JP2009167672A - Soundproof floor substrate - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a floor substrate which is formed of a composite sheet of a polyolefin resin foamed sheet and a nonwoven fabric, exerts excellent soundproof properties, and achieves positive and firm bonding of the polyolefin resin foamed sheet poor in adhesiveness onto a sill such as a floor slab. <P>SOLUTION: The floor slab is produced by laminating the nonwoven fabric 2 on the polyolefin resin foamed sheet 1, perforating a number of small-diameter sound absorbing pores 3 formed of micropores penetrating from the nonwoven fabric 2 to a lower surface of the polyolefin resin foamed sheet 1 by needle-punching to shove a part of the nonwoven fabric 2 into the small-diameter sound absorbing pores 3. Thus the floor slab is formed into a laminated unitary body and exerts improved sound-absorbing properties by virtue of fiber portions 2a in the small-diameter sound absorbing pores 3 without bonding the polyolefin resin foamed sheet 1 and the nonwoven fabric 2 to each other. Further part of the nonwoven fabric fibers are protruded from an opening lower edge of each small-diameter sound absorbing pore 3, and therefore the presence of the fibers brings about positive and firm bonding between the floor substrate and the sill. <P>COPYRIGHT: (C)2009,JPO&INPIT

Description

  The present invention relates to a soundproof floor base material made of a sheet material having soundproof performance.

  Conventionally, when flooring is laid in a building such as an apartment house or a detached house, the floor under the floor has soundproofing to prevent the impact sound generated on the flooring from propagating downstairs. Ground material is laid. Such flooring materials are made of polyethylene foam sheet with excellent cushioning properties, urethane, compressed urethane, nonwoven fabric, foamed rubber, etc., and many fine through holes and irregularities are formed to improve the soundproofing performance. The sheet is widely used.

  For example, as described in Patent Document 1, an ethylene resin closed cell foam sheet provided with a large number of fine through-holes and a non-woven fabric are laminated and laminated integrally with an adhesive, and bonded together. Ground sheets are known.

Japanese Patent Laid-Open No. 11-22168

  Closed-cell foamed sheets such as ethylene-based resin closed-cell foamed sheets are less likely to sag due to load compared to open-celled foamed sheets. There is a drawback that the sound absorption coefficient is extremely low compared to sheets and non-woven fabrics. Porous materials such as open-cell foamed sheets, nonwoven fabrics, or glass wool are excellent in sound absorbing function because the energy of incident sound is converted to thermal energy when passing through this material and is reduced and disappears. However, the closed-cell foamed sheet does not have such a property, so as described above, a large number of fine through-holes are formed into continuous bubbles, and the sound-absorbing action is obtained by the through-holes. It is comprised so that it may play.

  However, even if a large number of fine through-holes are drilled in the closed cell foam sheet, this sheet alone has a limit in soundproofing performance as a floor base material, and therefore, as described in Patent Document 1, The nonwoven fabric is laminated and bonded to this closed cell foam sheet, but if the closed cell foam sheet and the nonwoven fabric are bonded, the sound absorption rate is lowered by the adhesive layer, and the soundproofing as a floor base material is required unless the thickness exceeds the expected level. There is a problem that it is difficult to ensure performance.

  Furthermore, since polyolefin resin foam sheets such as the above-mentioned ethylene resin closed cell foam sheets have poor compatibility with adhesives, when laminating and bonding the nonwoven fabric to the polyolefin resin foam sheets, corona discharge is applied to the surface. If treatment is not performed, there is a problem that adhesion failure occurs. In addition, when the polyolefin resin foam sheet is adhered to a base such as a floor slab, the adhesion becomes difficult, so that the back surface of the polyolefin resin foam sheet can be easily adhered to the base. Although it will be necessary to adhere | attach other materials, such as a long-fiber nonwoven fabric and urethane, if it does so, as above-mentioned, ensuring of the sound-insulation performance as a floor base material will become difficult.

  The present invention has been made in view of such problems, and the object of the present invention is to use a floor base material in spite of employing a composite sheet of a polyolefin resin foam sheet and a nonwoven fabric as a floor base material. An object of the present invention is to provide a soundproof floor base material that ensures excellent soundproofing performance as a material and can also reliably adhere to a base such as a floor slab.

