JP2013113067A - Soundproof floor material - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a soundproof floor material that is excellent in the sense of walking, load bearing, and settling resistance as well as soundproof performance, by a simpler method.SOLUTION: To prevent the sinking of a soundproof floor material, filament nonwoven fabric formed of fiber mainly composed of thermoplastic resin with a fineness of 250-1700 dtex is used, so that the soundproof performance and the sense of walking become excellent, and the soundproof floor material can be produced by a very simple method.

Description

  The present invention relates to a soundproof flooring material that is excellent not only in soundproofing performance but also in a feeling of walking.

  Conventionally, in apartment houses such as condominiums, tatami mats, cushioned floors, foamed resin tiles, carpets, wooden floor materials, etc. have been used as flooring in living spaces to prevent noise from upstairs to downstairs. It was. Since people's lifestyles vary, floor materials have recently been required to have further improved soundproofing performance. In addition, an increasing number of people desire a healthy life in harmony with nature, and in particular, there is an increasing demand for wooden floor materials.

  Living noise is classified into two types: heavy impact sound and light impact sound. In order to reduce the heavy impact sound, it is effective to mainly change the rigidity of the building structure and the density of the structure, for example, increasing the floor slab. On the other hand, in order to reduce the light impact sound, it is effective to improve the finish state of the floor surface and to appropriately select a soundproof floor material that can suppress the transmission of the impact sound. However, soundproof flooring has a layer (soundproofing layer) made of a soft material such as non-woven fabric or foamed urethane. When people walk, When heavy objects such as pianos and bookshelves are installed for a long period of time, the floor is partially tilted and the soundproof layer sinks.

  Therefore, in recent years, various flooring materials that have excellent noise propagation prevention performance and good walking ability have been studied. For example, a soundproof flooring material having a soft layer made of a synthetic resin non-woven fabric or foamed soft urethane and a hard layer made of a three-dimensional network structure in which upper and lower mesh fiber knitting parts are connected to each other by a large number of support yarns ( Patent Document 1), there is a floor structure in which a non-woven fabric having soundproof performance and a foam sheet in which a through-hole penetrating between upper and lower surfaces is formed are laminated (Patent Document 2). Moreover, in order to improve walkability, there exists a floor sound-absorbing material in which dot grains or lines are provided in any one of the laminated body (cured layer, buffer layer) and the water shielding layer (Patent Document 3).

JP 2011-111817 A JP 2010-053559 A JP 2010-174438 A

  However, a hard layer made of a three-dimensional network structure is very expensive and is not economical. Moreover, even if the foam sheet in which the through-hole was formed is used, since the nonwoven fabric is crushed down by weight, sinking of the floor cannot be reduced. Furthermore, in order to provide dot grains or lines, the resin composition as a raw material must first be stirred in advance with an oak mixer until the desired foaming ratio and viscosity are obtained. The manufacturing process is complicated because it is uniformly applied in the thickness and width directions using a coater or the like.

  In addition, it has been pointed out that the hard layer made of a three-dimensional network structure has low load resistance in the thickness direction (paragraph 0019 of Patent Document 1), and when a foamed sheet in which a through hole is formed is used. In addition, when dot grains or lines are provided, the soundproof layer that does not come into contact with them easily enters these, and there is a concern that the soundproof layer may be damaged by long-term use.

Under such circumstances, an object of the present invention is to provide a soundproof flooring material excellent not only in soundproofing performance but also in walking feeling by a simpler method.
Another object of the present invention is to provide a soundproof flooring material excellent in load resistance and sag resistance.

  As a result of intensive studies to solve the above-mentioned problems, the inventors of the present invention have developed a very long length formed from fibers made of a thermoplastic resin having a fineness of 250 to 1700 dtex in order to prevent sinking of the soundproof flooring. It has been found that when a fiber nonwoven fabric is used, the soundproofing performance and the walking feeling are excellent, and this soundproofing flooring material can be produced by a very simple method, and the present invention has been completed. Further, such a soundproof flooring material is excellent in load resistance and sag resistance.

That is, the soundproof floor according to the present invention is a soundproof floor composed of a floor surface material (A) and a soundproof floor main body (E) formed of a plurality of layers and supporting the surface material (A) on the back surface. The plurality of layers include a soundproofing part (B) having a soundproofing layer and a sinking prevention part (C), and the sinking prevention part (C) has a fineness of 250 to 1700 dtex. It is characterized in that it is an extremely thick long-fiber nonwoven fabric formed from fibers made of this thermoplastic resin. In the soundproof flooring of the present invention, the thickness of the extra-thick long fiber nonwoven fabric is 1.0 to 5.0 mm, the basis weight is 50 to 500 g / m ² , and the compression elasticity after pressing for 24 hours with a load of 10 kg / 100 cm ^2. The recovery rate is preferably 97 to 100%, and it is preferable that the fiber made of the thermoplastic resin forming the extra-thick long fiber nonwoven fabric is a polyolefin fiber. Furthermore, it is preferable that a sinking prevention part (C) is formed on the back side of the soundproof part (B). The soundproof portion (B) is a laminate of a smooth layer and a soundproof layer formed from a spunbond nonwoven fabric, and the soundproof layer is a chemical bond nonwoven fabric or a thermal bond nonwoven fabric and has a thickness of 2.0 to 6. It is preferable that the weight is 5 mm, the basis weight is 80 to 500 g / m ² , and the porosity is 93 to 99%. It is preferable that the soundproof floor main body (E) has a water shielding portion (D) for preventing water from passing through on the outermost surface, and the floor surface material (A) has a laminating slit. A wooden floor material is preferred.

