JP2013177777A - Light-weight waterproof sheet for building material - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide an excellent light-weight waterproof sheet for building material capable of maintaining excellent nail hole sealability, in order to solve the problem that although excellent waterproofness can be maintained in a water permeability test in a state of nails being driven in a previous technique, because of the complicate structure there is a need for development of a simpler waterproof sheet for building material capable of maintaining enough nail hole sealability.SOLUTION: A light-weight waterproof sheet for building material of this invention comprises a nonwoven fabric layer and a foam resin layer laminated on the upper part of the nonwoven fabric layer in order to maintain the nail hole sealability. Preferably the foam resin layer is foamed by a factor of 1.5-100 by a foaming agent.

Description

  The present invention relates to a lightweight waterproof sheet for building materials that is excellent in waterproofness, for example, used as a roof base material.

  Conventionally, fabrics impregnated with asphalt are often used as roof base materials for houses. The fabric impregnated with asphalt is excellent in that it has waterproofness, good dimensional stability, high physical strength, and good nail hole sealing performance around the nail axis when nails are driven.

  However, since the asphalt-impregnated fabric has a weight exceeding 20 kg with a roll of about 20 m due to the inclusion of asphalt, there is a problem that handling property at the time of construction is very poor. In addition, the asphalt-containing fabric is likely to deteriorate or stretch asphalt-impregnated fabric due to the temperature difference between the temperature and the temperature after construction. For this reason, the nail hole sealability around the nail shaft and the tucker portion is likely to deteriorate over time. .

  On the other hand, as a roof base material replacing the conventional asphalt-impregnated fabric, Patent Document 1 has a resin layer having stretchability and adhesion on the surface of the fabric, and a resin layer with less adhesion on the surface. Laminated roof base materials have been proposed.

  Further, in Patent Document 2, a nonwoven fabric having an anti-slip layer on the upper surface is bonded to the upper surface of a waterproof and moisture-permeable polyethylene film, and a swelling layer made of a superabsorbent polymer is formed on the lower surface of the polyethylene film. An architectural waterproof sheet is described in which a non-woven fabric is adhered.

JP-A-2-269277 JP 2002-316373 A

  However, in the above prior art, a good waterproof property is maintained in a water permeability test in a state where a nail is driven, but since the structure is complicated, the waterproof sheet for building materials that can more easily maintain a sufficient nail hole sealing property Development of was desired.

  The present invention has been made in view of such a technical background, and provides an excellent lightweight waterproof sheet for building materials that is lightweight and can maintain excellent nail hole sealing performance.

  In order to achieve the above object, the present invention provides the following means.

  [1] A lightweight waterproof sheet for building materials, comprising a nonwoven fabric layer and a foamed resin layer laminated on the upper side of the nonwoven layer.

  [2] The lightweight waterproof sheet for building materials as recited in the aforementioned Item 1, wherein the foamed resin layer is foamed 1.5 to 100 times by a foaming agent.

  [3] The lightweight waterproof sheet for building materials according to item 1 or 2, wherein the foamed resin layer contains a thermoplastic elastomer in an amount of 5% by mass to 40% by mass with respect to the foamed resin layer.

  [4] The lightweight waterproof sheet for building materials according to any one of items 1 to 3, wherein the nonwoven fabric layer is a spunbonded nonwoven fabric.

  In invention of [1], since the nonwoven fabric layer and the foamed resin layer laminated | stacked on the upper side of the said nonwoven fabric layer are provided, sufficient waterproofness can be ensured as a lightweight waterproof sheet for building materials. The foamed resin layer is in close contact with the placed nail and presses against the placed nail, so that it can be sufficiently waterproofed (excellent nail hole sealing performance is obtained) and the foamed resin layer is disposed so that it is lightweight. It is. Moreover, since the nonwoven fabric layer is provided, it can fully prevent that a foamed resin layer is damaged by the contact with a field board etc. at the time of construction.

  In the invention of [2], since the foamed resin layer is foamed 1.5 to 100 times with a foaming agent, the foamed resin layer is further in close contact with the placed nail and sufficiently pressed against the placed nail. It can be set as a lightweight waterproofing sheet for building materials.

  In the invention of [3], since the thermoplastic resin is contained in the foamed resin layer in an amount of 5% by mass to 40% by mass with respect to the foamed resin layer, the placed nail is further pressed and further waterproof. Can be improved.

