JP2004058367A - Soundproofing sheet made from polyolefin - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a soundproofing sheet made from a polyolefin which is lightweight, has soundproofing capacity and flexibility and is excellent in weather resistance and flame resistance. <P>SOLUTION: The soundproofing sheet made from the polyolefin is obtained by providing laminate layers each made of a polyolefin containing a flame retardant and a weather resistance agent or particularly a polyolefin thermoplastic elastomer on both surfaces of a laminated obtained by laminating two woven fabrics each made of oriented yarns of polyolefin resin via adhesive layers and forming a ruggedness or particularly a ruggedness having a difference of rugged heights of 100 μm or more on at least one laminate layer. <P>COPYRIGHT: (C)2004,JPO

Description

[0001]
TECHNICAL FIELD OF THE INVENTION
The present invention relates to a polyolefin soundproof sheet, and more particularly to a weatherproof and flameproof soundproof sheet used for a scaffold at a construction site.
[0002]
[Prior art]
Conventionally, as a work sheet stretched around a building construction site such as a building, a so-called PVC sheet in which polyvinyl chloride is laminated on a woven or knitted fabric using filament yarn such as polyester or nylon is generally used. I have. In order to suppress the noise from the construction site from leaking to the outside as much as possible, an inorganic filler was added to the PVC sheet to increase the specific gravity, and a soundproof sheet having an improved sound insulation function according to the mass law was used.
[0003]
However, the PVC sheet has a problem that toxic gas is generated at the time of combustion, and the sheet increased in weight as described above usually has a basis weight of about 1100 to 1300 g / m ² and 1.8 × 5.1 m. If the size of the temporary scaffold was 5.1 m pitch, the size of the temporary scaffold was 5.1 m in order to make it difficult to handle it. There was an inconvenience that the size reduced to 0.8 × 3.4 m became common.
[0004]
[Problems to be solved by the invention]
In order to solve such a problem, a curing sheet made of polyolefin, which has excellent filament formability and does not generate toxic gas, has been tried in recent years. The problem is that the soundproofing effect is not sufficient with the laminated cloth in which the layers are laminated, and if the thickness of the laminate is increased to improve the soundproofing effect, the flexibility decreases, the handling becomes poor, and the sewing process becomes difficult. Further, since the polyolefin is easily combustible, it has been necessary to impart weather resistance and flame resistance as a construction sheet.
[0005]
The present invention has been made in view of the above problems, and its object is to provide a lightweight and flexible polyolefin soundproofing having excellent soundproofing, weatherproofing and flameproofing properties. Is to provide a sheet.
[0006]
[Means for Solving the Problems]
The inventor of the present invention has conducted intensive studies in order to solve the above-described problems, and as a result, as a result, a flame retardant and a weatherproof agent are provided on both surfaces of a laminate obtained by laminating a woven or knitted fabric composed of two drawn polyolefin yarns via an adhesive layer. It has been found that the above object can be achieved by providing a laminate layer of a polyolefin containing an agent and forming irregularities on at least one of the laminate layers, and have accomplished the present invention.
That is, the present invention is provided with a polyolefin laminate layer containing a flame retardant and a weathering agent on both surfaces of a laminate obtained by laminating a woven or knitted fabric composed of two polyolefin drawn yarns via an adhesive layer, and at least A polyolefin soundproof sheet characterized in that unevenness is formed on one of the laminate layers.
[0007]
BEST MODE FOR CARRYING OUT THE INVENTION
Hereinafter, the present invention will be described in detail.
The drawn yarn made of polyolefin used in the present invention is a drawn yarn formed by a known production method using polyolefin. As the yarn form of the drawn yarn, any of a monofilament, a multifilament, a flat yarn, a split yarn and the like can be used, but a multifilament or a split yarn is preferable from the viewpoint of flexibility.
[0008]
Examples of the polyolefin include linear low-density polyethylene, branched low-density polyethylene, high-density polyethylene, ethylene-vinyl acetate copolymer, ethylene- (meth) acrylic acid alkyl ester copolymer, and a metallocene catalyst. A polyethylene resin such as an ethylene / α-olefin copolymer, or a polypropylene resin such as polypropylene, a propylene-ethylene block copolymer, or a propylene-ethylene random copolymer is used. These may be used alone or in combination of two or more. Among these, high-density polyethylene or polypropylene, which can provide high strength by the stretching effect, is preferred.
