JP2007314985A - Cushioning material for floating floor, floating floor structure using the cushioning material, and manufacturing method for the cushioning material - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a cushioning material for a floating floor, which can be easily constructed and has excellent floor impact sound insulating performance, a floating floor structure using the cushioning material, and a manufacturing method for the cushioning material. <P>SOLUTION: This cushioning material 10 for the floating floor comprises: a plurality of sponge rubber chips 1 capable of being obtained by crushing a sponge rubber containing air bubbles 1a; a binder 2 for bonding the plurality of sponge rubber chips 1 together; and a cavity 3 larger than the air bubble 1a, which is provided among the plurality of sponge rubber chips 1 bonded by bonding the plurality of adjacent sponge rubber chips 1 together with the binder 2. <P>COPYRIGHT: (C)2008,JPO&INPIT

Description

  The present invention relates to a floating floor cushioning material, a floating floor structure using the same, and a method for manufacturing the floating floor cushioning material, and more particularly, to a floating floor cushioning material for suppressing floor impact noise of a building and the same. The present invention relates to a floating floor structure used and a method for manufacturing a floating floor cushioning material.

  In the conventional floating floor structure, on the housing slab, a liquid A (one or a mixture of active hydrogen compounds added with a foaming agent, a reinforcing material as necessary) and a liquid B (polyisocyanate) are compressed. Spraying is performed with a spray gun equipped with Alternatively, the A liquid and the B liquid are mixed in a container and coated on the housing slab with a trowel, brush, roller, or the like, or the A liquid and the B liquid are poured directly onto the housing slab, and the iron, spatula, etc. And then foamed (see, for example, Patent Document 1).

  Further, a required number of cushioning materials made of vibration-proof rubber having performance necessary for supporting the floating floor are provided on the lower slab. Further, glass wool is laid in place other than the anti-vibration rubber in place of the discard frame, and the height thereof is set as the lower surface height of the floating floor to be formed (see, for example, Patent Document 2).

  Further, the buffer body is formed of a foam having a large number of closed cells inside and having a very low water content, for example, foamed polyethylene, and is compressed and compressed after foaming. The buffer body has a plurality of through holes penetrating in the vertical direction at appropriate intervals, and an elastic body made of natural or synthetic rubber having water resistance is provided in each through hole. Insertion arrangement is carried out (for example, refer to patent documents 3).

In addition, the concrete slab has a cushioning body made of a polypropylene resin foam and a cylindrical elastic body, and a rising insulating material made of a polypropylene resin foam, and concrete is cast as a floating floor layer. (For example, see Patent Document 4).
JP 57-112563 A (3rd page, FIG. 2) Japanese Patent Laid-Open No. 03-1000026 (2nd page, FIGS. 1 to 3) Japanese Patent Laid-Open No. 2001-200269 (pages 4-5, FIGS. 1-2) JP 2002-294997 A (page 4, FIG. 1)

Glass wool and rock wool, which are conventional cushioning materials for floating floors, have a problem that the vibration-proof performance and sound-insulating performance are reduced by containing moisture.
In addition, in the conventional floating floor construction method using the cushioning material for floating floor, glass wool is laid after projecting the vibration-proof rubber on the slab, or the polyurethane foam foam layer is formed on the slab by the spray foaming method or the coating foaming method. There was a problem that the number of man-hours on site was large, such as forming, and the construction period was long.

  In addition, as other conventional floating floor cushioning materials, there are floating floor cushioning materials in which through holes are formed in foams such as foamed polystyrene, foamed polypropylene, foamed polyethylene, and foamed polyurethane, and an elastic body is inserted and disposed. Since the elastic body is a natural rubber or stainless steel coil spring, the elastic body becomes a conductor for transferring heat, and there is a problem that the heat insulating performance is lowered.

  The present invention has been made to solve the above-described problems, and is a floating floor cushioning material that is easy to construct and has excellent floor impact sound insulation performance, a floating floor structure using the cushioning material, and a floating floor cushioning. It aims at providing the manufacturing method of material.