  In the invention of [4], since the nonwoven fabric layer is formed of a spunbond nonwoven fabric, it is possible to improve the nail hole sealability and improve the strength of the entire sheet.

It is sectional drawing which shows one Embodiment of the lightweight waterproof sheet for building materials which concerns on this invention. It is typical sectional drawing which shows the foamed resin layer of one Embodiment of the lightweight waterproof sheet for building materials which concerns on this invention.

  One embodiment of a lightweight waterproof sheet for building materials according to the present invention will be described with reference to the drawings. FIG. 1 is a cross-sectional view showing an embodiment of a lightweight waterproof sheet for building materials according to the present invention. FIG. 2 is an enlarged cross-sectional view showing a foamed resin layer of one embodiment of the lightweight waterproof sheet for building materials according to the present invention. In the figure, 1 is a lightweight waterproof sheet for building materials, 2 is a foamed resin layer, 3 is a nonwoven fabric layer, and 4 is a bubble.

  As shown in FIG. 1, a lightweight waterproof sheet for building material 1 according to an embodiment of the present invention is a sheet that is particularly preferably used as a roof base material. This lightweight waterproof sheet 1 for building materials is a lightweight waterproof sheet 1 for building materials provided with a nonwoven fabric layer 3 and a foamed resin layer 2 laminated on the non-woven layer 3. The foamed resin layer 2 has bubbles 4 as shown in FIG.

  Although it does not specifically limit as the foamed resin layer 2 in this invention, For example, polyolefin resin, such as a polyethylene resin and a polypropylene resin, a polystyrene resin, a polyurethane resin etc. can be mentioned. Of these, polyolefin resins are preferable, and polyethylene resins are more preferable.

  The melt flow rate of the resin of the foamed resin layer 2 is preferably 1 to 100. If the melt flow rate is less than 1, it is difficult to form a uniform layer. Moreover, if the melt flow rate exceeds 100, the inside of the nonwoven fabric layer 3 may be impregnated, which is not preferable.

  The foamed resin layer 2 is preferably foamed 1.5 to 100 times with a foaming agent. Although a foaming agent is not specifically limited, For example, an inorganic type foaming agent and an organic type foaming agent can be mentioned. The foaming agent can be added to the resin and extruded and foamed at a set temperature of 170 ° C. to 210 ° C. with an extruder, for example. Further, if the expansion ratio is less than 1.5, the effect of pressing the driving nail is small, which is not preferable. On the other hand, if the expansion ratio exceeds 100 times, the waterproof property is lowered and the strength of the foamed resin layer 2 may be lowered.

  Furthermore, the foamed resin layer 2 preferably contains a thermoplastic elastomer in an amount of 5% by mass to 40% by mass with respect to the foamed resin layer. Although it does not specifically limit as a thermoplastic elastomer, For example, an olefin type elastomer, a styrene type elastomer, a PVC type elastomer, an EVA type elastomer, a urethane type elastomer, and a polyester type elastomer can be mentioned. Of these, olefin-based elastomers are preferred. If the content of the thermoplastic elastomer with respect to the foamed resin layer is less than 5% by mass, the effect of pressing the placed nail may be reduced. Moreover, since workability will fall when it exceeds 40 mass%, it is unpreferable. More preferably, it is 10 mass%-20 mass%.

  The thickness of the foamed resin layer 2 is preferably 0.2 mm to 10 mm. Since it is 0.2 mm or more, a sufficient nail hole seal can be obtained to fill the gap (nail hole) generated between the nail and the foamed resin by placing the nail during construction. In addition to exhibiting the properties, sufficient lightness can be ensured by being 10 mm or less.

  The thickness of the nonwoven fabric layer 3 is preferably set to 0.2 to 3 mm. By setting the thickness to 0.2 mm or more, the driving nail can be sufficiently pressed. By setting the thickness to 3 mm or less, the weight can be further reduced and the cost can be reduced.

  Although it does not specifically limit as the nonwoven fabric layer 3, For example, a spun bond nonwoven fabric, a spunlace nonwoven fabric, a melt blown nonwoven fabric, a needle punch nonwoven fabric etc. are mentioned. Among these, it is preferable to use a spunbond nonwoven fabric or a melt blown nonwoven fabric because the certainty of the waterproof effect can be further increased. Among these, it is particularly preferable to use a spunbond nonwoven fabric made of polypropylene.

