JP2002309758A - Foam resin composite floor structure - Google Patents

Abstract

(57) [Abstract] [Problem] It has excellent vibration and sound insulation, load resistance, and earthquake resistance, does not require uneven adjustment of the floor slab, is easy to construct, and has good adhesion to the floor slab. The present invention provides a floor structure having high heat insulation and a comfortable walking feeling. A foam in which a polypropylene resin plate foam and a hard resin plate foam are laminated and adhered, and an elastic body is provided so as to penetrate at least the polypropylene resin plate foam. Structure for resin composite floor.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION The present invention relates to a construction of a floor of a building, which is arranged between a floor slab and a floor surface finishing material to support a load of the floor surface material and articles to be placed on the floor. The present invention relates to a floor structure having vibration-proof, sound-proof, heat-insulating, and earthquake-resistant properties.

[0002]

2. Description of the Related Art In a building floor called a dry-floating floor method, for example, on a concrete slab, an anti-vibration material is used as a floor material.
There is a floor flooring method in which metal or resin support legs having a base made of soundproof rubber or glass wool wrapped with rubber are attached, and a particle board, a laminating plate and the like are laid thereon and finished with a surface finishing material. Further, as one method of the dry floating floor method, there is a foamed polystyrene floor method in which a concrete slab and a foamed polystyrene floor panel are attached using a mortar dumpling or an adhesive and finished with a surface finishing material.

[0003] However, the above-mentioned flooring method has good sound insulation in the middle and high frequency ranges, but has insufficient sound insulation and heat insulation in the low frequency range, and requires support legs and a plurality of plate layers. As a result, construction is time-consuming and costly, and the earthquake resistance in the event of an earthquake is often insufficient.

Further, in the expanded polystyrene floor method,
When attaching concrete floor slabs and expanded polystyrene floor panels with mortar dumplings, there is an advantage that adjustment of the floor slab surface is not necessary, but when the room is heated in winter, condensation may occur on the floor slab surface. , Mold was easy to occur. In addition, due to the use of mortar dumplings, the adhesiveness to the low water-absorbing expanded polystyrene floor panel is small,
It has been sometimes difficult to use expanded polystyrene floor panels.

[0005] In addition, when the expanded polystyrene floor panel and the concrete floor slab are adhered with an adhesive, dew condensation hardly occurs and the heat insulating performance is high. Poor adhesion between polystyrene floor panel and floor slab surface. For this purpose, it is necessary to adjust strict smoothness by applying mortar to the floor slab surface or the like, which may deteriorate the workability.

For example, Japanese Patent Application Laid-Open No. 10-244609 describes
In the case where a soft foam sheet having a cushioning property as described above is combined with a hard foam plastic board and a surface layer material, when a heavy object is placed on the floor, it is not yet sufficient to prevent the sinking.

As described above, it is possible to easily lay a floor structure in any of the dry floating flooring methods, such as the laying floor method and the expanded polystyrene floor method, and also to withstand load, vibration and sound insulation, sound insulation, heat insulation, and earthquake resistance. At present, there is no floor structure that has sufficient properties and can be easily constructed at low cost.

[0008]

SUMMARY OF THE INVENTION The present invention provides a load bearing,
An object of the present invention is to provide a floor structure that is excellent in vibration and sound insulation, heat insulation, and earthquake resistance, does not require uneven land adjustment, and is easily constructed.

[0009]

Means for Solving the Problems The present inventors have solved the above-mentioned problems by using a floor structure made of a polypropylene resin plate foam, a hard resin plate foam, and an elastic material having small creep deformation. The present invention has been found.

That is, the present invention relates to a floor structure which is provided on a floor slab and supports a load by an article or the like on a floor when forming a floor of a building. A foamed resin composite floor structure in which a rigid resin plate-like foam is laminated and adhered, and an elastic body is provided so as to penetrate at least the polypropylene resin plate-like foam (claim 1).

