JP2005273274A - Sound absorption underlayer material - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a sound absorption underlayer material which resolves a problem of a conventional sound absorption underlayer material, effectively absorbs the sound generated upstairs, excels in feeling upon walking, and forms no level difference or wave on a floor surface even when a load is applied thereto for a long time. <P>SOLUTION: The sound absorption underlayer material comprises a nonwoven fabric layer formed of resin fibers, and a resin sheet laminated on and integrated with the nonwoven fabric layer. The resin sheet has a number of projecting bodies which project downward from a lower surface of a base part having a uniform thickness, and fit into the nonwoven fabric layer. Each of the projecting bodies is formed to have a shape of a hemisphere, and has a projecting height of 1.0 to 2.0 mm. The arrangement pitch of the projecting bodies is 5.0 to 10.0 mm. A basis weight of the unwoven fabric layer is 100 to 200 g/m<SP>2</SP>. <P>COPYRIGHT: (C)2006,JPO&NCIPI

Description

  The present invention relates to a sound-absorbing base material capable of reducing the propagation of sound generated on the floor of a building to the lower floor and enhancing the feeling of walking.

  In order to mitigate floor impact noise on the floor, as shown in FIG. 7, a slit b is formed on the back surface of the floor material main body a in order to control floor impact vibration inside the floor material main body a, and a foaming ratio of 3 Laminate foam layer c made of foamed polystyrene such as foamed polystyrene, foamed polyethylene, foamed polyurethane, foamed polyvinyl chloride, foamed rubber such as foamed natural rubber, foamed synthetic rubber, etc. The soundproofing floor material d integrated in (1) is proposed (for example, see Patent Document 1).

  In these soundproof flooring materials, the increase and diffusion of impact vibration due to the resonance phenomenon of the flooring material main body a are restricted by the action of the slit b, and the foamed layer c is compressed or deformed by the impact, so that during the deformation Even if the collision time becomes longer and the temporal integration value of momentum change, impulse, impact force is constant, the impact input energy is reduced by lowering the peak value of impact force and the natural frequency of impact. This can reduce the sound and vibration caused by impact.

JP-A-10-88778

  However, even though these foamed layers c can reduce impact energy, they do not have a sound absorbing function for absorbing sound energy generated on the floor and transmitted to the lower floor, and suppress the propagation of sound to the lower floor. There is a limit to work. Further, in order to obtain a sufficient effect by reducing the impact energy, it is necessary to provide a foam layer c that is 2 to 3 times the thickness of the flooring body a, and the foam layer c has such a thickness. If set, the flexure of the flooring main body a will increase when it receives a load, for example, the real part e of the flooring main body a may be damaged, and there is a possibility of generating a step at the joint with the adjacent flooring, In addition, when walking on the floor, sinking occurs and the feeling of walking is poor. Also, if an excessive stress such as placing a heavy object such as a piano, refrigerator, large furniture, etc. is applied, the foam layer c is compressed, so the buffering effect is greatly reduced, and furthermore, such a large load is sustained for a long period of time. When added, the restoring force of the foam layer c itself is reduced, and there is a problem that the floor surface is wavy and a step is generated at the abutting portion with the adjacent floor material body a.

  The problem of the present invention is to solve the problems of the above-mentioned sound-absorbing base material, to effectively absorb the sound generated on the floor and to have excellent walking feeling, and even when a long-term load is applied to the floor surface. The object is to provide a sound-absorbing base material that does not cause steps and undulations.

  In order to achieve the above object, the invention described in claim 1 is composed of a nonwoven fabric layer formed using resin fibers and a resin sheet laminated and integrated on the nonwoven fabric layer, and the resin sheet is fixed. It has a large number of protrusions projecting downward on the lower surface of the thickness base and fitting into the nonwoven fabric layer.

  The invention according to claim 2 is the sound-absorbing base material according to claim 1, wherein the protrusion is formed in a hemispherical shape.

  The invention according to claim 3 is characterized in that the protrusion has a protrusion height of 1.0 to 2.0 mm and an arrangement pitch of 5.0 to 10.0 mm. It is a sound-absorbing base material.

The invention according to claim 4, wherein the nonwoven layer is a sound-absorbing underlayer material according to claim 1, wherein the basis weight is 100 to 200 g / m ^2.