  According to the present invention, by using an extremely long fiber nonwoven fabric formed of fibers made of a thermoplastic resin having a fineness of 250 to 1700 dtex, a soundproof flooring material excellent not only in soundproofing performance but also in walking feeling can be easily obtained. It can be provided by the method. The soundproof flooring of the present invention has good load resistance and can prevent deformation of the soundproof layer even when used for a long time.

FIG. 1 is a schematic sectional view showing an example of a soundproof flooring according to the present invention. FIG. 2 is a photograph of an example of the subsidence prevention part (C) of the present invention. FIG. 3 is a photograph of a sectional view of the subsidence prevention part (C) of the present invention.

  Hereinafter, the sound-insulating flooring according to the present invention will be described in detail with reference to the drawings showing the embodiments. However, the present invention is not limited to the illustrated examples, and can be adapted to the purpose described above and below. It is also possible to carry out by appropriately changing the range, and all of them are included in the technical scope of the present invention.

<< Example of illustration >>
FIG. 1 is a schematic cross-sectional view showing an example of a soundproof flooring 15 according to the present invention. As shown in FIG. 1, a soundproof floor 15 of the present invention includes a floor surface material (A) 1 made of a known floor material, and a soundproof floor main body (E) 16 that supports the surface material (A) 1 on the back surface. The main body (E) 16 includes a soundproof portion (B) 12 having soundproof performance, a sinking prevention portion (C) 13 for improving walking feeling, and a room for moisture and moisture from the downstairs The water shielding portion (D) 14 that prevents intrusion into the structure has a multilayer structure in which the layers are stacked in this order. Since the soundproofing flooring 15 has the soundproofing part (B) 12 and the sinking-preventing part (C) 13, it is possible to achieve both excellent soundproofing performance and a feeling of walking.

  And in the soundproofing flooring 15 of the example of illustration, the said subsidence prevention part (C) 13 is comprised with the nonwoven fabric (very thick long fiber nonwoven fabric 6) formed from a very thick long fiber, Specifically, the photograph of FIG. It has a structure as shown in FIG. When such a subsidence prevention part (C) 13 is adopted, not only can the subsidence prevention part (C) 13 be easily formed, but also the load in the thickness direction of the subsidence prevention part (C) 13 can be reduced by the diameter of the fiber. Since it can be supported by directional stress, the load resistance can be remarkably enhanced. Moreover, since it is a nonwoven fabric, eyes are clogged to some extent, and the soft soundproofing part (B) 12 hardly enters the sinking prevention part (C) 13, and the sag resistance can be improved.

  In the soundproof flooring 15 of the illustrated example, the soundproofing part (B) 12 is composed of a thin fiber nonwoven fabric having a small diameter and has soundproofing performance, and a smooth nonwoven fabric (smooth) that serves as a base material for the soundproof layer 4. Layer) 3, and the soundproof layer 4 and the smooth layer 3 are joined by a needle punch. The water shielding portion (D) 14 is composed of a film layer 8 having a water shielding performance and a smooth nonwoven fabric (smooth layer) 9 serving as a base material of the film layer 8. The film layer is formed on the smooth layer 9. They are joined by extruding 8. Also, between the floor covering (A) 1 and the soundproofing part (B) 12; between the soundproofing part (B) 12 and the sinking prevention part (C) 13; the sinking prevention part (C) 13 and the water shielding Between the part (D) 14 and between the water-impervious part (D) 14 and the floor slab 11 are connected via adhesive layers 2, 5, 7 and 10, respectively.

<< Example of change >>
<Sink prevention part (C) 13>
The subsidence prevention part (C) 13 is not limited to the examples of FIGS. 1 and 2 and can be appropriately changed within a range showing a predetermined subsidence prevention characteristic. For example, a non-woven fabric (extra-thick long fiber non-woven fabric 6) that is a long fiber formed from a thermoplastic resin and has a fineness of 250 to 1700 dtex can be used as the subsidence prevention part (C) 13 of the present invention. . By using a nonwoven fabric made of very thick fibers, deformation of the entire nonwoven fabric is suppressed, and the sinking prevention performance is improved. In addition, by using very thick fibers for the subsidence prevention part (C) 13, it becomes possible to secure a gap between the fibers, and furthermore, the pressure in the thickness direction can be evenly distributed, so that the deformation of the soundproof layer is suppressed. can do.