[0011] The polypropylene resin plate foam is obtained by compressing a pre-compressed foam obtained by foaming a polypropylene resin 40 to 60 times so as to have a thickness of 5 to 90% of the original thickness. The foamed resin composite floor structure according to claim 1, wherein a structure having a density of 10 to 50 kg / m ³ , which is recovered to 30 to 100% of the original thickness after removal, is used (claim 2).

[0012] The rigid resin plate-like foam has a density of 10 to 50K.
g / m ³ and a thermal conductivity of 0.01 to 0.04 W
/ MK. The structure for a foamed resin composite floor according to claim 1, wherein the ratio is / mK (claim 3).

The foamed resin composite floor structure according to claim 1, wherein the dynamic spring constant at a load of 250 kg / m ² is 0.8 to 10 × 10 ⁶ N / m ^3. 4).

The foamed resin composite floor structure according to claim 1, wherein the residual strain in the first to the first time is 2.5 mm or less and the residual strain in the first to the second time is 1.5 mm or less. ).

[0015]

BEST MODE FOR CARRYING OUT THE INVENTION The inventors of the present invention have a flexible, sound-proof and vibration-proof polypropylene-based resin plate-like foam which also has heat insulation, an elastic body with high compressive strength, and excellent strength with excellent heat insulation. We found that a floor structure that combines a rigid resin plate-like foam that exerts the effect of enhancing the feeling has high vibration and sound insulation, load resistance, heat insulation, and earthquake resistance. When used as a structural body, it is not necessary to adjust the floor slabs for unevenness, making it easy to construct, and it is clear that it adheres to the floor slab, prevents dew condensation, and exhibits a comfortable walking feeling. As a result, the present invention has been completed.

That is, in the present invention, a polypropylene resin plate-like foam and a hard resin plate-like foam are laminated and adhered, and an elastic body is provided so as to penetrate at least the polypropylene resin plate-like foam. And a foamed resin composite floor structure.

Here, a specific manufacturing method and structure of the foamed resin composite floor structure of the present invention will be described.

First, a pre-compression foam obtained by foam-forming a polypropylene-based resin 40 to 60 times is obtained. As the polypropylene-based resin, a resin obtained by melt-mixing a polypropylene resin having a linear molecular structure with a radical polymerization initiator and a monomer, or a resin having a foaming property, such as one subjected to an electron beam irradiation treatment, is used. be able to. Further, up to 40% by weight of a resin such as polystyrene or polyethylene, a foam nucleating agent, etc. can be blended with the polypropylene resin within a range not impairing its flexibility, vibration and sound insulation, heat insulation and the like.

As a method for foaming the polypropylene resin, it is possible to use a method such as an extrusion foam molding method or a bead foam molding method, and the shape is not particularly limited. Preferably, a prefoam is obtained.

Then, the foam before compression obtained in this way is deformed by applying a compressive load in order to further enhance the flexibility, vibration-proof / sound-proofing and heat-insulating properties. A resin-based plate-like foam is obtained.
The foam before compression is compressed to 5 to 90% of the original thickness, preferably 20 to 80%, and then 30 to 100% of the original thickness after removal of the compression load, preferably Recover to 50-95%. The compression method is not particularly limited, and examples thereof include a method of continuously compressing with a roll or a belt, and a method of compressing in a batch manner with a press or the like. Further, the density of the polypropylene-based resin foam of the present invention is 10 to 50 kg / m ³ . If the density is 10 kg / cm ³ or less, it is too soft to obtain sufficient strength to support a load, and if the density is 50 kg / cm ³ or more, sufficient vibration / sound insulation performance cannot be obtained. In addition, the flexibility at the time of construction is insufficient, and the floor slab cannot cope with irregularities.

The rigid resin foam may be laminated and adhered to the polypropylene resin foam, and is usually a polystyrene resin foam, a rigid polyurethane resin foam, a rigid polyvinyl chloride resin foam, or the like. It is a rigid foam composed of:

The method of laminating and bonding the polypropylene resin foam and the hard resin foam is not particularly limited.