  In the floating floor cushioning material according to the present invention, a plurality of sponge rubber chips obtained by pulverizing sponge rubber containing bubbles, a binder for bonding the plurality of sponge rubber chips, and a plurality of adjacent sponge rubber chips are used as the binder. And having a gap larger than the bubbles between the bonded sponge rubber chips.

Moreover, in the cushioning material for floating floors according to the present invention, the sponge rubber chip is obtained by pulverizing a plurality of sponge rubbers having different densities as required.
In the floating floor cushioning material according to the present invention, the sponge rubber chip is obtained by pulverizing a plurality of sponge rubbers as different raw materials as required.
Further, in the floating floor structure according to the present invention, the floating floor cushioning material is laid on the upper surface of the slab, and the concrete is placed on the floating floor cushioning material.

Further, in the method for producing a cushioning material for floating floor according to the present invention, a step of pulverizing sponge rubber into a sponge rubber chip, a step of kneading a binder which is a thermosetting resin into the sponge rubber chip, and the kneading Heating and / or pressurizing the sponge rubber chip and binder.
Moreover, in the method for producing the cushioning material for floating floor according to the present invention, the sponge rubber chip has a particle diameter of 6 mm to 9 mm as necessary.

  In the present invention, the cushioning material for floating floors includes a plurality of sponge rubber chips obtained by pulverizing sponge rubber containing bubbles, a binder for bonding the plurality of sponge rubber chips, and a plurality of adjacent sponge rubber chips by the binder. By bonding and having a gap larger than the bubbles between the bonded plurality of sponge rubber chips, floor impact sound generated on the floor of the building can be cut off against the slab side. It exhibits excellent floor impact sound blocking performance against lightweight impact sounds when a relatively light and hard impact such as walking with shoes is applied to the floor.

  In the floating floor cushioning material according to the present invention, if necessary, the sponge rubber chip is obtained by pulverizing a plurality of sponge rubbers having different densities, so that the sponge rubber used for other applications can be obtained. The end material which is an unnecessary part can be effectively used as a sponge rubber chip.

  In addition, in the floating floor cushioning material according to the present invention, the sponge rubber chip is obtained by pulverizing a plurality of sponge rubbers which are different raw materials as necessary, so that the sponge rubber used for other applications can be obtained. The end material which is an unnecessary part can be effectively used as a sponge rubber chip.

  Furthermore, in the floating floor structure according to the present invention, the cushioning material for floating floors is laid on the upper surface of the slab, and the concrete is placed on the cushioning material for floating floors. It becomes easy, the number of man-hours on site is small, and the construction period can be shortened.

  Further, in the method for producing a cushioning material for floating floor according to the present invention, a step of pulverizing sponge rubber into a sponge rubber chip, a step of adding a binder which is a thermosetting resin to the sponge rubber chip and kneading, and the kneading The step of heating and / or pressurizing the sponge rubber chip and the binder, the volume of the floating floor cushioning material is changed according to the degree of pressure applied to the kneaded sponge rubber chip and binder, and the inside of the floating floor cushioning material is changed. The bubble size can be adjusted.

  In addition, in the method for manufacturing the cushioning material for floating floor according to the present invention, the sponge rubber chip floats while maintaining the elasticity of the cushioning material for floating floor, if necessary, because the particle size of the sponge rubber chip is 6 mm to 9 mm. It is possible to manufacture a floating floor cushioning material that suppresses variations in density of the floor cushioning material and exhibits excellent floor impact sound blocking performance.

(First embodiment of the present invention)
FIG. 1 is a partially enlarged cross-sectional view showing a floating floor cushioning material in a first embodiment for carrying out the present invention, and FIG. 2 shows sound pressure levels in each measurement sample with respect to a measurement frequency using a standard lightweight impact source FIG. 3 is a graph showing the sound pressure level in each measurement sample with respect to the measurement frequency using a standard weight impact source, and FIG. 4 is a schematic perspective view showing a floating floor structure using the floating floor cushioning material shown in FIG. FIG.

