JP2002038381A - Fiber mat for floor groundwork and flooring material - Google Patents

Abstract

PROBLEM TO BE SOLVED: To obtain a fiber mat for a floor groundwork for directly laid floors, capable of improving a walking feeling while enhancing a noiseproof performance. SOLUTION: This fiber mat 4 for floor groundwork is obtained by subjecting an original fabric 3 comprising a fibrous material 1 and a thermoplastic resin binder 2 to a preheating process followed by a press-forming operation; wherein during the preheating process, the air occluded in the fibrous material 1 is expanded on heating to afford an entanglement of three-dimensional structure with voids in the fibrous material 1, thus imparting the final fibrous mat 4 with uniform resilience.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a floor mat and a floor material used for a soundproof floor directly attached.

[0002]

2. Description of the Related Art Directly attached soundproof floors are constructed by a method of directly attaching a floor material to a floor surface, such as a slab of a building, and are manufactured mainly for the purpose of reducing lightweight floor impact noise. The impact applied to the floor surface is reduced, and the transmission of impact noise downstairs is reduced.

[0003] The conventional wooden flooring material used for construction of the directly attached soundproof floor has a method of reducing the bending rigidity by providing a groove on the lower surface of the floorboard, and a method of laminating a cushion material on the lower surface of the floorboard so as to integrate the entire floor. Improve soundproofing performance through various measures such as a method of reducing the spring constant per unit area, a method of damping the vibration generated by an impact by laminating the damping material on the lower surface of the floorboard, etc. Is being planned.

[0004]

However, when the impact is relaxed by reducing the bending rigidity or the spring constant as described above, there is a problem that the walking feeling is deteriorated due to the sinking of the floor material. It was easy to occur.

The present invention has been made in view of the above points, and an object of the present invention is to provide a floor mat and a floor material for a directly-attached sound-insulating floor, which can improve walking feeling while obtaining soundproofing performance. It is the purpose.

[0006]

According to a first aspect of the present invention, there is provided a fiber mat for floor substrate, wherein a raw material comprising a fiber material and a thermoplastic resin binder is formed into a mat by press molding after a preheating step. It is characterized by becoming.

[0007] The invention of claim 2 is characterized in that the preheating temperature in the preheating step is higher than the melting point of the thermoplastic resin binder.

The invention according to claim 3 is characterized in that the raw fiber material is waste fiber.

The invention of claim 4 is characterized in that the thermoplastic resin binder is a composite of polyethylene and polypropylene.

The invention according to claim 5 is characterized in that the two-layer raw material is formed into a mat by press molding, and the density of the lower layer is higher than the density of the upper layer.

A flooring material according to a sixth aspect of the present invention is characterized in that a floorboard is laminated on the fiber mat for floor substrate according to any one of the first to fifth aspects. .

[0012]

Embodiments of the present invention will be described below.

In the fiber mat for floor substrate according to the present invention, organic fibers such as natural fibers such as hemp, cotton and palm and synthetic fibers are mainly used as the fiber material. It is preferable to use waste fibers such as offcuts and recycled products in the production process. By using the waste fiber in this way, the material cost can be reduced, and the use of the waste material can contribute to the effective use of resources.

A raw material can be obtained by dispersing and mixing a thermoplastic resin binder in the fiber material and forming the fiber into a constant basis weight. The mixing amount of the thermoplastic resin binder is 25 to 35% by mass based on the whole raw material.
Is preferably set in the range. The mixing amount of the thermoplastic resin binder is preferably set in this range in order to obtain a cohesive force that sufficiently secures the plane tensile strength for the floor substrate while obtaining the soundproof performance.