If the laminating / adhering method is exemplified, when the rigid resin plate-like foam is a polystyrene resin foam,
A method in which a polystyrene resin is foamed and molded into a plate shape by a method such as an extrusion foam molding method or a bead foam molding method, and this is bonded to a polypropylene resin plate foam using an adhesive or a double-sided tape-like material. Can be

When the rigid resin plate-like foam is a rigid polyurethane resin foam, the plate-shaped foamed rigid polyurethane resin foam is applied to the polypropylene resin plate-like foam with an adhesive or a double-sided tape. A rigid polyurethane-based resin foam is formed by a method in which the polyol component and the isocyanate component are directly mixed and sprayed onto the polypropylene-based resin plate-like foam, and the surface is formed during the foaming process. Or a method of laminating and bonding a polyurethane resin foam having a smooth surface by mechanically slicing after foaming is completed.

Further, when the rigid resin plate-like foam is made into a rigid polyurethane-based resin foam, a continuous laminating / adhering method can be used as shown in FIG. That is,
While continuously moving the face material 1 such as kraft paper, the urethane undiluted solution 2 is discharged onto the upper surface of the face material 1 by the discharge device 3 to foam it. On the other hand, the polypropylene-based resin plate-like foam 5 is transported toward the double conveyor 6 by the transport conveyor 4. The face material may be turned upside down during the feeding, and a method may be employed in which the foaming hard urethane-based foam formed on the face material is heated and simultaneously self-adhered to the polypropylene-based resin plate-like foam. .

The density of the hard resin plate-like foam is 10 to 50K.
g / m ³ , and if it is 10 Kg / m ³ or less, sufficient strength cannot be obtained when the floating floor layer is formed, and 50 kg / m ³ or less.
^In the case of ³ or more, the heat insulation becomes insufficient, and further, adverse effects such as a poor walking sensation occur. Further, the thermal conductivity of the hard resin plate-like foam is 0.01 to 0.04 W / mK.
When it is 0.04 W / mK or more, sufficient heat insulation cannot be exhibited.

The method of attaching the elastic body of the present invention is not particularly limited, but it is necessary that the elastic body is disposed so as to penetrate at least the polypropylene resin foam plate. As a method of attaching the elastic body, for example,
There is a method in which a hole is formed in the polypropylene-based resin foam before bonding, through which an elastic body is placed, and then the hard resin foam is laminated and bonded. Furthermore, after laminating and bonding the polypropylene resin foam and the hard resin plate foam, a hole is made from the surface of the polypropylene resin plate foam, and the polypropylene resin plate foam is penetrated there. A method of arranging an elastic body is described. Further, the elastic body penetrated the polypropylene-based resin plate-like foam, and further opened a hole to a portion of the hard resin plate-like foam, so that the thickness of the hard resin plate-like foam was 0 to 0.
Elastic bodies can be placed up to 50%.

The elastic material used in the present invention may be any material as long as it has a smaller creep deformation than the above-mentioned polypropylene resin plate foam. For example, natural rubber, neoprene rubber, coil springs, and the like can be used, but those made of natural rubber are preferable because they are inexpensive.

The shape of the elastic body is not particularly limited, and various shapes can be selected, such as a columnar shape, a polygonal columnar shape, and a hemispherical shape having one or both ends of the columnar shape. it can.

There is no particular limitation on the ratio of the elastic body to the laminated and bonded polypropylene-based resin plate-like foam and hard resin plate-like foam, but preferably the volume ratio is 0.00.
1 to 50% by volume, more preferably load bearing capacity,
0.1 to 25Vo in terms of easy vibration and sound insulation and heat insulation
1%.

The foamed resin composite floor structure of the present invention has a dynamic spring constant of 0.8 to 10 at a load of 250 kg / m ² .
× 10 ⁶ N / m ^3.
A structure having soundproof performance can be obtained.

The residual strain of the product of the present invention in the 0th to 1st time is 2.5 mm or less, and the residual strain in the 1st to 2nd time is 1.5 mm or less. More preferably, the first to second residual strain is 1.0 mm or less, and the first to second residual strain is 0.3 mm or less. As a result, a structure excellent in load resistance can be obtained.