  1 and 2, a sponge rubber chip 1 is a granular material obtained by pulverizing an existing sponge rubber, which will be described later, with a pulverizer. In the first embodiment, the sponge rubber chip 1 is made by using, as a pulverized product, an unnecessary end material in a sponge rubber product such as an automobile door packing material made of a raw rubber component described later. Sponge rubber that has been scrapped for other purposes is used effectively.

  Sponge rubber is made by mixing organic foaming agent, cross-linking agent, softening agent or reinforcing agent into raw rubber (natural rubber, synthetic rubber), and by separating the foaming agent by vulcanization in a closed mold Sponge rubber containing 1a is made.

Raw rubber includes natural rubber (NR), styrene butadiene rubber (SBR), nitrile rubber (BR), chloroprene rubber (CR), silicon rubber (Q), ethylene propylene rubber (EPDM), polysulfide rubber (T), etc. The properties of sponge rubber can be adjusted by combining these raw material rubbers and compounding agents, but the physical properties such as hardness can be adjusted. from and manufacturing methods, product density of 0.1g / cm ³ ~0.3g / cm ³ is generally used.

In the first embodiment, the raw rubber is natural rubber (NR), chloroprene rubber (CR), or ethylene propylene rubber (EPDM), and the density is 0.1 g / cm ^{3 to} 0.7 g / cm. Sponge rubber ³ is used as a raw material for the sponge rubber chip 1 as a mixture of any one or a plurality of kinds, but if the sponge rubber that has become a waste material in other applications can be used, It is not limited to sponge rubber.

  A plurality of adjacent sponge rubber chips 1 are bonded with a binder 2, and a gap 3 larger than the bubbles 1 a is provided between the bonded plurality of sponge rubber chips 1 to constitute the floating floor cushioning material 10.

Below, the manufacturing method of the shock absorbing material 10 for floating floors is demonstrated.
First, the above-described sponge rubber is pulverized into a plurality of sponge rubber chips 1 by a pulverizer such as a roll machine or a rotary blade type shredder using a pulverizer mesh having an average particle diameter of 9 mm. .

If the diameter of the sponge rubber chip 1 is smaller than 6 mm, the bonding between the adjacent sponge rubber chips 1 in the finished floating floor cushioning material 10 increases, and the elasticity of the floating floor cushioning material 10 decreases. Further, as the diameter of the sponge rubber chip 1 is smaller, the necessary amount of the binder 2 is increased and the cost is increased.
Further, when the diameter of the sponge rubber chip 1 is larger than 9 mm, the density variation of the floating floor cushioning material 10 increases, and the quality of the floating floor cushioning material 10 is not stable.
Therefore, it is preferable to set the mesh of the pulverizer so that the diameter of the sponge rubber chip 1 is in the range of 6 mm to 9 mm.

  Next, the binder 2 is added to the sponge rubber chip 1 and kneaded. In this case, the blending ratio of the sponge rubber chip 1 and the binder 2 is 100 considering that the cost increases when the amount of the binder 2 is increased, and there is a risk of adhesion failure and deterioration of physical properties when the amount of the binder 2 is decreased. 5 to 35 parts by weight, preferably 10 to 30 parts by weight, more preferably 10 to 20 parts by weight of the liquid polyurethane resin as the binder 2 is added to the parts by weight of the sponge rubber chip 1 and kneaded for 5 to 10 minutes. . Further, the liquid polyurethane resin is mixed by a kneader so that the sponge rubber chip 1 is uniformly coated. As the kneader, a spiral mixer, a planetary mixer, a Hensiel mixer, or the like can be used.

