JP2004036324A - Underlaid cushion sheet - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a lightweight underlaid cushion sheet having excellent flexibility at low temperatures and excellent adhesive property, and easy to manufacture. <P>SOLUTION: The underlaid cushion sheet is provided with a cushion layer 12 having an overlaid face overlaid on a substrate 20, and a foundation 11 having an application formation face forming a waterproof application film by application of a liquid-like waterproof material on a reverse side to the overlaid face. The cushion layer 12 is made of a synthetic resin foaming body, and ventilation grooves 14 are reticulately extended and formed on the whole face in the form of meshes. Sol consisting of a synthetic resin is applied on the foundation 11, and heated and foamed to provide the underlaid cushion sheet 10 forming the cushion layer 12. The cushion layer 12 is heated, foamed and formed, and the ventilation grooves 14 are reticulately extended and formed by a roll with a mold on the whole laid face of the cushion layer 12 in the form of the meshes. <P>COPYRIGHT: (C)2004,JPO

Description

[0001]
TECHNICAL FIELD OF THE INVENTION
TECHNICAL FIELD The present invention relates to an underlay buffer sheet laid on a base material made of concrete or the like before being sprayed or poured with a resin waterproof material at a waterproof site of the base material made of concrete or the like.
[0002]
[Prior art]
2. Description of the Related Art Conventionally, in waterproofing work on a structure requiring waterproofing, such as a floor surface (basement) made of concrete or the like on the roof of a building, a waterproof sheet formed into a target shape such as a belt-like shape or a rectangular shape (hereinafter referred to as a “submersion buffer sheet”). Is laid on a floor or the like and adhered, and a resin waterproofing material is sprayed or cast on the underlay buffer sheet to form a waterproof coating film. The underlay cushioning sheet not only has a waterproof effect, but also has a function of cushioning cracks on the floor surface caused by shrinkage of the concrete and external stress or the movement thereof.
As the subbing buffer sheet, those formed mainly of polyolefin, vinyl chloride, vulcanized rubber, asphalt, and rubber asphalt are generally used.
[0003]
[Problems to be solved by the invention]
However, since the specific gravity of the material of the conventional sub-buffer sheet is 1.0 or more, if the length of the sub-buffer sheet wound in a roll shape is 25 m or more, the work of waterproofing construction requires weight. He had to carry a roll of 25kg or more of the submersion buffer sheet.
In addition, among the conventional cushioning sheets, the cushioning sheet mainly made of asphalt or rubber asphalt becomes hard at low temperatures such as in winter and loses its flexibility and follows the unevenness of the base. And it became difficult to deform. For this reason, the conventional underlay buffer sheet sometimes causes lifting or peeling at the interface with the base.
[0004]
Furthermore, since the conventional submersion buffer sheet is manufactured by calender molding or extrusion molding, there is a problem that the manufacturing equipment becomes large and the manufacturing cost increases.
Further, in the case where the underlay buffer sheet is manufactured by calendering, a lubricant is added to the material of the underlay buffer sheet in order to enhance the releasability of the underlay buffer sheet and the calender roll. The presence of this lubricant has been a cause of deteriorating the adhesiveness between the base and the buffer sheet.
[0005]
The present invention has been made in view of the above circumstances, and has as its object to provide a lightweight cushioning sheet excellent in flexibility at low temperatures, easy to manufacture, and excellent in adhesiveness.
[0006]
[Means for Solving the Problems]
The present invention includes a buffer layer having a superimposed surface that is superimposed on a base, and a base fabric having a coating film forming surface on which a waterproof coating film is formed by applying a liquid waterproof material on a side opposite to the superposed surface. A cushioning layer, wherein the cushioning layer is made of a synthetic resin foam, and ventilation grooves are formed to extend in a mesh pattern on the entire surface of the overlapping surface.
The present invention provides a submersion buffer sheet in which a sol made of a synthetic resin is applied on the base fabric, and the sol is heated and foamed to form the buffer layer.
