.5 mm, and the groove depth is 0.5 to
1.3 mm.

The rigid resin foam used in the present invention is not particularly limited, and examples thereof include a rigid polyurethane foam having a magnification of 5 to 25 times and a polystyrene foam having a magnification of 10 to 30 times. Is disclosed in JP-A-10-23
No. 80915, wherein the thermoplastic resin foam is a continuous foam layer made of a thermoplastic resin, a high foam body made of a thermoplastic resin disposed on at least one surface of the continuous foam layer, and an outer surface of the high foam body And a low-foaming thin film made of a thermoplastic resin, which is a thermoplastic resin foam, wherein the plurality of high-foaming bodies are thermally fused to each other via the low-foaming thin film.

The resin used for the continuous foam layer, high foam body, and low foam thin film constituting the thermoplastic resin foam is not particularly limited as long as it is a foamable thermoplastic resin. Olefin-based resins such as polyethylene and polypropylene or a mixture thereof are preferable because they can enhance the smoothness of the obtained thermoplastic foam, and both the surface smoothness and the prevention of sinking of the obtained floor finishing material during walking can be achieved. For this purpose, high-density polyethylene, homopolypropylene or a mixture containing at least one of them is particularly preferred.

The method for producing the thermoplastic resin foam is not particularly limited. For example, a foamable thermoplastic resin composition containing a foaming agent is foamed in a predetermined container, and one side is removed. A high-foamed body whose outer surface is coated with a low-foaming thin film made of a thermoplastic resin is produced, and this is heat-sealed through the low-foaming thin film to form a continuous foam sheet layer made of a separately produced thermoplastic resin. Lamination may be performed by heat fusion or the like, but the expandable thermoplastic resin particles are arranged in a plane, and the expandable thermoplastic resin particles are integrally connected via an expandable thermoplastic resin thin film. It is preferable to obtain a foamable thermoplastic resin sheet by heating the foamed thermoplastic resin sheet to a temperature equal to or higher than the decomposition temperature of the foaming agent and foaming.

The thermoplastic resin used for the foamable thermoplastic resin granules and the foamable thermoplastic resin thin film constituting the foamable thermoplastic resin sheet may be a resin used for the thermoplastic resin foam. The same is used.

The thermoplastic resin used for the foamable thermoplastic resin particles and the thermoplastic resin used for the foamable thermoplastic resin thin film do not need to be the same resin. From the viewpoint of the above, it is preferable to use the same type of resin.

The thermoplastic resin used for the foamable thermoplastic resin sheet may be crosslinked, if necessary. This is because cross-linking can prevent foam breakage during foaming, increase the foaming ratio, and reduce the weight of the floor finish. The crosslinking method is not particularly limited.For example, after melt-kneading the silane graft polymer into a thermoplastic resin, a water treatment is performed, and a method of crosslinking, the peroxide is added to the thermoplastic resin from the decomposition temperature of the peroxide. After melt-kneading at a low temperature, a method of crosslinking by heating above the decomposition temperature of the peroxide,
A method of cross-linking by irradiating radiation may be used. However, a cross-linking method using a silane graft polymer is preferable in order to obtain a high cross-linking resin and a low (no) cross-linking resin described later.

The resins used for the continuous foamed layer, the high foamed body and the low foamed thin film constituting the thermoplastic resin foam do not need to be the same resin. It is preferable to use the same kind of resin because it is hard to break when the object is placed. In this case, it is preferable that the resin used for the high-foamed body and the low-foamed thin film is formed of the same resin in view of adhesiveness.

The silane-grafted polymer is not particularly limited, and examples thereof include silane-grafted polyethylene and silane-grafted polypropylene.

The above-mentioned water treatment method includes, for example, a method of immersing in hot water at normal pressure, a method of exposing to steam, and a method of immersing in hot water at a temperature higher than 100 ° C. under pressure.

If the added amount of the silane graft polymer is too large, crosslinking is excessively performed, and the expansion ratio of the obtained thermoplastic resin foam is reduced. If the added amount is too small, cells are broken and uniform foam cells are formed. Therefore, the addition amount of the silane graft polymer is preferably 5 to 50% by weight, and particularly preferably 10 to 35% by weight, based on the total thermoplastic resin.

Soft Resin Foam In the present invention, if necessary, a soft resin foam may be further laminated on the back surface of the hard resin foam. The soft resin foam is not particularly limited as long as it has a small compression elastic modulus relative to the hard resin foam,
For example, a polyethylene foam having an expansion ratio of 10 to 30 times and a polyurethane foam having an expansion ratio of 20 to 40 times can be used.

The hard resin foam and the soft resin foam may be provided with a groove or a groove in order to further increase the soundproofing performance as necessary or to cope with the unevenness of the adherend (generally, concrete). Irregularities may be applied.