As the binder 2, a liquid material such as an unsaturated polyester resin, an epoxy resin, a phenol resin, or a melamine resin, which is a thermosetting resin, may be used.
Further, in order to bond the plurality of sponge rubber chips 1 with the binder 2 so as to have a gap 3 larger than the bubbles 1a of the sponge rubber, for example, the sponge rubber chips 1 may be charged into the kneader twice. In this case, the sponge rubber chip 1 introduced first is kneaded over a certain period of time so that the binder 2 completely covers the sponge rubber chip 1. In addition, the sponge rubber chip 1 put in the second time is kneaded for a time such that the binder 2 only partially covers the sponge rubber 1. As a result, the sponge rubber chip 1 completely covered with the binder 2 and the partially covered sponge rubber 1 are adhered to each other with a gap therebetween, thereby providing the gap 3.

Next, the mixture of the sponge rubber chip 1 and the binder 2 is filled into a block-shaped or plate-shaped mold, and the mixture in the mold is heated and pressed at a pressure of 0.3 to 0.5 MPa through the lid of the mold. To do.
As a result, the polyurethane resin, which is a thermosetting resin, as the binder 2 is cured, and the mixture is formed into a layer, whereby the floating floor cushioning material 10 is completed.

  The molding time and temperature by the press are the time and temperature necessary for curing the binder 2, and the fuel cost and work cost increase when the temperature is increased for a long time. -30 minutes, more preferably 110-150 ° C for 10-20 minutes.

In addition, the volume of the floating floor cushioning material 10 as a finished product can be changed according to the degree of pressure applied to the mixture of the sponge rubber chip 1 and the binder 2 to adjust the size of bubbles in the floating floor cushioning material. it can.
Further, if the plurality of adjacent sponge rubber chips 1 can be bonded by the binder 2 which is a thermosetting resin, the pressure can be applied by bonding the plurality of adjacent sponge rubber chips 1 only by a heating process without applying pressure. Compared to the case, the size of the gap 3 can be increased.

The floating floor cushioning material 10 manufactured by the process described above has a density of 0.16 to 0.35 g / cm ³ when calculated with a porosity of 60% (a filling rate of 40%), and is static per unit area. Since the spring constant is in the range of 2.5 to 8.0 × 10 ⁶ N / m ³ , two kinds of glass wool cushioning materials for floating floors in Japanese Industrial Standard (JIS A 6322 (glass wool impact material for floating floors)) or Comparable to 3 types.

  In this first embodiment, the floating floor cushioning material 10 is manufactured by hot pressing, but the sponge rubber chip 1 and the binder 2 are placed in the cavity formed by the upper mold and the lower mold. After the mixture is filled and clamped, heated and pressurized steam is sent into the cavity from a plurality of air holes provided so as to communicate with the cavity from the outside, and the mixture is crosslinked and cured. Thus, it is possible to manufacture the cushioning material 10 for floating floors.

  Hereinafter, regarding the floor impact sound insulation performance of the cushioning material 10 for floating floors, using the examples and comparative examples according to the present invention, Japanese Industrial Standards (JIS A 1418-1 (Method for measuring floor impact insulation performance of buildings) -Part 1: Method based on standard lightweight impact source), JIS A 1418-2 (Method for measuring floor impact sound insulation performance of buildings-Part 2: Method based on standard weight impact source))) I will explain.

First, the Example which concerns on this invention among measurement samples is described.
Sponge rubber EP whose raw material rubber is ethylene propylene rubber (EPDM) and sponge rubber CR whose raw material rubber is chloroprene rubber (CR) are made into sponge rubber chips having an average particle diameter of 9 mm by a pulverizer. Crush each.

A liquid polyurethane resin is added and kneaded as a binder to the sponge rubber chip EP of the sponge rubber EP and the sponge rubber chip CR of the sponge rubber CR. In this case, the blending ratio of the sponge rubber chip EP, the sponge rubber chip CR, and the binder is, by weight ratio, sponge rubber chip EP: sponge rubber chip CR: binder = 440: 440: 130.
The examples can be produced by subjecting the kneaded sponge rubber chip EP, the sponge rubber chip CR, and the binder to the heating press described above.