The thickness of the product of the present invention is 10 to 200 mm, preferably 20 to 100 mm. The ratio of the thickness of the polypropylene-based resin foam or the rigid resin foam to the thickness of the product of the present invention is 20 to 80%, preferably 50%.

An example of the construction method and procedure when the foamed resin composite floor structure of the present invention is used for a floating floor method will be described. In the product of the present invention, a surface of a polypropylene-based resin plate-like foam having flexibility is laid on a concrete floor slab. As a result, even if there is an uneven portion on the floor slab surface, the portion can be filled with the polypropylene-based resin plate-like foam, so that it is not necessary to adjust the unevenness, dew condensation can be prevented, and high heat insulation can be secured. it can. Note that the floor slab surface and the product of the present invention may be fixed and laid using an adhesive or the like in order to secure sufficient heat insulation and earthquake resistance, but, for example, nails, tacks, and screws may be used to improve the working environment. The effect of the present invention is not impaired even if physical fixing means such as are used. The product of the present invention may be fixed and laid on a floor slab, and may be subjected to a surface finishing material such as a flooring board or a tatami mat.
The surface finishing material may be applied after being pasted on a particle board or plywood. Between the product of the present invention and the disposing or surface finishing material, such as using an adhesive or a physical method,
It can be fixed in any way.

Next, the present invention will be described based on examples and comparative examples, but the present invention is not limited to only these examples. (Embodiment) FIG. 2 schematically shows a floor structure when a foamed resin composite floor structure of the present invention is used in a floating floor method.
On the concrete floor slab A, the product of the present invention comprising a polypropylene resin plate-like foam B, a polystyrene resin foam C as a hard resin plate-like foam, and an elastic body D is laid, and further laminated as a surface finishing material This shows a state where the flooring board E is installed. In the illustrated example, the elastic body has a columnar shape and is arranged so as to penetrate the polypropylene resin plate-like foam. The effect of the present invention is not impaired even if the concrete floor slab and the product of the present invention or the product of the present invention and the laminated flooring board are fixed and bonded. By constructing the product of the present invention from a polypropylene-based resin plate-like foam, a hard resin plate-like foam, and an elastic body, it is possible to easily lay the floor slab in close contact with the floor slab and prevent dew condensation on the floor slab. A floating floor structure that has high heat insulation, withstands heavy loads, has excellent vibration and sound insulation performance, and exhibits a comfortable walking sensation can be obtained.

The density of the polypropylene-based resin plate-like foam and the rigid resin plate-like foam constituting the resin composite floor structure of the present invention and the thermal conductivity of the hard resin plate-like foam were evaluated by the following methods. Further, the dynamic spring constant as a measure of vibration and sound insulation performance of the resin composite floor structure and the residual strain as a measure of load bearing performance were evaluated by the following methods.

Density of plate-like foam: 20 × from the plate-like foam of polypropylene or hard resin plate-like foam of the present invention.
A small piece of 20 × 20 mm was cut out and the weight was measured to calculate.

Thermal conductivity of rigid resin plate-like foam: A 200 × 200 × 20 mm rigid resin plate-like foam was cut out from the product of the present invention except for the skin portion, and a thermal conductivity measuring device (Eikoseiki Co., Ltd.) was used in accordance with JIS A1412. HC-072) was used, and the measurement conditions were 250 kg / m ² and an average temperature of 2 under a load.
The thermal conductivity at 0 ° C. was measured.

Dynamic spring constant: The product of the present invention is JIS A63
Based on the measurement method specified in 22, the damped oscillation waveform is measured, the period is read from three adjacent peaks of the damped oscillation waveform that has become free oscillation, and the natural frequency is obtained from the average value to determine the natural frequency. Constants were calculated. The shape of the product of the present invention used for the measurement is such that a hole of 60 mm in diameter is cut out at the center of a polypropylene resin plate-like foam of 450 mm square and 25 mm thick, and a cylindrical elastic body made of natural rubber 25 mm thick ( (Hardness 60 degrees) One piece is arranged, and further 450 mm
A rigid resin plate-like foam having a square shape and a thickness of 25 mm was used.