  The fineness of the fiber used for the subsidence prevention part (C) 13 is 250 to 1700 dtex, more preferably 300 to 1000 dtex, and still more preferably 400 to 700 dtex. If the fineness is 250 dtex or more, even when a heavy object or the like is placed on the floor, it is preferable that the floor does not sink. Further, if the fineness is 1700 dtex or less, the amount of voids existing between the fibers is appropriate, so that the subsidence prevention part (C) 13 can also exhibit soundproof performance.

  As the fiber, a fiber made from a thermoplastic resin is used. Synthetic fibers such as polyester fiber, nylon fiber, polyolefin fiber, polyurethane fiber, etc., may be used as the fiber made of thermoplastic resin, and fibers having high compression elastic recovery ability, such as polyolefin fiber, elastic polyester fiber, elastic polyurethane, etc. A fiber etc. can be used more suitably. Among them, among the polyolefin fibers, fibers made of low-density polyethylene resin not only have excellent load resistance in the thickness direction, but also easily form a non-woven fabric with less porosity than fibers made from other resins. Since the sound shielding efficiency of the obtained nonwoven fabric is increased, it is preferable.

  The melt flow rate (MFR) at 190 ° C. of the thermoplastic resin is 20 g / 10 min to 150 g / 10 min, more preferably 50 g / 10 min to 100 g / 10 min, and further preferably 60 g / 10 min. ~ 80 g / 10 min. When the melt flow rate is less than 20 g / 10 minutes, the fluidity is poor, and it is not preferable because the spinnability is poor and it is difficult to become a fiber, and when it exceeds 150 g / 10 minutes, the fluidity is large and the yarn is likely to break. Absent.

  The extra-thick long fiber nonwoven fabric 6 is preferably a long fiber (non-cut fiber) nonwoven fabric, particularly a spunbonded nonwoven fabric, in order to ensure inter-fiber voids.

Basis weight of the thick long-fiber nonwoven fabric 6 is preferably 50 to 500 g / m ^2, more preferably 50 to 350 g / m ^2, and most preferably from 100 to 200 g / m ^2. When the basis weight is less than 50 g / m ² , the soundproof performance of the extra-thick long fiber nonwoven fabric 6 becomes difficult to be exhibited. In order to prevent the floor from sinking and sag over time, the thickness reduction ratio of the extra-thick fiber nonwoven fabric 6 is preferably 0 to 25%, more preferably 3 to 20%, and even more preferably 5 to 15%. It is. For the same reason, the compression elastic recovery rate of the very thick fiber nonwoven fabric 6 is preferably 97 to 100%, more preferably 98 to 100%, and further preferably 100%. The thickness reduction rate and the compression elastic recovery rate will be described in detail in the column of Examples.

  The thickness of the subsidence prevention part (C) 13 is preferably 1.0 to 5.0 mm, and more preferably 1.2 to 4.0 mm, in order to increase the load resistance in the thickness direction. If the thickness of the sinking prevention part (C) 13 exceeds 5.0 mm, the sinking prevention part (C) 13 may be bent by pressing in the thickness direction, which is not preferable.

<Soundproof part (B) 12>
The soundproofing part (B) 12 usually has a soundproofing layer 4 and a smoothing layer 3 as a base material of the soundproofing layer 4 as shown in the illustrated example. The soundproof layer 4 is a layer having soundproofing performance, and is not limited to the small-diameter short fiber nonwoven fabric of the illustrated example. Other nonwoven fabrics can be used as long as the nonwoven fabric has a high porosity between fibers, and further inside the structure. It may be a foamed resin layer having many independent bubbles. When the soundproof layer 4 is formed of a foamed resin layer, it is preferable to use a resin such as polystyrene or polyurethane as a raw material.

  When a nonwoven fabric is used for the soundproof layer 4, the fibers constituting the nonwoven fabric for the soundproof layer include synthetic fibers such as polyester fiber, nylon fiber, and olefin fiber; recycled fibers such as rayon fiber and acetate fiber; cotton, hemp, It is recommended to use natural fibers such as wool. Since the fiber is hardly deteriorated and is easily available, it is preferable to use a synthetic fiber, particularly a polyester fiber.

  A fiber may be used by 1 type, and may mix and use multiple types. In particular, when the sound-insulating flooring material 15 is cut with a saw or a rotary blade, or when slits are made, if the fibers of the sound-insulating layer 4 are fixed in advance, the operation can proceed smoothly. Therefore, when using a polyester fiber as a fiber constituting the soundproof layer 4, a regular type fiber having a melting point of about 150 to 260 ° C. and a so-called modified polyester fiber having a melting point of about 100 to 200 ° C. (low melting point fiber, It is preferable to heat-bond the fibers by blending the heat-fusible fibers) and heating the resulting nonwoven fabric.