In this example, a plate-like cushioning material for a floating plate having a density of 0.16 g / cm ³ , a top surface and a bottom surface of 500 mm □ (length 500 mm × width 500 mm) and a thickness of 25 mm was produced. The filling rate is such that the specific gravity 0.4 of the floating plate cushioning material is 40% by weight.

In the example, the static spring constant per unit area is 4.0 × 10 ⁶ N / m ³ or less, and the loading load (the load necessary to bend (compress) the sample by 5 mm) is 200 mm □. Is assumed to be 400 N or more (about 1000 kg / m ² ).

Next, a comparative example among the measurement samples will be described.
Comparative Example 1 is an unpulverized sponge rubber EP in which the raw rubber is ethylene propylene rubber (EPDM), the density is 0.20 g / cm ³ , and the top and bottom surfaces are 500 mm □ (length 500 mm × width 500 mm). This is a plate-like sample having a thickness of 25 mm.

Comparative Example 2 is a non-crushed sponge rubber CR1 whose raw material rubber is chloroprene rubber (CR), has a density of 0.20 g / cm ³ , and an upper surface and a bottom surface of 500 mm □ (length 500 mm × width 500 mm). This is a plate-like sample having a thickness of 25 mm.
Comparative Example 3 is a non-pulverized sponge rubber CR2 whose raw material rubber is chloroprene rubber (CR), has a density of 0.15 g / cm ³ , and an upper surface and a bottom surface of 500 mm □ (length 500 mm × width 500 mm). This is a plate-like sample having a thickness of 25 mm.

Next, the measurement method will be described.
The floor impact shielding performance by the lightweight impact source of Example 1 and Comparative Examples 1 to 3 is JIS A 1418-1 (Method for measuring floor impact shielding performance of a building-Part 1: Method by standard lightweight impact source), weight The floor impact insulation performance by the impact source was determined in accordance with JIS A 1418-2 (Measurement method of floor impact sound insulation performance of buildings-Part 2: Method by standard weight impact source).

  A measurement sample is placed on a slab having a thickness of 150 mm, a concrete (PC) plate having a thickness of 60 mm is placed on the measurement sample, and a tapping machine or a standard weight impact source, which is a standard lightweight impact source, is placed thereon. I was shocked by a certain bang machine.

  The measurement result of the sound pressure level in each measurement sample with respect to the measurement frequency using the standard lightweight impact source is shown in Table 1, and a graph showing the frequency characteristics based on Table 1 is shown in FIG. In FIG. 2, the solid line indicates Example 1 according to the first embodiment, the broken line indicates Comparative Example 1, the alternate long and short dash line indicates Comparative Example 2, and the alternate long and two short dashes line indicates Comparative Example 3.

  Moreover, the measurement result of the sound pressure level in each measurement sample with respect to the measurement frequency using the standard weight impact source is shown in Table 2, and a graph showing the frequency characteristics based on Table 2 is shown in FIG. In FIG. 3, the solid line indicates Example 1 according to the first embodiment, the broken line indicates Comparative Example 1, the alternate long and short dash line indicates Comparative Example 2, and the two-dot chain line indicates Comparative Example 3.

  As shown in FIG. 2, the sound pressure level of the cushioning material 10 for the floating floor according to the embodiment using the standard lightweight impact source is clearly lower than those of Comparative Examples 1 to 3, and the sponge rubber is crushed from the sponge rubber. After forming a sponge rubber chip 1, a plurality of adjacent sponge rubber chips 1 are bonded with a binder 2, and a gap 3 larger than the sponge rubber bubbles 1 a is provided between the plurality of bonded sponge rubber chips 1. It can be seen that the floor impact sound insulation performance is significantly improved in light impact.