Residual strain: The product of the present invention is JIS A632
Based on the measurement method specified in 2, load 100 kg / m
After the reference to the position of the pressing plate after pressurized for 5 minutes with ^2, was pressurized then 5000 kg / cm ² in pressure for 5 minutes, the load 1
The strain was removed up to 00 kg / m ^2, and the strain after elapse of 5 minutes was defined as 0 to 1 residual strain. By repeating the same process, the amount of increase from 0 to 1 residual strain was defined as 1 to 2 residual strains. The shape of the product of the present invention used for the measurement, the shape of the product of the present invention used for the measurement is 450 mm square, cut out a hole with a diameter of 60 mm in the center of a 25 mm thick polypropylene resin plate foam, 25mm thick cylindrical
The elastic body (hardness: 60 degrees) made of a natural rubber was placed, and a 450 mm square, 25 mm thick hard resin plate-like foam was bonded to the elastic body.

Table 1 shows the densities of the polypropylene-based resin plate-like foams after the compression treatment used in Examples and Comparative Examples, as well as the material, thermal conductivity, and density of the hard resin plate-like foams. In the compression treatment of the polypropylene resin plate-like foam, the foam was compressed to 75% of the thickness of the foam, maintained for 15 minutes, and then cured and recovered to 70% before compression.

[0042]

[Table 1] Table 2 shows the vibration and sound insulation performance determined from the dynamic spring constant, the load resistance performance determined from the residual strain, and the heat insulation performance for the examples and comparative examples. From Table 2, it can be seen that the products of the present invention are all excellent in vibration and sound insulation performance, and have high load-bearing performance and heat insulation performance.

[0043]

[Table 2]

[0044]

According to the present invention, excellent vibration and sound insulation properties
Floor that has load resistance and earthquake resistance, does not require uneven adjustment of the floor slab, is easy to construct, and has high insulation properties because it can be in close contact with the floor slab, and yet exhibits a comfortable walking feeling Structure can be provided.

[Brief description of the drawings]

FIG. 1 is a production example of a laminate of a polypropylene-based resin foam and a hard foam.

FIG. 2 shows an example of a floating floor structure using a foamed resin composite floor structure.

[Explanation of Signs] 1 face material 2 urethane stock solution 3 discharge machine 4 conveyor 5 polypropylene resin plate foam 6 double conveyor A concrete floor slab B polypropylene resin plate foam C polystyrene resin foam D elastic body E Laminated flooring board

──────────────────────────────────────────────────続 き Continued on the front page (51) Int.Cl. ⁷ Identification symbol FI Theme coat ゛ (Reference) E04F 15/20 E04F 15/20

Claims (5)

[Claims] 1. A foamed resin in which a polypropylene resin plate foam and a hard resin plate foam are laminated and adhered, and an elastic body is disposed at least through the polypropylene resin plate foam. Composite floor structure. 2. A pre-compressed foam obtained by foaming a polypropylene-based resin 40 to 60 times with a polypropylene-based resin plate-like foam so as to have a thickness of 5 to 90% of the original thickness, and then compressing. consisting allowed to recover 30 to 100 percent of the original thickness with the exception of the load, foamed resin composite floor construction according to claim 1, wherein with one of density 10 to 50 kg / ^{m 3.} 3. The rigid resin plate-like foam has a density of 10 to 50.
Kg / m ³ and a thermal conductivity of 0.01 to 0.04
The foamed resin composite floor structure according to claim 1, wherein the ratio is W / mK. 4. The foam resin composite floor structure according to claim 1, wherein the dynamic spring constant at a load of 250 kg / m ² is 0.8 to 10 × 10 ⁶ N / m ³ . 5. The foamed resin composite floor structure according to claim 1, wherein the first to second residual strains are 2.5 mm or less, and the first to second residual strains are 1.5 mm or less.