  The fineness of the fiber constituting the nonwoven fabric for soundproofing layer is, for example, 1 to 30 dtex, more preferably 2 to 25 dtex, and still more preferably 2.2 to 22 dtex. When the fineness is less than 1 dtex, the structure of the nonwoven fabric becomes excessively dense, propagates through the soundproof layer 4 and does not exhibit soundproof performance, which is not preferable. On the other hand, when the fineness exceeds 30 dtex, the structure of the nonwoven fabric becomes rough, and the vibration energy of the generated sound is not sufficiently absorbed and diffused by the soundproof layer 4, which is not preferable.

  In the most preferable nonwoven fabric for soundproof layer, a plurality of fibers having different finenesses are used in combination from the fibers of 1 to 30 dtex. For example, one or more fibers having a fineness of less than 15 dtex and one or more fibers having a fineness of 15 dtex or more are combined. The mass ratio (the former / the latter) of fibers having a fineness of less than 15 dtex and fibers having a fineness of 15 dtex or more is, for example, 30/70 to 70/30, preferably 40/60 to 60/40, and more preferably 45/55. 55/45.

It is preferable that the fiber length of the fiber which comprises the nonwoven fabric for soundproof layers is 20-100 mm, More preferably, it is 32-76 mm. As the fibers, both solid type fibers and hollow type fibers can be preferably used. The basis weight of the soundproof layer 4 is preferably 80 to 500 g / m ² , more preferably 90 to 400 g / m ² , and most preferably 100 to 300 g / m ² .

  The thickness of the soundproof layer 4 is preferably 2.0 to 6.5 mm, more preferably 2.3 to 6.0 mm, and still more preferably 3.5 to 5.5 mm. If the thickness of the soundproof layer 4 is within the above range, it is preferable because the soundproof flooring 15 can sufficiently exhibit the soundproof performance, and the soundproof layer 4 is not too thick and the sinking amount can be reduced.

  The nonwoven fabric for soundproofing layers can be appropriately manufactured by employing a known method. For example, a method in which fibers are blended, an intermediate web formed by a card machine or the like is wrapped using a cross wrapper, etc., and the web is mechanically entangled by a needle punch method or a hydroentanglement method; A method of thermally bonding a non-woven fabric mixed with melting point fibers using a hot air dryer or a hot roll (thermal bond method); spraying or applying various resins (binders) to a nonwoven fabric in which fibers are mechanically entangled Various methods such as a chemical bond method for fixing fibers can be used. The generated sound wave collides with the fiber and the vibration energy is attenuated by resonance in the inter-fiber gap and friction with the fiber. Use of a non-woven fabric produced by a punch method, a hydroentanglement method, or the like is preferable because of excellent sound absorption. However, the mechanically entangled nonwoven fabric has poor resistance to pressing in the thickness direction, and the flooring tends to sink. Therefore, in the present invention, the nonwoven fabric is preferably produced by a chemical bond method in order to prevent the shape of the soundproof layer 4 from collapsing due to the long-term use of the flooring material and the sinking of the floor. The porosity of the soundproof layer 4 is preferably 93 to 99%, more preferably 94 to 98%. If the porosity is within the above range, vibration energy absorption efficiency is good and sound does not propagate downstairs.

  The binder used in the chemical bond method is not particularly limited as long as it is used in the production of nonwoven fabrics. For example, polyacrylate resin, polyurethane resin, ethylene-vinyl acetate resin, polyvinyl chloride resin, polyvinylidene chloride resin, etc. An emulsion binder such as styrene-butadiene latex or neoprene-butadiene latex is preferably used. In order to prevent sinking, it is preferable that the nonwoven fabric for soundproof layer is appropriately cured, but if the nonwoven fabric is cured too much, the generated noise propagates through the nonwoven fabric and leads downstairs. Therefore, it is preferable that the glass transition temperature (Tg) of a binder is -30-30 degreeC. If the glass transition temperature exceeds 0 ° C., the nonwoven fabric is cured and noise is propagated, which is not preferable. On the other hand, if the glass transition temperature is less than −30 ° C., the nonwoven fabric is not sufficiently cured, and the dried nonwoven fabric is a binder. When the nonwoven fabric is produced, various devices (for example, rolls) are soiled with the binder, and when the product is wound up on the roll, the nonwoven fabric is in close contact and it is difficult to unwind the roll.