  Since the present invention is configured as described above, the sound generated on the floor is effectively absorbed in innumerable fine spaces formed inside the nonwoven fabric layer, and the sound transmitted to the floor can be greatly reduced. In addition, since the contact area between the resin sheet and the nonwoven fabric layer is increased by fitting the protrusions of the resin sheet into the nonwoven fabric layer, the countless number of nonwoven fabric layers from the surface of the resin sheet due to vibration propagating from the floor on the floor. The amount of sound emitted toward the small space increases, and the sound absorption effect in the nonwoven fabric layer increases. And since the said vibration is buffered by the said resin sheet, the propagation rate to the downstairs of the sound which generate | occur | produced upstairs is reduced. Furthermore, since the nonwoven fabric layer and the resin sheet are laminated and integrated, and the protrusions of the resin sheet are fitted into the nonwoven fabric layer to improve the integrity of the nonwoven fabric layer and the resin sheet, the overall rigidity is improved. There are no steps or undulations in the finished flooring material.

  Hereinafter, an embodiment of the present invention will be described with reference to the drawings. FIG. 1 is a longitudinal sectional view illustrating an embodiment of the present invention. The sound absorbing base material 1 of the present invention comprises a nonwoven fabric layer 2 and a resin sheet 3 laminated and integrated thereon.

The nonwoven fabric layer 2 is formed with a basis weight of 100 to 200 g / m ² . If the basis weight is less than 100 g / m ² , the strength as the base material is insufficient, and the fine space formed by the resin fibers is insufficient, so that the necessary sound absorption effect cannot be obtained, and the compression set for a long-term load is not obtained. Remain. If it exceeds 200 g / m ² , it becomes too thick and the workability deteriorates, and the solid propagation elements increase, and the lightweight floor impact sound blocking performance is reduced.

  The single fiber fineness of the resin fiber is, for example, about 2 to 20 denier, preferably about 5 to 15 denier. If it is less than 2 deniers, the bonding force between the resin fibers decreases, and furthermore, the ratio of fine spaces decreases, so the sound absorbing effect decreases. If it exceeds 20 deniers, the surface smoothness is impaired, so that the adhesiveness is lowered, and therefore the construction becomes difficult.

  The nonwoven fabric layer 2 is formed by forming a fleece that is an accumulation layer of resin fibers by a dry method, a wet method, a spun bond method, and other manufacturing methods, and further bonding the resin fibers of the fleece. In addition, in order to bond resin fibers, an adhesive resin of emulsion type is attached to the fleece by a method such as impregnation or spraying, and a fleece mixed with a heat bonding fiber, a chemical bond method in which the intersections of the fibers are bonded by heating, A thermal bond method in which fibers are bonded by thermocompression bonding or heat treatment, a needle punch method in which piercing is repeatedly performed with a needle that moves up and down at high speed, and resin fibers are entangled and bonded are used. And in the said thermal bond method, the resin fiber in which 50 to 100% of heat welding fibers and 50 to 0% of non-heat welding fibers are contained is used.

  As the resin fiber, any kind of synthetic resin fiber can be used for both heat-welded fiber and non-heat-welded fiber. For example, polyolefin resin such as polyethylene (PE) polypropylene (PP), polyethylene terephthalate (PET), polybutylene terephthalate. Polyester resins such as polyamide resins and polyamide resins including nylon can be used. Polyolefin resins are particularly preferred from the standpoints of bulkiness, compression elasticity, economy, and the like. In the thermal bond method, it is not always necessary to use the same kind of resin or the same single yarn fineness as the heat-welded fiber and the non-heat-welded fiber used by mixing.

  The nonwoven fabric layer 2 has a large number of fine spaces formed between resin fibers. As a result, the sound energy generated on the floor is absorbed in the minute space, so that the sound pressure level is lowered and the sound transmitted to the floor is reduced. Further, the nonwoven fabric layer 2 using the resin fiber does not have a large cushioning property like the elastic cushioning material such as rubber and sponge which has been conventionally used, and therefore does not cause undulations or steps on the floor surface. A good feeling of walking is obtained, and even if a heavy object such as a piano is placed for a long time, it is not compressed.