By pressing the raw material thus obtained, a fiber mat for flooring can be obtained. Before the forming, the raw material is preheated through a preheating step. This preheating temperature is set to be equal to or higher than the melting point (melting temperature) of the raw thermoplastic resin binder.
The upper limit of the preheating temperature is not particularly set, but is preferably a temperature at which the fiber material is not deteriorated by the preheating, for example, 200 ° C. or less. The preheating is desirably performed so that the thermoplastic resin binder inside the raw material is sufficiently heated to the melting point or higher. For this purpose, when the raw material is placed in a heating atmosphere and preheated, if the raw material has a thickness of 15 to 20 mm, it is necessary to set a preheating time of about 25 to 30 minutes. 5 to 10 in case of forced heating such as feeding from one side and vacuuming from the other side
A preheating time of about a minute is sufficient.

Immediately after preheating the raw material in this way, the raw material is press-formed and the fiber material is pressed to a predetermined thickness, whereby a floor mat fiber mat can be obtained. The press molding may be performed by applying the hot pressure and the cold pressure in this order, or by applying only the cold pressure. When applying hot and cold pressure, set the heat pressure to 1
60 to 180 ° C, 0.2 to 0.3 MPa (2 to 3 kg /
cm ² ) Under the condition of 5 minutes or more, the cold pressure is 15 to 20 ° C.,
It is preferable to carry out the reaction under the conditions of 0.2 to 0.3 MPa ( ² to 3 kg / cm ² ) for 3 minutes or more. When only cold pressure is applied, the temperature is 15 to 20 ° C. and 0.2 to 0.3 MPa (2 to 3 MPa).
kg / cm ² ), preferably for 3 minutes or more. When press molding is performed only by cold pressure,
It is necessary that the thermoplastic resin binder of the raw material is sufficiently melted by preheating.

Here, when the raw material 3 is immediately press-molded in the order of hot and cold without preheating, the floor mat 4 is produced. The thermoplastic resin binder 2 is melted while being heated, and the thermoplastic resin binder 2 is solidified in a state where the fiber material 1 is thus compressed at the time of cold pressure, so that the space between the fiber materials 1 is reduced as shown in FIG. The dense state is fixed by the thermoplastic resin binder 2. Further, at the time of hot pressing, the thermoplastic resin binder 2 is heated and melted from the vicinity of the surface of the raw fabric 3, so that the floor mat 4 has a hard surface. For this reason, the floor mat fiber mat 4 may lose elasticity and may not be able to sufficiently exhibit soundproof performance.

On the other hand, as in the present invention, when the raw material 3 is preheated in the preheating step and then press-formed, the air between the fiber materials 1 is heated and expanded at the time of preheating, and the thermoplastic resin binder 2 is also used in the raw material 3. 1 is sufficiently heated to the inside of
As shown in FIG. 1A, a floor mat 4 having a three-dimensional structure with voids between the fiber materials 1 can be obtained. It can provide elasticity. In particular, when the preheating is performed by heating at a temperature equal to or higher than the melting point of the thermoplastic resin binder 2, the thermoplastic resin binder 2 is heated and contracted, so that the fiber materials 1 having a three-dimensional entanglement are easily bonded to each other, and the soundproof performance is improved. Necessary elasticity is more easily provided.

Therefore, the floor mats 4 according to the present invention are laid on a floor surface such as a slab 10 of a building and a floor board 5 is laid on the floor mats 4. In the material, the floor mat 4
It is possible to easily obtain an anti-vibration effect by reducing a spring constant per unit area of the device itself and a vibration-damping effect by the fiber material 1, thereby improving soundproof performance and improving walking sensation. Can be done.

FIG. 2 shows an example of a soundproof floor material.
In this example, a floor mat fiber mat 4 is placed on a slab 10.
Is laid, and a plurality of floor boards 5 are arranged and laid thereon to form a floor material. A large number of hemispherical embossed protrusions 11 are provided on the entire lower surface of the floor mat fiber mat 4 so that high soundproofing performance can be obtained. It is fixed to the fiber mat 4. Floorboard 5 is plywood, particle board,
It is formed of a wooden board such as a wood powder resin composite board, and a surface material such as a decorative veneer is adhered to the surface of the flooring material 5 as necessary. Adjacent floor material 5 is male 12 at the side edge.
And a female nut 13.