Although the smooth layer 3 is not essential, it is desirable to use the smooth layer 3 as a base material of the soundproof layer 4. The material of the smooth layer 3 is not particularly limited as long as it can be used as a base material. For example, a fabric such as a nonwoven fabric, a woven fabric, or a knitted fabric; In the case of a fabric, as the fibers, synthetic fibers such as polyester fibers, nylon fibers, and olefin fibers; regenerated fibers such as rayon fibers and acetate fibers; natural fibers such as cotton, hemp, and wool may be used. In particular, in the case of a non-woven fabric, a long-fiber non-woven fabric may be used in order to suppress fuzz and improve workability. For example, a spunbond non-woven fabric is suitable. The laminate of the smooth layer 3 and the soundproof layer 4 is preferably fixed by a mechanical entanglement method, a thermal bond method, a chemical bond method, or the like. The basis weight of the smooth layer 3 is preferably 10 to 100 g / m ² , and more preferably 15 to 50 g / m ² . Moreover, it is preferable that the thickness of the smooth layer 3 is 0.1-0.5 mm.

  When the smooth layer 3 and the soundproof layer 4 are both non-woven fabrics, the fiber / binder ratio is 95/5 to 65/35 in terms of the amount of fibers constituting the non-woven fabric and the amount of binder used for chemical bonding (dry weight). It is preferably 90/10 to 70/30, more preferably 85/15 to 75/25. When the binder ratio exceeds 35% by weight, the fibers are fixed and the sound is easily propagated downstairs. On the other hand, if the binder ratio is less than 5% by weight, it is difficult to cut with a saw or a rotary blade.

The basis weight of the soundproof part (B) 12 is preferably 100 to 600 g / m ² , and more preferably 120 to 400 g / m ² . Moreover, the thickness of the soundproofing part (B) 12 is preferably 2.0 to 7.0 mm, more preferably 2.5 to 6.5 mm. If the thickness of the soundproofing part is within the above range, it is possible to achieve both soundproofing performance and reduction in sinking.

  In the present invention, it is important to form the thickness of the sinking prevention part (C) 13 in an appropriate range with respect to the thickness of the soundproof part (B) 12. That is, when the soundproof portion (B) 12 is thick, the sound absorbing performance is improved. However, since the soundproof layer 4 is made of a soft material, when the soundproof portion (B) 12 is thick, the soundproof layer 4 sinks due to external force. It becomes easy to put. Similarly, when the sinking prevention part (C) 13 becomes thick, the sinking prevention part (C) 13 is easily bent. Therefore, in the present invention, the thickness of the subsidence prevention part (C) 13 is preferably 0.2 to 2.5, more preferably the thickness of the soundproof part (B) 12 (referred to as 1). 0.3 to 1.0.

  When the soundproof layer non-woven fabric is required to have antibacterial properties, antistatic properties, flame retardancy, etc., components having these functions may be added to the binder, or dispersed or applied before and after the production of the non-woven fabric.

<Water shielding part (D) 14>
In the soundproof flooring 15 of the present invention, the water shielding part (D) 14 is not essential, but it is desirable to provide the water shielding part (D) 14 in order to prevent moisture and moisture from entering the room from entering the room. . Although the water-impervious portion (D) 14 only needs to have at least the film layer 8, it is usually laminated with a smooth layer 9 that becomes a base material of the film layer 8. As the smooth layer 9, the material detailed in the column of the smooth layer 3 can be used. The smooth layer 9 and the smooth layer 3 may be the same or different. In order to improve water repellency, it is particularly preferable that the smooth layer 9 has a compaction between fibers by embossing or the like.

  The film layer 8 is preferably laminated on the smooth layer 9, and as a lamination method, a method of fixing the film layer 8 and the smooth layer 9 with an adhesive or the like (dry lamination method or the like); A method (such as an extrusion lamination method) in which the raw material resin is melted and extruded on the smooth layer 9 is suitable.

  For the film layer 8, a film formed from a thermoplastic resin is suitably used. Examples of the thermoplastic resin include polyester resin, nylon resin, polyolefin resin, and the like. These resins may be used as a mixture. Usually, since the floor slab 11 of a condominium or the like is concrete, a film excellent in alkali resistance is suitable for the film layer 8, a film made of polyolefin resin or the like is preferable, and a film made of a low density type polyolefin resin is particularly preferable. preferable.

The basis weight of the water shielding portion (D) 14 is preferably 30 to 55 g / m ² , and more preferably 40 to 50 g / m ² . Moreover, the thickness of the water shielding part (D) 14 is preferably 0.1 to 0.6 mm, more preferably 0.2 to 0.5 mm.

<Floor surface material (A) 1>
As the floor covering (A) 1 used for the soundproofing flooring 15, a known flooring can be appropriately employed, and various wooden floor materials, cushioned floors, foamed resin tiles, carpets, and the like are used. be able to. A wooden floor material is preferable because it is hard and can reduce the amount of floor sinking compared to other floor materials. As the wooden floor material, a single-layer flooring (solid) material or a composite flooring material can be used. As the shape of the floor material, both a rectangular type and a laminating type are preferable. A single-layer flooring (solid) material having a good texture and excellent humidity control effect is preferred as a flooring material.