  As shown in FIG. 3, with respect to the sound pressure level of the floating floor cushioning material 10 according to the embodiment using the standard weight impact source, the floor impact sound blocking performance of the floating floor cushioning material 10 using the standard lightweight impact source is improved. Although not so remarkable, it is lower than those of Comparative Examples 1 to 3, and it can be seen that the floor impact sound blocking performance is improved in weight impact.

Next, a floating floor structure in which the cushioning material 10 for floating floor according to the first embodiment is used for a building will be described.
As shown in FIG. 4, a plurality of floating floor cushioning materials 10 are laid over substantially the entire upper surface of the slab 4, and the floating floor cushioning materials 10 are also disposed around the slab 4 as necessary. In this case, 1 m □ (length 1 m × width 1 m) floating floor cushioning material 10 is inconvenient to carry because product productivity is poor, and 300 mm □ (length 300 mm × width 300 mm) floating floor cushioning material 10 is used for construction. It takes time and effort. For this reason, the cushioning material 10 for floating floors is formed in a block that is convenient to carry and is easy to carry out on-site, for example, a block having a length of 500 ± 5 mm × width of 500 ± 5 mm × thickness of about 25 ± 2 mm. .

  Further, a waterproof layer 5 such as a polyethylene film is disposed over the entire upper surface of the floating floor cushioning material 10 as necessary. Further, concrete is placed over the entire upper surface of the floating floor cushioning material 10 through the waterproof layer 5. Thus, the floating floor structure is configured to support the load of the concrete floor portion 6 on the slab 4 via the floating floor cushioning material 10.

As described above, the floating floor cushioning material 10 according to the first embodiment can reuse the end material, which is an unnecessary part of sponge rubber used for other applications, and the conventional cushioning material. Compared to the case where the manufacturing cost can be reduced as compared with the case where the sponge rubber is used as a cushioning material without pulverizing the sponge rubber, the floor impact sound blocking performance is high.
Moreover, by using the cushioning material for floating floors for the floating floor structure, the construction when laying the cushioning materials becomes easy, the number of man-hours on site is small, and the construction period can be shortened.

It is a partial expanded sectional view which shows the buffer material for floating floors in 1st Embodiment for implementing this invention. It is the graph which showed the sound pressure level in each measurement sample with respect to the measurement frequency using a standard lightweight impact source. It is the graph which showed the sound pressure level in each measurement sample with respect to the measurement frequency using a standard weight impact source. It is a schematic perspective view which shows the floating floor structure using the shock absorbing material for floating floors shown in FIG.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Sponge rubber chip 1a Bubble 2 Binder 3 Gap 4 Slab 5 Waterproof layer 6 Floor 10 Buffer material for floating floor

Claims (6)

A plurality of sponge rubber chips obtained by pulverizing sponge rubber containing bubbles,
A binder that bonds the plurality of sponge rubber chips;
A cushioning material for a floating floor, wherein a plurality of adjacent sponge rubber chips are bonded with the binder, and a gap larger than the bubbles is provided between the bonded sponge rubber chips. In the floating floor cushioning material according to claim 1,
The cushioning material for a floating floor, wherein the sponge rubber chip is obtained by pulverizing a plurality of sponge rubbers having different densities. In the floating floor cushioning material according to claim 1 or 2,
The sponge rubber chip is obtained by pulverizing a plurality of sponge rubbers which are different raw materials. Laying the cushioning material for floating floor according to claim 1 on the upper surface of the slab,
A floating floor structure in which concrete is placed on the cushioning material for the floating floor. Crushing sponge rubber into sponge rubber chips;
Adding and kneading a binder which is a thermosetting resin to the sponge rubber chip;
Heating and / or pressurizing the kneaded sponge rubber chip and binder;
A method for producing a cushioning material for floating floors, comprising: In the manufacturing method of the shock absorbing material for floating floors of the said Claim 5,
The sponge rubber chip has a particle size of 6 mm to 9 mm.

Images