[0009]
The fineness of the drawn yarn of the polyolefin is in the range of 300 to 3000 dtex (hereinafter referred to as dt), and preferably in the range of 500 to 2000 dt. If the fineness is less than 300 dt, the mechanical properties as a woven or knitted fabric are insufficient, and if it exceeds 3000 dt, the flexibility is poor, which is not preferable.
[0010]
The drawn yarn is used as the warp yarn, and woven and knitted to form a woven knitted fabric. The implantation density is in the range of 10 to 30 pieces / 2.54 cm, preferably in the range of 15 to 20 pieces / 2.54 cm. Various shapes such as plain weave, twill weave, entangled weave, and mosaic weave are used as the weave structure of the woven fabric, and the knitted fabric may be either a flat knit or a warp knit. Knitting and the like.
[0011]
In the present invention, the two woven and knitted fabrics are overlapped and laminated with an adhesive layer therebetween to form a laminate. The configuration of the two woven / knitted fabrics may be the same woven / knitted fabric, or may be of different configurations. The weight of the woven or knitted fabric is in the range of 100 to 800 g / m ² , and preferably in the range of 200 to 600 g / m ² . When the basis weight is less than 100 g / m ² , the mechanical strength of the construction sheet is inferior, and it is difficult to achieve the soundproofing effect which is the object of the present invention. When the basis weight exceeds 800 g / m ² , the weight is reduced. It is not preferable because it increases the handleability and lowers the flexibility.
[0012]
As a method for forming the soundproof sheet of the present invention, an adhesive layer is provided and laminated between two woven and knitted fabrics by a sandwich lamination method, and then a laminate layer is provided on both surfaces thereof. A method in which an embossing process is performed on one side of the laminate layer to provide irregularities, an adhesive layer is provided between two woven and knitted fabrics by a sandwich lamination method and laminated, and then a laminate layer is provided on one side and the other side is provided. A method of providing a laminate layer by laminating a film provided with irregularities on the laminate obtained by providing an adhesive layer by a sandwich lamination method between laminates in which a laminate layer is provided on one side of a woven or knitted fabric in advance. A method of embossing one side of the laminate layer to provide irregularities, laminating a film in which a laminate layer is provided on one side of one woven and knitted fabric in advance and one side of the other woven or knitted fabric is provided with irregularities The method or the like to provide a laminate layer. The embossing can be easily performed, for example, by inserting the laminate between a pair of male and female molds having a predetermined mold shape and applying heat and pressure.
[0013]
As a method for forming the adhesive layer, a sandwich lamination method using a polyolefin is preferable, and the thickness of the adhesive layer is in a range of 30 to 200 μm, and preferably in a range of 50 to 150 μm. If the thickness of the adhesive layer is less than 30 μm, the adhesive strength becomes insufficient, which is not preferable. If it exceeds 200 μm, the rigidity increases, which is not preferable.
[0014]
Laminated layers made of polyolefin are provided on both sides of the laminate. As a method for providing a laminate layer, an extrusion lamination method or a lamination method is preferable. Regarding the thickness of the laminate layer, one flat laminate layer has a thickness of 50 to 400 μm, preferably 100 to 200 μm, and the other laminate layer having irregularities has a thickness of 100 μm or more, preferably 100 to 2000 μm. The difference between the heights of the irregularities is 100 μm or more, preferably 100 to 1000 μm. The width of the concave portions is 0.3 mm or more, preferably 0.5 to 2 mm. 5 mm or more, preferably in the range of 0.7 to 2 mm. If the difference between the heights of the irregularities is less than 100 μm, the width of the concave portions is less than 0.3 mm, and the interval between the irregularities is less than 0.5 mm, the soundproofing effect at the irregularities decreases, which is not preferable.
[0015]
As the polyolefin used for the adhesive layer and the laminating layer, a polyolefin conventionally used in an extrusion lamination method is used. Is preferred. Specifically, if the drawn yarn is polypropylene, a polyolefin-based thermoplastic elastomer, polypropylene, a propylene-ethylene copolymer or the like is preferable, and if the drawn yarn is high-density polyethylene, linear low-density polyethylene, low-density polyethylene, A metallocene catalyst-based ethylene / α-olefin copolymer, ethylene-vinyl acetate copolymer, ethylene- (meth) acrylate copolymer, and the like are preferable. These may be used alone or as a mixture of two or more.