In the present invention, in order to obtain a soundproof floor finish by laminating a decorative surface plate, a plate-like body, and a hard resin foam, a lamination method using an adhesive or a pressure-sensitive adhesive for each layer can be mentioned. Examples of the adhesive used include a modified silicone adhesive, a vinyl acetate adhesive, a vinyl ester adhesive, and a chloroprene adhesive, and examples of the adhesive include an acrylic adhesive. Can be

[0030]

EXAMPLES The present invention will be described in more detail with reference to Examples. (Example 1)

Preparation of a plate-like body A glass fiber (30 mm in length,
Cured plate-shaped cured product (length 900 x width 145 mm x) composed of 30% by weight unsaturated polyester resin containing 0.1% fiber diameter
Thickness 3 mm, linear expansion coefficient 4 × measured according to JIS
(10 ⁻⁶ / ° C.), a groove having a width of 1 mm, a depth of 2 mm, and a pitch of 10 mm was formed on the entire back surface to obtain a plate-like body. The flexural rigidity of the obtained plate was measured by the following method and found to be 10 MPa · cm ⁴ .

Measurement of Flexural Rigidity The back of the obtained plate was placed on concrete, and the displacement of the center of the plate when a load of 50 kgf was applied to the center of the plate from the front side was measured. It was measured.

Preparation of Hard Resin Foam High-density polyethylene (manufactured by Nippon Polychem Co., Ltd., product number "HY3"
40 ", MI = 1.5 g / 10 min) 50% by weight, polypropylene (manufactured by Nippon Polychem Co., Ltd., product number" MA3 ", MI =
10 g / 10 min.) 20% by weight, silane-grafted polypropylene (manufactured by Mitsubishi Chemical Corporation, trade name "Linklon XPM80")
0MH ", MI = 11 g / 10 min, gel fraction after crosslinking 8
100 parts by weight of a thermoplastic resin consisting of 30% by weight), 5 parts by weight of an azodicarboxylic acid amide (manufactured by Otsuka Chemical Co., Ltd., product number "SO-20", decomposition temperature 210 ° C.) as a foaming agent, and 5 parts by weight as a silane crosslinking catalyst. A composition containing 0.1 part by weight of dibutyltin dilaurate is supplied to a twin-screw co-extruder (screw diameter: 65 mm), melt-kneaded at 180 ° C., and extruded from a T die having a surface length of 1200 mm and a lip interval of 0.7 mm. The softened foamable resin sheet was extruded.

The extruded resin sheet was placed on one outer peripheral surface with a cylindrical recess having a depth of 20 mm and a diameter of 4.0 mm of 10 m.
After being supplied between a pair of shaping rolls (clearance 1 mm) having a diameter of 500 mm and a surface length of 1500 mm (clearance 1 mm), which are arranged in a zigzag pattern at intervals of m and the other has a smooth outer peripheral surface, hot water at 98 ° C. For 2 hours to crosslink silane-grafted polypropylene or silane-grafted polyethylene.

The foamable thermoplastic resin sheet obtained as described above is placed on a polyfluorinated ethylene sheet, and the polyfluorinated ethylene sheet is further placed on the upper surface thereof. After supply and foaming, the mixture was passed between 12 pairs of rolls with a roll interval of 6.5 mm set at 25 ° C. to have a thickness of 6.5 mm and a foaming ratio of 10
A double hard resin foam was obtained.

Preparation of Soundproof Floor Material A wooden decorative sheet having a thickness of 0.25 mm on the surface (the side not subjected to groove processing) of the plate-like body obtained as described above is adhered. After applying the modified silicone adhesive on the back surface, the hard resin foam obtained as described above is laminated, pressed at a pressure of 1.0 kgf / cm ² for 30 minutes, depressurized, and left for 24 hours Then, the adhesive was cured to produce a soundproof floor material.

Example 2 As a plate-like cured product, aluminum hydroxide powder (having an average particle size of 1) prepared in advance by a conventional method was used.
0 μm) A plate-like body was obtained in the same manner as in Example 1 except that a plate-like cured body (linear expansion coefficient: 5 × 10 ⁻⁶ / ° C.) comprising a vinyl chloride resin containing 50% by weight was used. The bending rigidity of the obtained plate-like body was 10 MPa · cm ⁴ . Using the above plate-like body, a soundproof flooring material was produced in the same manner as in Example 1.

Example 3 A glass powder (average particle size: 8 μm) prepared in advance by a conventional method as a plate-like cured product 5
A plate-like body was obtained in the same manner as in Example 1, except that a plate-like cured body (linear expansion coefficient: 4 × 10 ⁻⁶ / ° C.) made of a polypropylene resin containing 0% by weight was used. The bending rigidity of the obtained plate was 9 MPa · cm ⁴ . Using the above plate-like body, a soundproof flooring material was produced in the same manner as in Example 1.