The present invention provides a submersion buffer sheet in which the buffer layer is heated and foamed, and at the same time, ventilation grooves are formed in a mesh-like manner on the entire surface of the buffer layer by using a mold roll. .
[0007]
BEST MODE FOR CARRYING OUT THE INVENTION
Hereinafter, the present invention will be described in detail.
FIG. 1 is a schematic perspective view showing an embodiment of the underlay buffer sheet of the present invention and an example of laying the underlay buffer sheet. FIG. 2 is a schematic perspective view in which a part of the underlay cushioning sheet of the present invention is enlarged.
The underlay buffer sheet 10 of this embodiment is a laminated sheet in which a buffer layer 12 made of a synthetic resin foam having waterproofness is laminated on a base cloth 11.
[0008]
The lower cushioning sheet 10 is laid so that the buffer layer 12 faces the foundation 20 made of concrete or the like so as to cover the foundation 20. In FIG. 1, the upper surface of the base 20 forms a substantially horizontal floor surface, and is waterproofed by joining a plurality of sub-buffer sheets 10 laid on the base 20. Further, a waterproof coating is formed on the laid sub-buffer buffer sheet 10 by spraying, applying, or the like, of a liquid waterproof material made of a room-temperature-curable resin such as urethane resin. The sheet 10 forms a waterproof layer.
Further, the buffer cushioning sheet 10 is fixed to the base 20 by anchor pins or the like that penetrate the sheet and are driven into the base 20. As the base cloth 11 and the buffer layer 12, those through which anchor pins can be penetrated are employed.
[0009]
A large number of projections 13 are formed on the lower surface side of the buffer layer 12 facing the base 20 (the lower surface side of the lower cushioning buffer sheet 10, hereinafter also referred to as “overlapping surface”). The formed ventilation groove 14 is formed so as to extend in a mesh pattern on the entire lower surface of the buffer layer 12. The protrusions 13 and the ventilation grooves 14 are formed, for example, by pressing the roll mold against the buffer layer 12 when the submersion buffer sheet 10 is roll-formed using a mold roll.
In FIG. 1, the protruding portion 13 has a tortoiseshell shape. However, the present invention is not limited thereto, and the shape of the protruding portion 13 is circular, rectangular, or rhombic. Various shapes such as can be adopted.
[0010]
As the base cloth 11, for example, a woven cloth (cloth), a non-woven cloth (cloth), a net cloth (net-like cloth), or the like formed of a single fiber or a bundle of fibers in a cloth or net shape, or a plurality of these types A combination is used.
In addition, it is preferable that the thickness of the base fabric 11 is not too large, from the viewpoint of facilitating the buffer layer 12 following irregularities of the base 20. Specifically, the thickness of the base cloth 11 is preferably from 0.1 to 0.5 mm, more preferably from 0.2 to 0.3 mm.
[0011]
The fibers constituting the base fabric 11 include natural fibers such as cotton and hemp, synthetic fibers including thermoplastic resins such as polyester, nylon, polypropylene, polyethylene, acrylic, and ethylene-vinyl acetate copolymer, glass fibers, and carbon fibers. Inorganic fibers such as fibers are used.
Among these, the base fabric 11 made of a polyester nonwoven fabric is preferably used from the viewpoint of securing the adhesiveness with the buffer layer 12 and the waterproof coating film.
[0012]
The buffer layer 12 is made of a synthetic resin foam having closed cells, and its thickness is preferably about 1.0 to 3.0 mm, more preferably about 1.5 mm.
In addition, the lower limit of the thickness of the buffer layer 12 is for securing the adhesive force with the waterproof coating film, and the upper limit is limited by the weight of the subbed buffer sheet 10, workability, and the like.
[0013]
The buffer layer 12 is composed of 100 parts by weight of a thermoplastic resin, 80 to 120 parts by weight of a plasticizer, 90 to 130 parts by weight of a filler, 3 to 7 parts by weight of a foaming agent, and 2 to 5 parts by weight of a pigment. It is a resin foam. The preferable mixing ratio of the various materials forming the buffer layer 12 is 100 parts by weight of the thermoplastic resin, 110 parts by weight of the plasticizer, 120 parts by weight of the filler, 6 parts by weight of the foaming agent, and 5 parts by weight of the pigment.