  In order to achieve the above object, the sound-insulating floor base material of the present invention is a sound-insulating floor base material comprising a composite sheet in which a nonwoven fabric and a polyolefin resin foam sheet are stacked one above the other as described in claim 1. The polyolefin resin foam sheet is provided with a large number of small-diameter sound absorbing holes penetrating between the upper and lower surfaces, and some of the non-woven fabric fibers are filled in the small-diameter sound absorbing holes. The resin foam sheet is laminated and integrated without using an adhesive, and a part of the nonwoven fabric fiber is protruded from the opening end of the small-diameter sound absorbing hole opened on the lower surface of the polyolefin resin foam sheet. It has a structure.

  In the soundproof floor base material configured as described above, in the invention according to claim 2, the polyolefin resin foam sheet is formed of a polyethylene resin closed cell foam sheet, and a lower surface facing a base such as a floor slab is formed on an uneven surface. And the lower end of the small-diameter sound absorbing hole is opened downward from the uneven surface.

  According to the first aspect of the present invention, there is provided a soundproof floor base material composed of a composite sheet in which a nonwoven fabric and a polyolefin resin foam sheet are stacked one above the other, and penetrates between the upper and lower surfaces of the polyolefin resin foam sheet. A large number of small-diameter sound absorbing holes are provided, and some of the non-woven fabric fibers are filled in each small-diameter sound absorbing hole, and the non-woven fabric and the polyolefin resin foam sheet are laminated and integrated without adhesives. Therefore, despite the fact that it uses a polyolefin resin foam sheet that has poor compatibility with adhesives and is difficult to bond to nonwoven fabrics, this polyolefin is filled with nonwoven fabric fibers filled in many small-diameter sound absorbing holes. A floor base material can be constructed by firmly laminating and integrating a resin-based resin foam sheet and a non-woven fabric. Since the adhesive layer is not provided on the joint surface with the cloth, the sound absorbing function by the small-diameter sound absorbing holes and the nonwoven fabric can be effectively exhibited, and a floor base material excellent in soundproofing can be provided. it can.

  Furthermore, since the multilayered fine voids are formed in the small-diameter sound absorbing holes by the nonwoven fabric fibers filled in the large number of small-diameter sound absorbing holes penetrating the polyolefin resin foam sheet, the impact sound is not very small. When passing through the air gap, the sound energy can be smoothly converted into heat energy by friction with the surroundings, and sound absorption can be achieved. be able to.

  Moreover, in addition to the synergistic effect of the sound absorption performance of the large number of small-diameter sound absorption holes into which the nonwoven fabric fibers are pushed in and the sound absorption capability of the nonwoven fabric itself, as described above, the joint surface between the polyolefin resin foam sheet and the nonwoven fabric is Since the adhesive layer is not provided, it is possible to suppress a decrease in vibration damping due to the curing of the adhesive, and thus improve the transmission soundproofing property (LL-value measured according to JIS A1440) at the same thickness. Can be made.

  In addition, when laying a soundproof floor base material composed of a composite sheet of the nonwoven fabric and polyolefin resin foam sheet on a base such as a floor slab, the soundproof floor base material has flexibility and cushioning properties. Of course, it is easy to lay on a flat surface such as a floor slab and can be easily laid. Slabs, etc. by adhering and permeating the nonwoven fabric fibers protruding from the small-diameter sound absorption holes without corona discharge treatment to eliminate poor adhesion on the lower surface of the polyolefin resin foam sheet. The floor base material can be easily and reliably adhered to the laying surface of the floor.

  According to the invention of claim 2, since the polyolefin resin foam sheet is made of a polyethylene resin closed cell foam sheet, it can function as a floor base material for a long period of time without causing a sag like an open cell foam sheet. Of course, since the lower surface of this polyolefin-based resin foam sheet is formed as an uneven surface, it can exhibit good cushioning and cushioning properties as a floor base material. Since the groove-shaped space portion is formed vertically and horizontally in the plane direction on the lower surface of the polyolefin resin foam sheet, the groove passes through the small-diameter sound absorbing hole that opens downward from the groove bottom surface. The sound that enters the groove-like space part is diffused in the groove-like space part, and the air layer is vibrated while being irregularly reflected by the groove wall. Energy is then converted into heat energy, effectively absorbing in the groove-like space, it can be attenuated.