Among these, a polyolefin-based thermoplastic elastomer is most preferable in terms of flexibility and vibration damping action.
[0016]
The polyolefin-based thermoplastic elastomer (hereinafter sometimes referred to as TPO) is a resin composition comprising a crystalline polyolefin component such as polypropylene and polyethylene and a rubber component such as an ethylene-propylene copolymer. Conventionally, a blend type of both components or a crosslinked TPO thereof is known. In recent years, both components have been copolymerized by multistage polymerization of ethylene, propylene and, if necessary, a diene (EPDM (ethylene-propylene diene methylene bond). )) There is known a reactor-type TPO which can be obtained by the following method.
Among these, the reactor type TPO is preferable, and as commercial products of the reactor type TPO, "NEWCON" (manufactured by Chisso Corporation), "Cataroy" (trade name: manufactured by Montell ESDK Sunrise "MSS" Corporation), "PER" (trade name: manufactured by Tokuyama Corporation), "CAP350" (manufactured by Ube Industries, Ltd.) and the like.
[0017]
It is preferable to add at least one selected from a styrene-based thermoplastic elastomer and a polyurethane-based thermoplastic elastomer to the polyolefin constituting the laminate layer. Commercially available styrene-based thermoplastic elastomers include "HIBLER" and "Septon" (trade name, manufactured by Kuraray Co., Ltd.). Commercially available polyurethane-based thermoplastic elastomers include "Chramylon U" (trade name). : Manufactured by Kuraray Co., Ltd.). These thermoplastic elastomers are composed of a crystalline component and a rubber component, and have a vibration damping performance that quickly attenuates the vibration transmitted by the composition. The performance is improved.
[0018]
The amount of the thermoplastic elastomer to be added is preferably 5 to 50% by weight, more preferably 10 to 30% by weight, based on the polyolefin constituting the laminate layer. If the addition amount is less than 5% by weight, the soundproofing property is not sufficiently improved by the addition, and if it exceeds 50% by weight, the adhesion between the laminate layer and the woven or knitted fabric is undesirably reduced.
[0019]
The total thickness of the soundproof sheet of the present invention is 1 mm or more, preferably 1 to 3 mm. In order to achieve a total thickness of 1 mm or more, the basis weights of the woven and knitted fabrics may be different from each other, and the thicknesses of the laminate layers on both surfaces may be different from each other. The total thickness of 1 mm is a characteristic required in consideration of a soundproofing effect, strength, and an appropriate weight capable of suppressing flapping due to wind when used as a curing sheet for construction.
[0020]
Weight per unit area of the soundproofing sheet is preferably ^{500~1000g / m 2, 550~700g / m} 2 is more preferable. If the basis weight is less than 500 g / m ^2, it is difficult to achieve the soundproofing effect, which is the object of the present invention, and if the basis weight exceeds 1000 g / m ² , the weight increases, the handleability deteriorates, and the flexibility decreases. Absent.
[0021]
As the flame retardant used in the present invention, a known flame retardant such as a halogen-based, phosphorus-based, or inorganic flame-retardant is appropriately used. Are preferred, and a brominated flame retardant is particularly preferred.
[0022]
Examples of brominated flame retardants include aromatic brominated flame retardants such as tetrabromobisphenol A, decabromodiphenyl oxide, octabromodiphenyl oxide, bisdibromopropyl ether tetrabromobisphenol S, hexabromocyclododecane, and dibromoethyldibromocyclohexane. And a liquid bromine-based flame retardant such as pentabromodiphenyl oxide and tetrabromodiphenyl oxide.
These may be used alone or as a mixture of two or more.
[0023]
The mixing ratio of the bromine-based flame retardant is in the range of 1 to 10% by weight, preferably 2 to 6% by weight, based on the total weight of the soundproof sheet. If the compounding ratio is less than 1% by weight, the flame retardancy is insufficient, and if it is more than 10% by weight, the effect of the flame retardancy is not further improved, and conversely, the cost increases, which is not economical. Flame retardant is blended in the laminate layer, but if it is difficult to blend in the laminate layer at the above blending ratio, if it is difficult to blend in the adhesive layer within the range that does not impair the adhesive so that the above blending ratio Is also good.