Here, the thermoplastic resin binder 2 used in the raw fabric 3 is not particularly limited, but it is preferable to use polyethylene, polypropylene, or a composite material of polyethylene and polypropylene.
In the composite material of polyethylene and polypropylene, the ratio of polyethylene to polypropylene is 30:70 to 7
A mass ratio of 0:30 is preferable, and a mass ratio of 50:50 is particularly preferable. As the composite material of polyethylene and polypropylene, in particular, a composite material of polyethylene and polypropylene formed into a fibrous form having a core-sheath structure in which the sheath is polyethylene 2a and the core is polypropylene 2b as shown in FIG. It is preferably used. When a composite material composed of polyethylene having a melting point of 130 ° C. and polypropylene having a melting point of 160 ° C. is used as the thermoplastic resin binder 2, preheating is performed at 180 ° C. which is higher than the higher melting point.
The polyethylene 2a forming the sheath is melted first, and the polypropylene 2b forming the core is melted while uniformly connecting the fiber materials 1 with the polyethylene 2a to form a thermoplastic resin binder. 2 melts and shrinks so that the fiber materials 1 can be point-bonded. Also, when a fibrous material is used as the thermoplastic resin binder 2, the thermoplastic resin binder 2 used when the raw material 3 is prepared by uniformly mixing the fibrous material 1 with the fibrous material 1 is compared to the powdered material. The escape is reduced and the yield is improved.

The floor base fiber mat 4 is formed from upper and lower two layers 4a and 4b by press-molding the two-layer raw fabric 3 into a mat, and the density of the lower layer 4a is equal to that of the upper layer 4b. It is formed to be higher than the density. By forming the floor base fiber mat 4 in two layers so that the density of the lower layer 4a is higher than the density of the upper layer 4b, the dynamic spring constant of the upper layer 4b is reduced to the dynamic spring constant of the lower layer 4a. Thus, the soundproof performance can be improved and the walking feeling can be enhanced. The density of the lower layer 4a and the upper layer 4b is such that the dynamic spring constant of the lower layer 4a is 2
３3 × 10 ⁶ N / m / m ² , dynamic spring constant of upper layer 4b is 4
It is preferable to set each so as to be 5 × 10 ⁶ N / m / m ² .

[0023]

Next, the present invention will be described specifically with reference to examples.

(Example 1) The raw material 3 for the upper layer and the raw material 3 for the lower layer, each having a basis weight of 800 g / m ² , with the composition shown in Table 1.
Was prepared. Here, in Table 1, as the thermoplastic resin binder 2, a fibrous sheath-core structure having a mass ratio of polyethylene (melting point 130 ° C.) to polypropylene (melting point 160 ° C.) of 50:50 as shown in FIG. 3 is used. Was.

Then, the raw material 3 for the upper layer and the raw material 3 for the lower layer were overlapped and heated in a heating furnace at 180 ° C. for 30 minutes to perform preheating. Thereafter, 0.3 MPa (3 k
g / cm ² ), hot pressing at 170 ° C. for 5 minutes, and then cold pressing at 0.3 MPa (3 kg / cm ² ) at 15 ° C. for 3 minutes to perform press molding, thereby forming the upper layer 4b and the lower layer 4b. The thickness of the laminated 4a is 10.0 mm
Was prepared. 11. A hemispherical embossed protrusion 11 having a diameter of 10 mmφ and a height of 1.5 mm is provided on the back surface of the lower layer 4 a of the floor mat 4.
The whole surface is processed at a pitch of 5 mm.

The floor plate 5 is formed by fusing a resin fiber-containing reinforced paper having a thickness of 0.1 mm to the surface of a 2.5 mm-thick wood-resin composite plate, and applying a 0.2 mm-thick decorative veneer to the surface. And the surface is finished by urethane coating. Then, the floorboard 5 is laid on the floor base fiber mat 4 and laminated to form a directly attached soundproofing floor material. Here, the floor base fiber mat 4 and the floor board 5
At the interface of the floor plate 5, the both ends of the floor plate 5 have an adhesive material having a width of 20 mm (Acrylic double-sided adhesive tape “No.
501k ") and fixed to the floor base fiber mat 4.