  Next, a specific embodiment of the present invention will be described with reference to the drawings. FIG. 1 is a partially cutaway perspective view of a soundproof floor base material, and FIG. 2 is an enlarged longitudinal sectional view thereof. The material is composed of a composite sheet of a polyolefin resin foam sheet 1 such as polyethylene and polypropylene and a nonwoven fabric 2 laminated and integrally layered on the upper surface of the polyolefin resin foam sheet 1. Small-diameter sound absorbing holes 3 made up of a large number of fine holes penetrating from the upper surface to the lower surface of the polyolefin-based resin foam sheet 1 are vertically and horizontally spaced at small intervals, and the lower ends of all the small-diameter sound absorbing holes 3 are disposed at the polyolefin-based resin foam sheet. 1 is opened on the lower surface.

  In addition, some of the fibers of the nonwoven fabric 2 are pushed into the small-diameter sound absorbing holes 3 to form the filled fiber portion 2a, and the polyolefin resin foam sheet 1 and the nonwoven fabric 2 are formed by the filled fiber portion 2a. Are laminated and integrated without using an adhesive, and the lower end portion of the filling fiber portion 2a is protruded downward from the lower end of the small-diameter sound absorbing hole 3 below the lower surface of the polyolefin-based resin foam sheet 1, thereby protruding fiber portion 2b. Is formed. A number of small-diameter sound absorbing holes 3 penetrating between the upper and lower surfaces of the polyolefin-based resin foam sheet 1 are formed, and the small-diameter sound absorbing holes 3 are filled with the fibers of the nonwoven fabric 2, and the lower end portion of the fibers is connected to the polyolefin-based resin foam sheet 1. You may form in the protruding fiber part 2b which protruded below from the lower surface of the resin foam sheet 2. FIG.

As the polyolefin-based resin foamed sheet 1, an open-cell foamed sheet can be used, but a closed-cell foamed sheet is adopted in consideration of strength required as a floor base material. Since the sheet is extremely inferior in sound absorption compared to the open-cell foamed sheet, as described above, the small-diameter sound absorbing holes 3 made of a large number of fine holes are formed. Moreover, as the nonwoven fabric 2 laminated on the upper surface of the polyolefin resin foam sheet 1, natural fibers such as wood fibers or glass wool can be used. In this embodiment, however, fine fibers such as polypropylene and polyester are used. A non-woven fabric is used that is entangled with synthetic resin fibers that are flexible in diameter. In this case, the nonwoven fabric can use both short fibers and long fibers, and preferably has a basis weight of 20 to 500 g / m ² , and the fiber thickness is preferably 3 denier or more, more preferably 5 to 10 denier. preferable.

  The thickness of the sound-insulating floor base material composed of the composite sheet of the polyolefin resin foam sheet 1 and the nonwoven fabric 2 is not particularly limited, but in order to be practically usable as the floor base material, the thickness is 1.0 to 10.0 mm. It only has to be formed. Further, the aperture ratio of the small-diameter sound absorbing hole 3 with respect to the area of the soundproof floor base material may be set so that the strength as the floor base material, the sound absorbing property, and the like are balanced. Further, the expansion ratio and closed cell ratio of the polyolefin resin foam sheet 1 are not particularly limited, but the expansion ratio of the polyolefin resin foam sheet is preferably 5 to 50 times, and the polyolefin after the small-diameter sound absorbing holes are formed is provided. 20-60% of the closed cell ratio measured based on ASTM D2856 of the resin-based resin foam sheet is preferable.

  In order to manufacture the soundproof floor base material configured as described above, as shown in FIG. 3, the non-woven fabric 2 is directly laminated on the upper surface of the polyolefin resin foamed sheet 1 without subjecting it to corona discharge treatment. After the matching, the template 4 having a large number of small-diameter needles 5 protruding on the lower surface, which is longer than the thickness of the floor base material, is pressed against the nonwoven fabric 2 from above the nonwoven fabric 2 as shown in FIG. The needle 5 is penetrated from the upper surface of the nonwoven fabric 2 to the lower surface of the polyolefin resin foam sheet 1.