Example 4 50% by weight of wood flour (average particle size: 20 μm) prepared as a plate-like cured product by a conventional method in advance
A plate-like body was obtained in the same manner as in Example 1 except that a plate-like hardened body (linear expansion coefficient: 0.5 × 10 ⁻⁵ / ° C.) made of a contained linear bottom density polyethylene resin was used. The bending rigidity of the obtained plate was 8 MPa · cm ⁴ . Using the above plate-like body, a soundproof flooring material was produced in the same manner as in Example 1.

Comparative Example 1 Example 1 was repeated except that plywood (linear expansion coefficient: 3 × 10 ⁻⁶ / ° C.) was used as the plate-like cured product.
A plate was obtained in the same manner as described above. The bending rigidity of the obtained plate-like body was 15 MPa · cm ⁴ . Using the above plate,
A soundproof floor material was produced in the same manner as in Example 1.

Comparative Example 2 A medium-density fiberboard (linear expansion coefficient: 3 × 10 ⁻⁶ / ° C.) was used as a plate-like cured product, except that
A plate was obtained in the same manner as in Example 1. The bending rigidity of the obtained plate-like body was 20 MPa · cm ⁴ . Using the above plate-like body, a soundproof flooring material was produced in the same manner as in Example 1.

The soundproof flooring materials obtained in Examples 1 to 4 and Comparative Examples 1 and 2 were subjected to the following evaluation. Evaluation

High and low temperature repetition test The obtained soundproof flooring material was left at 80 ° C for 2 hours, and then left at 20 ° C.
And leave for 2 hours. This was repeated 10 cycles, and the occurrence of cracks on the floor material surface was visually observed, and the change in length in the longitudinal direction was measured with a vernier caliper.

Soundproof test In accordance with JIS A1418, a lightweight floor impact sound level (L
L value) was measured.

The above results are summarized in Table 1.

[0046]

[Table 1]

[0047]

The sound-insulating flooring material of the present invention is a sound-insulating flooring material in which a surface decorative plate, a plate-like body, and a hard resin foam are laminated in this order from the surface side. Since the constituent materials have a coefficient of linear expansion of −8 to 8 × 10 ⁻⁶ / ° C., there is little expansion and contraction due to a temperature change or the like, and there is no generation of cracks, floor material push-ups, and blind spots.

Further, the plate-like body having the shape of the sound-insulating floor material is placed on concrete with the back side of the plate-like body, and the plate-like body when a load is applied from the front side of the plate-like body is formed. Since the bending stiffness is set to 30 MPa · cm ⁴ or less, excellent soundproofing performance can be obtained despite no occurrence of the floor material connection portion thrusting and blinding.

Further, the plate-like body is composed of a synthetic resin and a filler, and the filler does not substantially melt or dissolve in the synthetic resin at the molding temperature of the synthetic resin. When the thickness of the plate-like body is the thickness normally used for flooring, remarkable soundproof performance is exhibited.

Further, when the synthetic resin constituting the plate-like body is a polyolefin-based resin and the filler is a powdery substance which does not substantially melt at the molding temperature of the polyolefin-based resin, the above-mentioned effect becomes more remarkable. The effect is further remarkable when the filler is made of a granular material of a woody material and its amount is 5 to 95% by weight of the material constituting the plate-like body.

Note that such an effect becomes more remarkable when a concave groove extending in an arbitrary direction is provided on the back surface of the plate-like body.

The soundproof floor constructed as described above has a remarkable effect not only in response to a change in environmental temperature but also when a heating means is provided inside or on the floor.

Claims (5)

[Claims] 1. A soundproof flooring material in which a decorative surface plate, a plate-like body, and a hard resin foam are laminated in this order from the surface side, wherein the material constituting the plate-like body has a linear expansion coefficient of -8
８8 × 10 ^-6 / ° C., and a plate-shaped body having a shape for constituting a soundproof flooring material is placed on concrete with the back side of the plate-shaped body, and a load is applied from the front side of the plate-shaped body. A soundproof flooring material, wherein the plate-like body has a flexural rigidity of 30 MPa · cm ⁴ or less when loaded. 2. The plate-like body is made of a synthetic resin and a filler, and the filler is formed at a molding temperature of the synthetic resin.
2. The acoustic flooring material according to claim 1, wherein the flooring material does not substantially melt and does not dissolve in a synthetic resin. 3. The method according to claim 1, wherein the synthetic resin is a polyolefin-based resin, and the filler is a powdery material that does not substantially melt at the molding temperature of the polyolefin-based resin. Soundproof flooring. 4. The filler as claimed in claim 1, wherein the filler comprises a granular material of a woody material, and the amount thereof is 5 to 95% by weight of the material constituting the plate-like body. The described soundproof flooring. 5. The back surface of the plate-like body is provided with a groove extending in an arbitrary direction.
The described soundproof flooring.