(Comparative Example 1) Without preheating, press molding was performed at a pressure of 0.3 MPa (3 kg / cm ² ) at 170 ° C. for 10 minutes, and at a pressure of 0.3 MPa (3 kg / cm ² ).
² ) The procedure was the same as that of Example 1 except that the fiber mat 4 was prepared under the conditions of 15 ° C. and a cold pressure of 3 minutes to produce a floor mat 4.

[0028]

[Table 1]

With respect to Example 1 and Comparative Example 1, the overall density of the floor mat 4, the densities of the upper layer 4 b and the lower layer 4 a, the plane tensile strength per 25 cm ^{2 of the} floor mat 4, and the stress during compression -The static spring constant calculated from the strain curve was measured, and the results are shown in Table 2. The performance of the soundproof flooring was measured, and the results are shown in Table 2. For comparison, Table 2 also shows the performance of the current LL-45 level soundproof flooring material (Comparative Example 2) shown in FIG. In FIG. 4, 16 is a plywood, 17 is a groove, 1
8 is a cushion material.

[0030]

[Table 2]

As can be seen from Table 2, it can be seen that by performing preheating, elasticity is imparted to the floor mat 4 and the soundproofing performance can be improved.

(Example 2) With the composition shown in Table 3, a raw material 3 for the upper layer and a raw material 3 for the lower layer having the same basis weight were produced.
Here, a raw material 3 for the lower layer was prepared by blending the lower layer in Table 3.

Next, the raw material 3 for the upper layer and the raw material 3 for the lower layer were individually heated in a heating furnace at 180 ° C. for 30 minutes to preheat. Thereafter, the raw material 3 for the upper layer and the raw material 3 for the lower layer are individually
a (3 kg / cm ² ), hot pressing at 170 ° C. for 5 minutes, then 0.3 MPa (3 kg / cm ² ), 15 ° C.
By performing press molding under cold pressure under the condition of 3 minutes, a fiber mat for the upper layer 4b having a thickness of 6 mm and a thickness of 4 m
Thus, a fiber mat for the lower layer 4a was obtained. And this upper layer 4
The fiber mat for b and the fiber mat for the lower layer 4a were bonded together with an acrylic adhesive ("No. 507" manufactured by Nitto Denko Corporation) to obtain a fiber mat 4 for floor base having a thickness of 10 mm. On the back surface of the lower layer 4a of the fiber mat 4 for floor substrate, an embossed protrusion 11 similar to that of the first embodiment is formed.

The floor panel 5 was the same as that of the first embodiment, and the other steps were carried out in the same manner as in the first embodiment to form a sound-insulating floor material directly attached.

Example 3 A raw material 3 for the upper layer and a raw material 3 for the lower layer having the same composition as in Table 3 were produced.
Here, a raw material 3 for the lower layer was prepared by blending the lower layer in Table 3. Except for this, a floor mat fiber mat 4 was produced in the same manner as in Example 2. However, in this case, the embossed protrusion was not provided on the floor mat 4. Then, using this fiber mat 4 for floor base, a sound-insulating floor material directly attached was formed in the same manner as in Example 2.

(Comparative Example 3) Without preheating, press forming was performed at a pressure of 0.3 MPa (3 kg / cm ² ) at 170 ° C. for 10 minutes, and at a pressure of 0.3 MPa (3 kg / cm ² ).
² ) The fiber mat for the upper layer 4b and the fiber mat for the lower layer 4a are formed at a cold pressure of 15 ° C. for 3 minutes to form the fiber mat 4 for the floor substrate. did. Others were the same as Example 2.

[0037]

[Table 3]

For Examples 2 and 3 and Comparative Example 3, the same performance measurements as described above were performed. Table 4 shows the results.