At this time, a small-diameter sound absorbing hole 3 made of the fine holes is formed in the polyolefin resin foam sheet 1 by the needle 5 pierced from the upper surface of the nonwoven fabric 2 until it penetrates the lower surface of the polyolefin resin foam sheet 1. When a portion of the fiber is pierced by the needle 5, it is pushed into the small-diameter sound absorbing hole 3 formed by the needle 5 together with the needle 5 and into the small-diameter sound absorbing hole 5, as shown in FIG. 2a is provided, and the lower end portion of the filling fiber portion 2a is pushed downward from the lower end of the small-diameter sound absorbing hole 3 by the tip portion of the needle 5 protruding downward from the small-diameter sound absorbing hole 3, thereby providing the protruding fiber portion 2b. . In addition, it is preferable to use a needle 5 having a thickness (diameter) of 0.1 to 5.0 mm, and drilled so that the number of needle holes (perforation density) is 3 to 50 / cm ^2. It is preferable to do.

  FIG. 5 shows an example of construction of the soundproof floor base material. A polyolefin resin foam sheet 1 in the soundproof floor base material is laid on the upper surface of a base 6 such as a slab with an adhesive 7. The lower surface of the foam sheet 1 is fixed on the base 6 with the adhesive 7. At this time, since the corona discharge treatment or the like is not performed on the lower surface of the polyolefin resin foam sheet 1, the adhesion to the base 6 is poor. However, the polyolefin resin foam sheet 1 is provided with a large number of small-diameter sound absorbing holes 3. Since some of the non-woven fibers protrude downward from the lower surface of the polyolefin resin foamed sheet 1 through the small-diameter sound absorbing holes 3, the adhesive 7 adheres to the protruding fiber portion 2b and solidifies in a permeated state. Thus, the polyolefin resin foam sheet 1 can be firmly fixed on the base 6.

As the above-mentioned soundproof floor base material, specifically, a nonwoven fabric having a basis weight of 200 g / m ² is superposed on a polypropylene resin foam sheet 1 having a thickness of 3.3 mm, and a needle 5 having a thickness of 2.5 mm. The small-diameter sound absorbing hole 5 is drilled so that the number of needle holes (perforation density) is 8 / cm ^2, and the closed cell ratio of the polypropylene resin foam sheet after the small-diameter sound absorbing hole 5 is drilled is 40%. A base material having a thickness of 6.0 mm can be given.

  After the soundproof floor foundation is thus constructed on the base 6, the flooring 9 is constructed via the adhesive 8 on the nonwoven fabric 2 in the soundproof floor foundation material. At this time, the adhesive 8 may be applied to the fibers of the nonwoven fabric 2 even if the adhesive 8 is applied in the form of a plurality of strips or evenly scattered dots without applying the adhesive 8 to the entire lower surface of the flooring 9. The agent 8 can be firmly adhered and penetrated to be firmly fixed.

  In the floor structure thus constructed, when an impact sound is generated due to an article falling on the floor material 9, the sound is first absorbed and attenuated by the nonwoven fabric 2 on the upper layer side of the soundproof floor base material. In addition, the small-diameter sound absorbing hole 3 and the small-diameter sound absorption hole 3 pass through the small-diameter sound absorbing hole 3 formed of a large number of fine holes provided in the polyolefin-based resin foam sheet 1 forming the lower layer of the soundproof floor base material from the nonwoven fabric 2. Sound is efficiently absorbed by the filled fiber portion 2a made of a part of the nonwoven fabric fibers pushed into the sound absorbing holes 3, and an adhesive layer is formed on the overlapping surface of the polyolefin resin foam sheet 1 and the nonwoven fabric 2. Since it is not provided, the vibration damping property due to the curing of the adhesive can be suppressed, and therefore, the propagation of the impact force to the downstairs or the like can be effectively suppressed.