  The resin sheet 3 has a uniform base portion 4 having a thickness of about 0.5 to 2.0 mm, for example, and a large number of protrusions 5 projecting downward on the lower surface of the base portion 4. As shown in FIG. 1, the non-woven fabric layer 2 is laminated and integrated on the non-woven fabric layer 2, and the protrusion 5 is fitted into the non-woven fabric layer 2. Therefore, the vibration generated on the floor generates a sound from the lower surface of the base 4 and the surface of the protrusion 5 toward the nonwoven fabric layer 2, but the amount of the sound is increased by the protrusion 5 protruding and the surface area increasing. And since the amount of sound energy absorbed by the nonwoven fabric layer 2 increases, the sound absorption effect is enhanced. And since the said vibration is buffered by the said resin sheet 3, the propagation rate to the downstairs of the sound generated on the floor reduces. Further, since the protrusions 5 are fitted into the nonwoven fabric layer 2 and the integrity of the nonwoven fabric layer 2 and the resin sheet 3 is increased, the rigidity of the entire sound-absorbing base material 1 is increased, and the floor finishing material laid thereon is It is supported stably and does not cause a level difference or undulation in the connecting portion.

  In the present embodiment, as shown in FIG. 2 (A), the protrusion 5 is spaced from the lower surface of the base 4 of the resin sheet 3 by a pitch p of 5.0 to 10.0 mm vertically and horizontally. It is formed side by side at equal intervals. When the arrangement pitch p is less than 5.0 mm, the sound generated by the adjacent protrusions 5 is mixed with each other, so that the improvement of the sound absorption effect is small. When the arrangement pitch p is more than 10.0 mm, the surface area increase ratio of the resin sheet 3 is small. There is no significant difference in effectiveness. Further, as shown in FIG. 2 (B), in the direction of the drawing, the horizontal arrangement in which the protrusions 5 are arranged in a horizontal line with the arrangement pitch p is shifted by a half pitch and arranged horizontally. Alternatively, the protrusions 5 can be arranged with the intervals between the pair of protrusions 5 and 5 adjacent in the oblique direction as the arrangement pitch p. Further, as shown in FIG. 2C, the resin sheet 3 can be formed by arranging the protrusions 5 at random in the vertical and horizontal directions with the average interval being the arrangement pitch p.

  As shown in FIGS. 3 and 4A, the protrusion 5 has a hemispherical shape and a protrusion height H of 1.0 to 2.0 mm. When the height H is less than 1.0 mm, since the surface area increase ratio of the resin sheet 3 is small, there is no significant difference in the sound absorption effect, and since the size that fits into the nonwoven fabric layer 2 is small, the resin sheet 3 is integrated with the resin sheet 3. The reinforcing effect of the nonwoven fabric layer 2 is small. If it exceeds 2.0 mm, the sound emitted from the vicinity of the tip of the protrusion 5 is transmitted to the lower side without being absorbed by the nonwoven fabric layer 2, so that the sound insulation performance is lowered. In addition, the outer diameter dimension D of the projection body 5 is formed to about 2.0-3.0 mm, for example. Further, as shown in FIG. 4B, the protrusion 5 may be formed by integrating a disk-shaped portion 21 and a hemispherical portion 22, and as shown in FIG. In addition, as shown in FIG. 4D, an inverted quadrangular pyramid shape may be used.

  The resin sheet 3 is made of a polyolefin resin such as polyethylene, polypropylene or polybutene, a polyvinyl resin such as polyvinyl chloride, polystyrene or polystyrene copolymer resin, or a polyester resin such as polyethylene terephthalate, polybutylene terephthalate, polycarbonate or polyarylate. Polyacetal, polyphenylene ether, aromatic polysulfone, polyether resin such as polyether ketone, polyamide resin such as nylon 6, nylon 6-6, nylon 11 and nylon 12, etc., and base 4 and protrusion 5 Are molded integrally.