[0014]
As the thermoplastic resin forming the buffer layer 12, a sol-forming powder such as an acrylic resin or a polyvinyl chloride resin is used.
The plasticizer is compounded to improve the plasticity of the thermoplastic resin forming the buffer layer 12 and to provide flexibility. For example, dibutyl terephthalate, dioctyl phthalate (DOP), diisodecyl phthalate (DIDP), diisononyl phthalate (DINP), diundecyl phthalate, trioctyl trimellitate, triisooctyl trimellitate, alkyl esters of aromatic polybasic acids such as pyromet, dibutyl adipate, dioctyl adipate, disiononyl adipate, dibutyl azelate, dioctyl azelate And alkyl esters of fatty acid polybasic acids such as diisononyl azelate.
[0015]
Examples of the filler include inorganic fillers such as calcium carbonate, titanium oxide, aluminum oxide, aluminum hydroxide, carbon black, and talc. By blending such an inorganic filler, the elastic modulus and thermal stability of the buffer layer 12 are improved.
As the foaming agent, those capable of forming an independent porous layer at a low temperature and in a short time are preferably used.For example, the surface of a polymer hollow microsphere containing polyacrylonitrile as a main component is formed of calcium carbonate, talc, titanium, or the like. Azodicarbamide, which is a thermally expandable microsphere coated with a powder, is used.
As the pigment, a commonly used inorganic pigment or organic pigment can be used.
[0016]
The expansion ratio of the buffer layer 12 made of such a material is preferably about 1.5 to 3.0 times, and more preferably about 2.0 to 2.5 times.
Further, the bulk density of the buffer layer 12 is preferably about 0.5 to 1.0 g / cm ³ .
[0017]
The weight per unit surface property of the underlay buffer sheet 10 composed of such a buffer layer 12 is the same as that of the conventional unfoamed polyolefin, vinyl chloride, vulcanized rubber, asphalt, rubber asphalt, or the like. Is about half of the weight per unit area. Therefore, the underlay cushioning sheet 10 is extremely lightweight and has excellent workability when laying.
Further, since the buffer layer 12 has elasticity, in a state where the buffer layer 12 is laid on the base 20, for example, an impact generated by walking of a person on the underlay buffer sheet 10 is absorbed by elastic deformation of the projections 13. Can be buffered. The ventilation groove 14 also functions as a space for facilitating the elastic deformation of the projection 13.
[0018]
Furthermore, the buffer layer 12 is not hardened even in a low-temperature environment such as winter, and its flexibility is not impaired. Therefore, even in a low-temperature environment, the underlay buffer sheet 10 deforms following the irregularities of the base 20. Therefore, the lower cushioning buffer sheet 10 has a high degree of close contact with the base 20, and does not float or peel off at the interface with the base 20.
[0019]
In order to manufacture such an underlay buffer sheet 10, a sol composed of a mixture of a thermoplastic resin powder, a plasticizer, a filler, a foaming agent, and a pigment is coated on a base cloth 11 with a bar coater or the like. After coating, the sol is heated to a temperature of about 140 to 220 ° C. to foam and form the buffer layer 12. Simultaneously with the foaming of the buffer layer 12, the molds of the protrusions 13 and the ventilation grooves 14 were formed on the entire surface (overlapping surface) of the buffer layer 12 opposite to the side adhered to the base cloth 11. The mold roll is pressed into contact, and a ventilation groove 14 extending in a mesh shape is formed on the entire surface of the buffer layer 12 opposite to the side adhered to the base cloth 11, thereby obtaining the underlay buffer sheet 10. .
As described above, the underlay buffer sheet 10 is formed by applying the sol of the material for forming the buffer layer 12 to the base cloth 11, heating the sol, forming the buffer layer 12 by foaming, and forming a roll on the surface of the buffer layer 12 with a mold. Can be easily manufactured by pressing. Therefore, unlike a conventional underlay buffer sheet, a large-scale production facility such as an asphalt dissolution facility, an extruder, and a calender roll is not required, and the production cost can be significantly reduced as compared with the related art.