  FIG. 6 shows another embodiment of the present invention, which is composed of a composite sheet of a polyolefin resin foam sheet 1 made of a polyethylene resin closed cell foam sheet and a nonwoven fabric 2, and the polyolefin resin foam sheet from the upper surface of the nonwoven fabric 2. A small-diameter sound absorbing hole 3 consisting of a large number of fine holes penetrating the lower surface of 1 is formed at every small interval in the vertical and horizontal directions, and the lower ends of all the small-diameter sound absorbing holes 3 are opened on the lower surface of the polyolefin resin foam sheet 1. Furthermore, a part of the fibers of the nonwoven fabric 2 are pushed into the small-diameter sound absorbing holes 3 to form the filled fiber portion 2a. The filled fiber portion 2a allows the polyolefin resin foam sheet 1 and the nonwoven fabric 2 to be formed. Are laminated and integrated without using an adhesive, and the lower end portion of the filling fiber portion 2a is connected to the polyolefin resin foam sheet 1 from the lower end of the small-diameter sound absorbing hole 3. The bottom surface of the polyolefin resin foam sheet 1 is formed on the concavo-convex surface 1a by embossing in the same manner as in the above embodiment in that it protrudes downward from the surface and is formed in the protruding fiber portion 2b. It is.

  According to the soundproof floor base material configured as described above, the lower surface of the polyolefin-based resin foam sheet 1 is formed on the concavo-convex surface 1a in addition to the operational effects exhibited by the soundproof floor base material shown in the above embodiment. In addition to exhibiting good cushioning and cushioning properties as a floor base material, a groove-like space 10 is formed on the bottom surface of the polyolefin-based resin foam sheet 1 vertically and horizontally in the plane direction by the uneven surface 1a. In the large number of small-diameter sound absorbing holes 3 penetrating from the upper surface of the nonwoven fabric 2 to the lower surface of the polyolefin resin foam sheet 1, the lower end opening is formed on the groove bottom surface of the groove-shaped space 10 or the side wall surface of the groove. In the small-diameter sound absorbing hole 3 penetrating through the small-diameter sound hole, when the impact sound passes through the small-diameter sound absorbing hole 3 from the nonwoven fabric 2 side, it diffuses in the groove-like space portion 10 and diffusely reflects on the groove wall. Air layer in the groove The sound energy is converted into thermal energy by vibration and friction with the surroundings, so that the sound can be absorbed and attenuated more effectively in the groove-like space.

  In addition, the manufacturing method of this soundproof floor base material is the same as the said Example, but the protrusion length is longer than the thickness of a floor base material in the composite sheet formed by superimposing the nonwoven fabric 2 on the upper surface of the polyolefin-type resin foam sheet 1. It can be obtained by applying a needle punch with a template 4 on which a large number of long small-diameter needles 5 are projected.

  In addition, the large number of small-diameter sound absorbing holes 3 are directly drilled in the polyolefin resin foam sheet 1 by a laser or the like without using a needle punch, and the fibers of the nonwoven fabric 2 are sucked from the lower surface side of the polyolefin resin foam sheet 1 by suction. A part of the small-diameter sound absorbing hole 3 may be sucked and filled, and a part of the small-diameter sound absorbing hole 3 may be formed as a protruding fiber portion 2b protruding downward.

FIG. 3 is a simplified perspective view with a partially cutout of a soundproof floor base material. FIG. The vertical side view which shows a manufacturing method. The vertical side view of the state which gave the needle punch. The vertical side view which shows a construction state. The vertical side view which shows another embodiment of this invention.

Explanation of symbols

1 Polyolefin resin foam sheet 2 Nonwoven fabric
2a Filled fiber part
2b Protruding fiber part 3 Small diameter sound absorption hole

Claims (2)

  A soundproof floor base material composed of a composite sheet in which a nonwoven fabric and a polyolefin resin foam sheet are stacked one above the other, and the polyolefin resin foam sheet is provided with a large number of small-diameter sound absorbing holes penetrating between the upper and lower surfaces. In addition, a part of the non-woven fabric fiber is filled in each small-diameter sound absorbing hole, and the non-woven fabric and the polyolefin resin foam sheet are laminated and integrated by this fiber without using an adhesive, and further, the polyolefin resin foam sheet. A soundproof floor base material, characterized in that a part of the nonwoven fabric fiber is protruded to the outside from the opening end of the small-diameter sound absorbing hole that is open on the lower surface of the floor.   The polyolefin-based resin foam sheet is made of a polyethylene resin closed cell foam sheet. The bottom surface of the floor slab or the like facing the base is formed as an uneven surface, and the lower end of the small-diameter sound absorbing hole is opened downward from the uneven surface. The soundproof floor base material according to claim 1, wherein:

Images