  The nonwoven fabric layer 2 and the resin sheet 3 are laminated and integrated by heat welding, adhesion, or the like. In the case of heat welding, as shown in FIG. 5, the resin sheet 3 with the protrusions 5 is placed on the nonwoven fabric layer 2, and passes between the transport roll R1 and the hot press roll R2 disposed thereon. By doing so, the nonwoven fabric layer 2 and the resin sheet 3 are integrated, and at the same time, the protrusions 5 are fitted into the nonwoven fabric layer 2. When adhering, an adhesive is applied to at least one of the nonwoven fabric layer 2 or the resin sheet 3 by a coating device such as a spray device or a curtain flow device (not shown), and then the nonwoven fabric layer 2 and The resin sheet 3 is superposed and pressed with a press device to be laminated and integrated, and at the same time, the protrusions 5 are fitted into the nonwoven fabric layer 2. The adhesives include vinyl acetate resin-based, EVA resin-based, acrylic resin-based emulsion-type adhesives, phenol resin-based adhesives, melamine resin-based adhesives, EVA resin-based, synthetic rubber-based hot melt adhesives, and others. Use. The protrusion 5 of the resin sheet 3 is inserted into the nonwoven fabric layer 2 as described above when the nonwoven fabric layer 2 and the resin sheet 3 are laminated and pressed as described above. This means that the protrusion 5 enters the recess.

  As shown in FIG. 6, the sound-absorbing base material 1 of the present invention is disposed between the floor base 23 and the floor finishing material 24 in the floor F on the floor. The floor base 23 is fixed on a joist 25 attached to a floor beam 26, and is composed of plywood, particle board, insulation board, medium density fiber board (MDF), cement board, or the like. The sound absorbing base material 1 is laid on the entire upper surface of the floor base 23 using an adhesive. Further, a floor finishing material 24 made of a wood flooring material is laid on the resin sheet 3 of the sound absorbing base material 1 using an adhesive. In addition, as the floor finish 24, floor tiles, carpets, tatami mats, and the like can be used.

As shown in Table 1, a non-woven fabric layer having a basis weight of 100 g / m ² formed using polyethylene terephthalate fiber, a protrusion having a protrusion height of 2.0 mm and an arrangement pitch of 8.0 mm on a substrate having a thickness of 1.0 mm A resin sheet using polypropylene was integrated by heat welding to produce a prototype of Example 1. Further, a non-woven fabric layer having a basis weight of 170 g / m ² formed using polyester fiber is provided with a protrusion having a protrusion height of 2.0 mm and an arrangement pitch of 8.0 mm on a base having a thickness of 1.0 mm, and using polypropylene. The obtained resin sheet was integrated with a silicon-based adhesive to obtain Example 2. Further, a conventional example made of a resin sheet using polypropylene was prepared by providing a protrusion having a protrusion height of 2.0 mm and an arrangement pitch of 8.0 mm on a substrate having a thickness of 1.0 mm.

  Examples 1 and 2 and the conventional example are each bonded to a floor base using an extruded concrete board having a thickness of 25 mm, and further, a floor finishing material made of plywood having a thickness of 12 mm is further laid on the floor body to constitute a floor body. did. A heavy floor impact sound level based on JIS1418-2 was measured for each floor using a lightweight floor impact source (tapping machine). As a result, compared with the conventional example, Example 1 confirmed the improvement effect of LL number 7, and Example 2 confirmed the improvement effect of LL number 9.

It is a longitudinal cross-sectional view which illustrates one embodiment of this invention. It is a front view of a resin sheet, (A), (B), (C) shows the example from which arrangement | positioning of a protrusion differs, respectively. It is a partial expansion longitudinal cross-sectional view of a resin sheet. It is the partial expansion perspective view, (A), (B), (C), (D) shows the example from which the shape of a protrusion differs, respectively. It is a front view which illustrates the manufacturing process of the sound-absorbing base material of this invention. It is a cross-sectional perspective view which illustrates the upper floor using the sound-absorbing base material of this invention. It is sectional drawing which shows the conventional soundproof flooring.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Sound absorption base material 2 Nonwoven fabric layer 3 Resin sheet 4 Base part 5 Protrusion body

Claims (4)

It consists of a nonwoven fabric layer formed using resin fibers, and a resin sheet laminated and integrated on the nonwoven fabric layer,
The sound-absorbing base material, wherein the resin sheet has a large number of protrusions that protrude downward on a lower surface of a base portion having a constant thickness and are fitted into the nonwoven fabric layer.   The sound absorbing base material according to claim 1, wherein the protrusion is formed in a hemispherical shape.   The sound absorbing base material according to claim 1 or 2, wherein the protrusion has a protrusion height of 1.0 to 2.0 mm and an arrangement pitch of 5.0 to 10.0 mm. The nonwoven layer, sound-absorbing base material according to claim 1, wherein the basis weight is 100 to 200 g / m ^2.

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