[0039]

[Table 4]

As can be seen from Table 4, it can be seen that by performing preheating, elasticity can be imparted to the floor mat 4 and the soundproofing performance can be improved. In addition, it can be seen that the provision of the embossed protrusions 11 on the lower surface of the floor mat 4 can improve the walking feeling by reducing the amount of sinking while having soundproofing performance.

[0041]

As described above, in the fiber mat for flooring according to the first aspect of the present invention, the raw material comprising the fibrous material and the thermoplastic resin binder is formed into a mat by press molding after passing through a preheating step. The air between the fiber materials is heated and expanded at the time of preheating, and the thermoplastic resin binder can be sufficiently heated to the inside of the raw material, and there is a three-dimensional structure entanglement with voids between the fiber materials. In this way, a floor mat can be obtained, and uniform elasticity can be imparted to the floor mat. Therefore, in the flooring material formed by laying the floorboard on the floor mat, the soundproofing performance can be improved and the walking feeling can be improved.

According to the second aspect of the present invention, the preheating temperature in the preheating step is set to be equal to or higher than the melting point of the thermoplastic resin binder. It is easy to perform point bonding between materials, and it is easier to impart elasticity required for soundproof performance.

According to the third aspect of the present invention, since waste fibers are used as the raw fiber material, low cost and effective use of waste materials can be realized.

According to a fourth aspect of the present invention, since the thermoplastic resin binder is a composite of polyethylene and polypropylene, when preheating is performed, first, polyethylene having a low melting point is melted first, and the polyethylene is used to separate the fiber material. Polypropylene with a high melting point melts while being connected uniformly, and the entire thermoplastic resin binder melts and shrinks, allowing point bonding between fiber materials, making it easier to impart the elasticity required for soundproofing performance. It is.

According to a fifth aspect of the present invention, a two-layer raw material is press-molded to form a mat, and a floor mat is prepared so that the lower layer has a higher density than the upper layer. The soundproof performance can be improved, and the walking feeling can be enhanced.

[Brief description of the drawings]

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 shows a floor mat fiber mat, and (a)
1 is a schematic diagram of an example of an embodiment of the present invention, and FIG. 1B is a schematic diagram of a conventional example.

FIG. 2 is a sectional view showing an example of an embodiment of a flooring material of the present invention.

FIG. 3 is an enlarged partially cutaway perspective view of a thermoplastic resin binder used in the first embodiment.

FIG. 4 is a sectional view of a conventional floor material.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Textile material 2 Thermoplastic resin binder 3 Raw material 4 Fiber mat for floor base 5 Floorboard

 ────────────────────────────────────────────────── ─── Continuing from the front page (72) Inventor Hiroaki Usui 1048 Kazuma Kadoma, Kadoma City, Osaka Prefecture F-term in Matsushita Electric Works, Ltd. 4F055 AA13 BA11 EA02 EA07 EA14 EA15 GA20 GA36 4F100 AK01A AK01B AK01C AK04A AK04AK07A AP02C AR00C BA02 BA03 BA07 BA10A BA10C BA26 CB05 DD01 DG01A DG01B DG10C EJ82C GB08 HB00C JA14A JA15B JB16A JB16B JH01 JL16A JL16B 4L047 AA08 AA21 AA27 AA28 AB02 BA09 CB09 BC03

Claims (6)

[Claims] 1. A fiber mat for flooring, wherein a raw material comprising a fiber material and a thermoplastic resin binder is formed into a mat by press molding after a preheating step. 2. The method according to claim 1, wherein the preheating temperature in the preheating step is equal to or higher than the melting point of the thermoplastic resin binder.
The floor mat fiber mat according to 1. 3. The floor mat according to claim 1, wherein the raw fiber material is waste fiber. 4. The fiber mat for floor base according to claim 1, wherein the thermoplastic resin binder is a composite of polyethylene and polypropylene. 5. The floor substrate according to claim 1, wherein a two-layer raw material is press-molded to form a mat, and the density of the lower layer is higher than the density of the upper layer. Fiber mat. 6. A flooring material comprising a floorboard laminated on the floor mat for fibers according to any one of claims 1 to 5.