[0020]
Since the submersion buffer sheet 10 manufactured in this manner has good releasability from a molding die, a component for enhancing releasability such as a lubricant is added in advance to the material forming the buffer layer 12. No need. Therefore, when the underlay buffer sheet 10 is bonded to the base 20 using an adhesive or the like, the adhesion between the two is good.
[0021]
Hereinafter, a method for laying the sub cushioning sheet according to this embodiment will be described.
FIG. 3 is a schematic cross-sectional view showing a waterproof structure using the underlay cushioning sheet 10.
In the waterproofing construction method using the underlay cushioning sheet of this embodiment, first, irregularities and irregularities on the surface of the base 20 are ground as necessary to adjust the base, and then the surface of the base 20 is cleaned. , Dust and foreign matter are removed.
Next, a primer for primer (not shown) is applied on the cleaned primer 20.
The primer for the base applied on the base 20 is for increasing the adhesiveness of the subbing buffer sheet 10 to the base 20, and since the base 20 may be wet, it can be adhered to a wet surface. Is preferred. As such a primer for the base, a resin that does not substantially foam at a moisture level of moisture is used, and a room-temperature-curable urethane-based resin used as an adhesive for wet surface adhesion, an epoxy resin, and a commonly used resin are used. A solvent such as chloroprene or acrylic, or a primer such as an emulsion is preferably used, and may be a one-part curing type or a two-part curing type.
As a method of applying the primer for the base on the base 20, a method of spraying with a spray gun or a method of applying with a roller, a brush or a rake is preferable.
Note that, depending on the surface condition of the base 20, the application of the primer for the base must be omitted.
[0022]
Next, the underlay buffer sheet 10 is laid on the base 20. The lower cushioning sheet 10 is fixed to the substrate 20 by anchor pins or the like that penetrate the sheet and are driven into the substrate 20. As the base cloth 11 and the buffer layer 12, those through which anchor pins can be penetrated are employed.
[0023]
Next, a liquid waterproof material made of a room-temperature-curable resin (or a two-component curable resin) is applied on the submersion buffer sheet 10, and a waterproof coating film 30 is applied. Thereby, excellent waterproofness can be ensured on the entire floor surface on the foundation 20.
As the liquid waterproofing material made of the room temperature curable resin (or the two-part curable resin) that forms the waterproof coating film 30, an ultra-fast curable room temperature curable resin is preferably used, and specifically, a polyurethane resin, a polyurea, and the like. Resins, epoxy resins, polyester resins, polyvinyl ester resins, polymethyl methacrylate resins, and the like are used. Among these room-temperature curable resins, it is preferable to use a super-rapid curable polyurethane resin or polyurea resin. As the ultra-fast curing polyurethane resin, Evercoat SP100, Evercoat SP200, Pramax 500, Pramax 1000, Pramax 2000, and as the polyurea resin, Pramax 5000 (all trade names, Daiflex Corporation) Manufactured).
Further, as the room temperature curable resin forming the waterproof coating film 30, a resin having flexibility is preferable. If the waterproof coating film 30 is formed of a flexible, room-temperature-curable resin, the waterproof coating film 30 is deformed following deformation due to bending of the base 20, etc., and is not easily broken.
[0024]
As a method of applying the waterproof coating film 30 on the buffer cushion sheet 10, a method of spraying the above-mentioned room temperature curable resin with a spray gun, or a method of applying with a roller, a trowel and a lake is preferable. For example, when a polyurethane-based resin is used as the room-temperature curable resin, in the case of spraying with a spray gun, a curable mixture obtained by previously mixing an isocyanate component and a polyol component is sprayed with a spray gun to form a waterproof coating film 30. Alternatively, the mixture obtained by separately supplying the isocyanate component and the polyol component to the spray gun and mixing in the spray gun is sprayed onto the subbing buffer sheet 10 to form the waterproof coating film 30. Is also good. In the application using a roller or the like, a curable mixture obtained by previously mixing an isocyanate component and a polyol component may be applied onto the subbing buffer sheet 10.