  Each layer of the soundproof flooring 15 can be bonded (adhered or fixed) by an appropriate means. Examples of the bonding means include thermal bonding using a thermoplastic resin layer (film, nonwoven fabric, etc.), known adhesives (for example, vinyl acetate adhesive, polyethylene-vinyl acetate (EVA) adhesive, acrylic adhesive). Etc.) and mechanical entanglement using fiber entanglement or the like can be employed.

  The stacking order of the soundproofing part (B) 12, the sinking prevention part (C) 13, and the water shielding part (D) 14 used in the preferred embodiment is not particularly limited, but the water shielding part (D) 14 is usually these. It is formed on the back side (bottom side) among the three. Either the soundproof part (B) 12 or the sinking prevention part (C) 13 may be formed on the back side (bottom side), but the sinking prevention part (C) 13 is behind the soundproofing part (B) 12. It is desirable to form on the (bottom side).

<< Manufacturing method of soundproof flooring >>
The soundproofing flooring material of the present invention comprises a soundproofing part (B) 12, a sinking prevention part (C) 13, and a water shielding part (D) 14 as required, and an adhesive layer (adhesive layers 5 and 7). It is good to stick together through. Even when each part is laminated from the front side in this order, the lamination order is not particularly limited, and the soundproof part (B) 12-sinking prevention part (in order from the floor surface material (A) 1 ( C) 13-waterproof part (D) 14, soundproof part (B) 12-waterproof part (D) 14-sink prevention part (C) 13, subsidence prevention part (C) 13-soundproof part (B) 12-water shielding part (D) 14, subsidence prevention part (C) 13-water shielding part (D) 14-sound insulation part (B) 12, etc. may be laminated in this order, and the function of each part is effectively exhibited. Therefore, it is preferable to laminate in the order of soundproof part (B) 12-sinking prevention part (C) 13-water shielding part (D) 14.

  Examples of the adhesive layer (adhesive layers 5 and 7) for bonding the portions include an adhesive layer and a heat-fusible nonwoven fabric layer. When an adhesive is used, the soundproof flooring 15 may be fixed by applying an adhesive between the respective parts by a dry lamination method, a wet lamination method, or the like. In addition, when using a heat-fusible nonwoven fabric, the sound-insulating flooring 15 is fixed by sandwiching the heat-fusible nonwoven fabric between the parts and passing it through a hot-air circulating heater (dryer) or between hot rolls and hot plates. Good. The heating temperature may be set in consideration of the melting point of the heat-fusible nonwoven fabric. As a method of laminating each part, when the portions are laminated separately for each part, no deviation or the like occurs. For example, when laminating in the order of the soundproof part (B) 12-the subsidence prevention part (C) 13-the water shielding part (D) 14, first, the subsidence prevention part (C) 13 and the water shielding part (D). 14 are bonded to each other through an adhesive layer between the film sides of the film 14, and then an adhesive layer is provided between the subsidence prevention part (C) 13 side of the laminate and the soundproof layer 4 side of the soundproof part (B) 12. The parts (B) 12 to (D) 14 may be integrated with each other.

  The floor surface material (A) 1 is preferably integrated with the parts (B) 12 to (D) 14 via the adhesive layer 2. The adhesive layer 2 is the same as the adhesive layers 5 and 7.

<< Usage of soundproof flooring >>
The soundproof flooring 15 of the present invention may be bonded onto the floor slab 11 with the adhesive layer 10 interposed therebetween. According to the soundproofing floor material of the present invention, the soundproofing performance equivalent to LL-45 can be obtained, and it is optimal for use as a flooring material for an apartment house such as an apartment. Further, since the sinking amount of the flooring can be reduced to less than 4.9 mm, and further less than 3.9 mm, various problems caused by the sinking of the flooring can be solved.

  Hereinafter, the present invention will be described more specifically with reference to examples. The present invention is not limited by the following examples, and can of course be implemented with appropriate modifications within a range that can be adapted to the above-described gist. Included in the range. In the following, “parts” means “parts by weight” and “%” means “% by weight” unless otherwise specified.