[0024]
It is preferable to use antimony trioxide as a flame retardant auxiliary in combination with the bromine-based flame retardant from the viewpoint of improving the flame retardant effect. The mixing ratio of the brominated flame retardant to antimony trioxide is not particularly limited, but is preferably 2: 1 to 3: 1.
[0025]
The polyolefin soundproof sheet thus obtained preferably has a performance that meets the flameproof standard specified in JIS A8952.
[0026]
In addition, the polyolefin soundproof sheet of the present invention is used outdoors and is required to have weather resistance when used for a long time because it is exposed to sunlight. As a method for improving the weather resistance, a method of adding a weather agent such as an ultraviolet absorber or a light stabilizer can also be adopted.
[0027]
Specific examples of the ultraviolet absorber include, specifically, 2-ethylhexyl-2-cyano-3,3′-diphenylacrylate, ethyl-2-cyano-3,3′-diphenylacrylate, octyl-2-cyano-3. Cyanoacrylate-based ultraviolet absorbers such as 2,3'-diphenylacrylate; benzophenone-based ultraviolet absorbers such as 2,4-dihydroxybenzophenone, 2-hydroxy-4-methoxybenzophenone and 2-hydroxy-4-octoxybenzophenone; Benzotriazole ultraviolet absorbers such as (2'-hydroxy-5'-methylphenyl) benzotriazole and 2- (2'-hydroxy-5'-t-octylphenyl) benzotriazole, resorcinol monobenzoate, 2,4- Di-tert-butylphenyl-3'-5'-di-tert-butyl And benzoate ultraviolet absorbers such as tyl-4'-hydroxybenzoate. The compounding ratio of the ultraviolet absorber is preferably 0.05 to 5% by weight, more preferably 0.1 to 1% by weight, based on polyethylene.
[0028]
As hindered amine light stabilizers, bis (2,2,6,6-tetramethyl-4-piperidyl) sebacate, tetrakis (2,2,6,6-tetramethyl-4-piperidyl) -1,2,3 , 4-butanetetracarboxylate, bis (1,2,2,6,6-pentamethyl-4-piperidyl) di (tridecyl) -1,2,3,4-butanetetracarboxylate, 1- (2- (Hydroxyethyl) -2,2,6,6-tetramethyl-4-piperidinol and a polycondensate of diethyl succinate. The compounding ratio of the light stabilizer is preferably 0.05 to 5% by weight, more preferably 0.1 to 1% by weight, based on polyethylene.
[0029]
The polyolefin used in the present invention includes, within a range not departing from the gist of the present invention, commonly used additives such as antioxidants, lubricants, antistatic agents, pigments, inorganic fillers, nucleating agents, foaming agents, and dispersants. May be blended.
[0030]
【Example】
Example 1
A woven fabric A woven in a plain weave at a density of 20 × 20 / 2.54 cm using a polypropylene multifilament having a fineness of 760 dt for the weft, and a polypropylene multifilament having a fineness of 1510 dt used for the weft. Then, a woven fabric B woven in a plain weave at a driving density of 16 × 16 / 2.54 cm was formed.
90% by weight of a polyolefin-based thermoplastic elastomer (trade name: NEWCON-NNT2005, manufactured by Chisso Corporation) as a laminating layer and an adhesive layer polyolefin, and decabromodiphenyl oxide: bisdibromopropyl ether tetrabromobisphenol S as a flame retardant: 0.5% by weight of a benzotriazole ultraviolet absorber was used in a mixture of 10% by weight of a master batch (flame retardant concentration: 40% by weight) in which antimony trioxide was mixed at a ratio of 1: 1: 1.