[0025]
This waterproof coating film 30 may be a dense layer, a foamed layer containing closed cells, or a layer made of a mortar of a room temperature curable resin. If the waterproof coating film 30 is to be a foamed layer, the foaming gas may be mixed with the curable mixture, and if the waterproof coating 30 is to be formed of a mortar of room temperature curable resin, the aggregate may be mixed with the curable mixture. Good.
[0026]
By the way, in the application of the waterproof coating film 30, an indication may be provided on the surface of the undercoat cushioning sheet 10 by printing or the like in order to provide an indication of the applied amount of the liquid waterproof material, that is, the coating thickness. By using a translucent liquid waterproof material and confirming the degree of concealment of the display provided on the surface of the submersion buffer sheet 10, a desired film thickness is secured. In the state where the display can be visually checked through the coating of the liquid waterproofing material, the coating thickness of the liquid waterproofing material is insufficient. It is preferable to obtain the required coating thickness by burying and concealing. This can prevent the liquid waterproof material coating film from being extremely thin, thereby ensuring waterproofness over the entire floor surface on the base 20.
Indications provided on the surface of the buffer cushioning sheet 10 can be formed by printing other than printing, for example, by attaching an adhesive tape or spraying paint.
[0027]
【The invention's effect】
As described above, the underlay buffer sheet of the present invention has a buffer layer having an overlapping surface overlaid on a base, and a waterproof coating film formed by applying a liquid waterproof material on the opposite side to the overlapping surface. A base cloth having a coating film forming surface, the buffer layer is made of a synthetic resin foam, and since the ventilation grooves are formed to extend in a mesh pattern over the entire overlapping surface, it is extremely lightweight, Excellent workability during laying.
In addition, the buffer layer of the underlay buffer sheet of the present invention does not become hard even in a low-temperature environment such as winter, and the flexibility is not impaired. , And the close contact with the base is enhanced, and no lifting or separation occurs at the interface with the base.
Furthermore, unlike the conventional underlay buffer sheet of the present invention, the large-scale production equipment such as asphalt dissolution equipment, an extruder, and a calender roll is not required unlike the conventional underlay buffer sheet, so that the production cost is greatly reduced. can do.
And since the underlay buffer sheet of the present invention has good releasability from a molding die or the like, it is not necessary to add a component which enhances releasability such as a lubricant in advance to the material forming the buffer layer. Therefore, the adhesiveness between the underlay buffer sheet of the present invention and the base is good.
[Brief description of the drawings]
FIG. 1 is a schematic perspective view showing an embodiment of a buffer cushioning sheet according to the present invention and an example of laying the cushioning cushioning sheet.
FIG. 2 is a schematic perspective view in which a part of the sub cushioning sheet of the present invention is enlarged.
FIG. 3 is a schematic cross-sectional view showing a waterproof structure using the underlay buffer sheet of the present invention.
[Explanation of symbols]
DESCRIPTION OF SYMBOLS 10 ... buffer cushion sheet, 11 ... base cloth, 12 ... buffer layer, 13 ... protrusion, 14 ... ventilation groove, 20 ... groundwork, 30 ... waterproof coating

Claims (3)

A subbing buffer comprising: a buffer layer having an overlapping surface to be overlaid on a base; and a base fabric having a coating film forming surface on a side opposite to the overlapping surface, on which a waterproof coating film is formed by applying a liquid waterproof material. A sheet,
The underlayer cushioning sheet according to claim 1, wherein the buffer layer is made of a synthetic resin foam, and ventilation grooves are formed in a net-like manner on the entire surface of the overlapped surface. The underlay buffer sheet according to claim 1, wherein a sol made of a synthetic resin is applied on the base cloth, and the sol is heated and foamed to form the buffer layer. 3. A ventilation groove is formed in a mesh-like manner by means of a mold roll over the entire surface of the buffer layer at the same time that the buffer layer is heated and foamed. Underlay buffer sheet.

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