The characteristic measurement and performance evaluation method of the soundproof flooring 15 (each layer and each part) is as follows.
(1) Thickness: in accordance with JIS L1913 6.1A method (2) Weight per unit; JIS L1913 in 6.2 method (3) Soundproofing performance: Soundproofing obtained in Examples according to JIS A1440-1 method A 500 g iron ball was dropped from a position 4 cm high on the concrete on which the flooring 15 was laid, and the impact sound was received by a microphone embedded in the concrete. The impact sound was subjected to frequency analysis, and the sound intensity (dB) at a frequency of 125 Hz was used for evaluation of soundproof performance.
○: Impact sound of −23 dB or less, ×: Impact sound exceeding −23 dB (4) Walking feeling: Conforms to the short-term local concentrated load test of the soundproof floor material property test standard of the Japan Soundproof Floor Industries Association. Specifically, the soundproof flooring 15 obtained in the example is cut to 300 mm × 340 mm to prepare a test piece, and this test piece is placed on a testing machine (“Tensilon UCT-1T” manufactured by Orientec Co., Ltd.). placed. Measure the thickness of the test piece after pressurization when pressing the test piece at 80 kgf / φ50 mm, and subtract the thickness after pressurization from the thickness of the test piece before pressurization. The amount of sinking of the flooring material 15 (mm) was used.
A: Subsidence amount is less than 3.9 mm B: Subsidence amount is 3.9 mm or more and less than 4.9 mm X: Subsidence amount is 4.9 mm or more (5) Thickening rate and compression elastic recovery rate;
The subsidence prevention part (C) 13 (extra-thick long fiber nonwoven fabric 6) obtained in the example was cut into 100 mm × 100 mm to prepare a test piece, and this test piece was pressurized with 100 gf, and after 20 seconds of pressurization The thickness (h ₀ ) of the test piece is measured. The test piece is further pressurized with 10 kgf for 24 hours. The thickness (h ₁ ) of the test piece after 24 hours is measured. Thereafter, the test piece is left unloaded for 5 minutes, and then the test piece is pressurized with 100 gf, and the thickness (h ₂ ) of the test piece after 30 seconds is measured. The thickness reduction rate and the compression elastic recovery rate are calculated based on the following formulas (i) and (ii).
Reduction ratio (%) = (h ₀ −h ₁ ) / h ₀ × 100 (i)
Compression elastic recovery rate (%) = (h ₂ / h ₀ ) × 100 (ii)

Example 1
1. Formation of soundproof part (B) 12 Regular polyester fiber 50% with a fineness of 22 decitex and fiber length of 64 mm, regular polyester fiber with a fineness of 6.6 decitex and fiber length of 64 mm, fineness of 2.2 decitex and fiber length of 51 mm Each 20% of regular polyester fibers was weighed and blended, an intermediate web was formed with a card machine, and this intermediate web was wrapped with a cross wrapper.
While continuously laminating the obtained web on a polyester (PET) spunbond layer (smooth layer 3), the needle depth was adjusted with a needle of needle number 40 ("FPD1-40" manufactured by Organ Needle Co., Ltd.). A needle punching process was performed at a depth of 8 mm and a driving number of 20 n / cm ² to obtain a laminated nonwoven fabric of the smooth layer 3 and the soundproof layer 4.
Next, the laminated nonwoven fabric was impregnated with a dilute solution of a polyacrylate emulsion having a glass transition temperature of −25 ° C. and dried to obtain a chemical bond type soundproof part (B) 12.

2. Formation of subsidence prevention part (C) 13 Low density polyethylene (PE) resin (MFR at 190 ° C .: 75 g / 10 min) is melt-spun from a nozzle with a diameter of 0.3 mm and placed in a water bath at a water temperature of 20 ° C. The spunbond non-woven fabric 6 having a predetermined basis weight and a predetermined thickness made of very long fibers (fineness 600 dtex) is formed by dropping onto the continuous conveyor and dehydrating the fibers. ) 13.

3. Formation of water-impervious portion (D) 14 By extruding a molten low-density polyethylene resin onto embossed polyester (PET) spunbond (smooth layer 9) and passing the laminate between cooling rolls (extrusion) Lamination), a water shielding part (D) 14 which is a film laminate was obtained.

4). Formation of soundproof floor main body (E) 16 The obtained subsidence prevention part (C) 13 and water shielding part (D) 14 are cut into 30 cm × 50 cm, and the subsidence prevention part (C) 13 and water shielding part (D ) Heat-sealing nonwoven fabric 7 (“DYNAC (registered trademark) G7015, manufactured by Kureha Tech Co., Ltd., weight 15 g / m ² )” sandwiched between 14 film layers 8 and hot air circulation in which the laminate was heated to 150 ° C. It was passed through a dryer and heat-sealed.
Next, a heat-fusible nonwoven fabric 5 ("Dynac (registered trademark) G7015" manufactured by Kureha Tech Co., Ltd.) is laminated on the sinking prevention part (C) 13 side of the laminate, and then the heat-fusible nonwoven fabric 5 After the soundproofing part (B) 12 was laminated so that the soundproofing layer 4 faced, the laminated body was passed through a hot-air circulating dryer heated to 150 ° C. and heat-sealed. The obtained soundproof floor main body (E) 16 had a total basis weight of 350 g / m ² .

5. Formation of soundproof flooring 15 Adhesive (vinyl acetate-based adhesive) is applied to the smoothing layer 3 side of the obtained soundproofing floor main body (E) 16, and a floor surface material (A) (woody flooring) is laminated. The soundproof flooring 15 was obtained by applying pressure.

Examples 2-3
A soundproof flooring 15 was obtained by the same method as in Example 1 except that the basis weight of the subsidence prevention part (C) 13 was changed to the amount described in Table 1.

Example 4
In the soundproof part (B) 12, the amount of the web to be laminated on the polyester (PET) spunbond (smooth layer 3) is changed, and the adhesion amount of the binder (polyacrylate) is 20 g / m ² by dry weight. A soundproof flooring 15 was obtained in the same manner as in Example 2 except that.