[0031]
As a method of manufacturing the soundproof sheet, first, a lamination layer having a thickness of 100 μm was provided on one surface of the woven fabric A by extrusion lamination using the polyolefin mixture for a lamination layer, and a 100 μm thickness was similarly formed on one surface of the woven fabric B. The base fabric provided with the laminate layer of was formed. Then, the woven fabric surfaces of the two base fabrics were overlapped, and a 60 μm-thick adhesive layer was provided between them by a sandwich lamination method using the above-mentioned polyolefin mixture for an adhesive layer to form a laminate. One side of this laminate was subjected to embossing by means of heat and pressure to form irregularities with a difference in height of irregularities of 200 μm, a width of concave portions of 1 mm, and an interval of irregularities of 1.5 mm.
[0032]
The thus obtained laminate had a thickness of 1.10 mm and a basis weight of 550 g / m ² . When the transmission loss was measured, the direct measurement value from the sound source was 80 decibels (hereinafter, referred to as dB), and the transmission loss was 32 dB after passing through the laminate with the uneven side facing the front. Further, it passed the flameproofing standard specified in JIS A8952.
The laminate is excellent in flexibility, folding, sewing, sewing and striking can be performed while four sheets are stacked, and is preferably used as a soundproof sheet excellent in flameproofness when spread on a scaffold at a construction site, Excellent weather resistance over a long period of time.
[0033]
Example 2
The procedure was performed in the same manner as in Example 1 except that 30% by weight of a styrene-based thermoplastic elastomer (trade name: Hibler, manufactured by Kuraray Co., Ltd.) was added to the polyolefin for the laminate layer. The transmission loss of the obtained laminate was 30 dB after passing through the laminate when the direct measurement value from the sound source was 80 dB. In addition, it had good flexibility, was spread on a scaffold at a construction site, was suitably used as a soundproof sheet having excellent flameproofing properties, and was excellent in weatherability for a long period of time.
[0034]
Example 3
The procedure was performed in the same manner as in Example 1 except that a polyolefin-based thermoplastic elastomer (trade name: Cataloy KS-357P, manufactured by MSS Corporation) was used as the polyolefin for the laminate layer and the adhesive layer.
The transmission loss of the obtained laminate was 31 dB after passing through the laminate when the direct measurement value from the sound source was 80 dB. In addition, it had good flexibility, was spread on a scaffold at a construction site, was suitably used as a soundproof sheet having excellent flameproofing properties, and was excellent in weatherability for a long period of time.
[0035]
Example 4
The procedure was performed in the same manner as in Example 1 except that a propylene-ethylene random copolymer (ethylene content: 6 mol%) was used as the polyolefin for the laminate layer and the adhesive layer.
The transmission loss of the obtained laminate was 34 dB after passing through the laminate, when the direct measurement value from the sound source was 80 dB. In addition, it had good flexibility, was spread on a scaffold at a construction site, was suitably used as a soundproof sheet having excellent flameproofing properties, and was excellent in weatherability for a long period of time.
[0036]
Comparative Example 1
The procedure was performed in the same manner as in Example 1 except that no ultraviolet absorber was added and one side of the obtained laminate was not embossed.
As a result, the transmission loss of the obtained laminate was 42 dB after passing through the laminate when the direct measurement value from the sound source was 80 dB, and the weather resistance over a long period was insufficient.
[0037]
【The invention's effect】
As described above, the polyolefin soundproof sheet of the present invention is composed of an adhesive layer for adhering a woven or knitted fabric composed of two polyolefin drawn yarns and a laminate layer of polyolefin on the front and back surfaces. Irregularities are formed, the total thickness is 1 mm or more, the basis weight is 500 g / m ² or more, and the laminate layer contains a flame retardant and a weathering agent. In addition, it is lightweight because it does not contain inorganic fillers, etc., and is flexible and has the effects of folding, sewing, sewing, eyelet punching with four sheets stacked, and flameproofing. Thus, an excellent polyolefin soundproof sheet having weather resistance was obtained.

Claims (3)

A laminate in which a woven or knitted fabric comprising two drawn polyolefin yarns is laminated via an adhesive layer is provided with a laminate layer of a polyolefin containing a flame retardant and a weathering agent, and at least one of the laminate layers has irregularities. A polyolefin soundproof sheet, characterized by being formed with: The polyolefin soundproof sheet according to claim 1, wherein the polyolefin constituting the laminate layer is a polyolefin-based thermoplastic elastomer. The polyolefin soundproof sheet according to claim 1, wherein the difference in height of the unevenness of the laminate layer is 100 µm or more.