Comparative Example 1
The sound insulation part (B) 12 and the water insulation part (D) 14 obtained in Example 1 are cut into 30 cm × 50 cm, and the sound insulation of the sound insulation part (B) 12 and the film layer 8 side of the water insulation part (D) 14. A heat-fusible non-woven fabric (“DYNAC (registered trademark) G7015” manufactured by Kureha Tech Co., Ltd.) is sandwiched between the layers 4 and the laminated body is passed through a hot air circulation dryer heated to 150 ° C. to be heat-sealed. Thus, the soundproof floor main body (E) 16 was obtained. By applying an adhesive (vinyl acetate adhesive) on the smoothing layer 3 side of the obtained soundproof floor main body (E) 16, laminating a floor surface material (A) (woody floor material), and pressurizing A soundproof flooring 15 was obtained.

Comparative Example 2
The subsidence prevention part (C) 13 and the water shielding part (D) 14 obtained in Example 2 are cut into 30 cm × 50 cm, and a film layer of the subsidence prevention part (C) 13 and the water shielding part (D) 14 is obtained. Heat-bondable nonwoven fabric 7 (“DYNAC (registered trademark) G7015” manufactured by Kureha Tech Co., Ltd.) is sandwiched between the 8 sides, and the laminate is passed through a hot-air circulating dryer heated to 150 ° C. and heat-sealed. It was.
Subsequently, on the sinking prevention part (C) 13 side of the laminate, a heat-sealable nonwoven fabric 5 (“DYNAC (registered trademark) G7015” manufactured by Kureha Tech Co., Ltd.) and a polyester spunbond having a basis weight of 30 g / m ² (smooth) The soundproof floor main body (E) 16 was obtained by laminating the layer 3) and passing the laminated body through a hot air circulating dryer heated to 150 ° C. and heat-sealing. By applying an adhesive (vinyl acetate adhesive) on the smoothing layer 3 side of the obtained soundproof floor main body (E) 16, laminating a floor surface material (A) (woody floor material), and pressurizing A soundproof flooring 15 was obtained.

  As shown in Table 1, in Comparative Example 1 lacking the sinking prevention part (C) 13 and Comparative Example 2 lacking the soundproofing part (B) 12, the sinking prevention performance or the soundproofing performance is inferior. Since the soundproofing flooring 15 of the present invention has the sinking prevention part (C) 13 and the soundproofing part (B) 12, both soundproofing performance and sinking prevention performance can be achieved. In particular, by controlling the basis weight of the very thick long fibers used in the subsidence prevention part (C) 13, the subsidence prevention characteristics can be improved without affecting the soundproof performance (Examples 1 and 2). ).

1 Floor material (A)
2, 5, 7, 10 Adhesive layer 3, 9 Smooth layer 4 Soundproof layer 6 Extra-thick long fiber nonwoven fabric 8 Film layer 11 Floor slab 12 Soundproof part (B)
13 Sink prevention part (C)
14 Water shielding part (D)
15 Soundproof floor material 16 Soundproof floor body (E)

Claims (7)

A flooring material (A) and a soundproofing flooring material comprising a plurality of layers and a soundproofing floor body (E) that supports the surfaceing material (A) on the back surface. A soundproofing part (B) having a soundproofing layer and a sinking prevention part (C);
The soundproof flooring, wherein the subsidence prevention part (C) is a very long and thin fiber nonwoven fabric formed of fibers made of a thermoplastic resin having a fineness of 250 to 1700 dtex. The thickness of the extra-thick long fiber nonwoven fabric is 1.0 to 5.0 mm, and the basis weight is 50 to 500 g / m ² .
Sound-insulating floor member according to claim 1 compressive elastic recovery rate after pressurization for 24 hours with a load 10 kg / 100 cm ² is 97 to 100%.   The soundproof flooring material according to claim 1 or 2, wherein the fiber made of a thermoplastic resin forming the extra-thick long fiber nonwoven fabric is a polyolefin fiber.   The soundproofing flooring material according to any one of claims 1 to 3, wherein a sinking prevention part (C) is formed on the back side of the soundproofing part (B). The soundproof portion (B) is a laminate of a smooth layer and a soundproof layer formed from a spunbond nonwoven fabric, and the soundproof layer is a chemical bond nonwoven fabric or a thermal bond nonwoven fabric and has a thickness of 2.0 to 6. 5 mm, a basis weight of 80~500g / m ^2, and sound-insulating floor member according to claim 1 porosity of 93-99%.   The soundproof floor material according to any one of claims 1 to 5, wherein the soundproof floor main body (E) has a water shielding portion (D) for preventing passage of water on the outermost surface.   The soundproof flooring material according to any one of claims 1 to 6, wherein the floor surface material (A) is a wood-based flooring material having a laminating slit.