  Next, specific examples of the present invention will be described, but the present invention is not limited to these examples. Tables 1 and 2 show configurations and evaluations of Examples and Comparative Examples.

<Example 1>
Spunbond made of polypropylene fiber while mixing and dispersing 88 parts by mass of polyethylene resin having a melt flow rate of 20, 10 parts by mass of olefin elastomer and 2 parts by mass of an inorganic foaming agent, heating and foaming with a T-die extruder, and extruding into a film. A nonwoven fabric (thickness 0.5 mm, basis weight 100 g / m ² ) was laminated and integrated to obtain a lightweight waterproof sheet for building materials having a thickness of 1.2 mm. The expansion ratio of the foamed resin layer was 2 times, the basis weight was 300 g / m ² , and the thickness was 0.7 mm.

<Example 2>
90 parts by mass of a polyethylene resin having a melt flow rate of 20 and 10 parts by mass of an inorganic foaming agent are mixed and dispersed, heated and foamed by a T-die type extruder, and extruded into a film to form a spunbond nonwoven fabric (thickness 0.5 mm, A lightweight waterproof sheet for building materials having a thickness of 6.4 mm was obtained by stacking and integrating with a basis weight of 100 g / m ² ). The expansion ratio of the foamed resin layer was 30 times, the basis weight was 200 g / m ² , and the thickness was 5.9 mm.

<Example 3>
A spunbond made of polypropylene fibers with 75 parts by mass of a polypropylene resin having a melt flow rate of 7, 10 parts by mass of an olefin elastomer and 15 parts by mass of an inorganic foaming agent mixed and dispersed, heated and foamed by a T-die extruder and extruded into a film. A nonwoven fabric (thickness 0.5 mm, basis weight 100 g / m ² ) was laminated and integrated to obtain a lightweight waterproof sheet for building materials having a thickness of 6.5 mm. The expansion ratio of the foamed resin layer was 60 times, the basis weight was 100 g / m ² , and the thickness was 6.0 mm.

<Example 4>
70 parts by mass of polyethylene resin having a melt flow rate of 20, 10 parts by mass of an olefin elastomer, and 20 parts by mass of an inorganic foaming agent are mixed and dispersed. A nonwoven fabric (thickness 0.5 mm, basis weight 100 g / m ² ) was laminated and integrated to obtain a lightweight waterproof sheet for building materials having a thickness of 8.7 mm. The expansion ratio of the foamed resin layer was 20 times, the basis weight was 100 g / m ² , and the thickness was 8.2 mm.

<Example 5>
In Example 1, a lightweight waterproof sheet for building materials having a thickness of 1.2 mm was obtained in the same manner as in Example 1 except that a styrene elastomer was used instead of the olefin elastomer.

<Example 6>
In Example 1, a lightweight waterproof sheet for building materials having a thickness of 0.75 mm was obtained in the same manner as in Example 1 except that the thickness of the foamed resin layer was adjusted. The basis weight of the foamed resin layer was 100 g / m ² , and the thickness was 0.25 mm.

<Example 7>
In Example 1, a lightweight waterproof sheet for building materials having a thickness of 1.8 mm was obtained in the same manner as in Example 1 except that the thickness of the foamed resin layer was adjusted. The basis weight of the foamed resin layer was 500 g / m ² and the thickness was 1.3 mm.

<Example 8>
In Example 1, a lightweight waterproof material for building materials having a thickness of 1.2 mm was obtained in the same manner as in Example 1 except that a spunlace nonwoven fabric (thickness 0.5 mm, basis weight 100 g / m ² ) made of polypropylene fiber was used instead of spunbond. A sheet was obtained.

<Example 9>
In Example 1, a spunbond nonwoven fabric (thickness 0.5 mm, basis weight 100 g / ^{m 2)} spunbonded nonwoven fabric (thickness 0.3 mm, basis weight 30 g / ^{m 2)} instead of except for using in the same manner as in Example 1 A lightweight waterproof sheet for building materials having a thickness of 1.0 mm was obtained.

<Example 10>
In Example 1, a spunbond nonwoven fabric (thickness 0.5 mm, basis weight 100 g / ^{m 2)} in place with spunbonded nonwoven fabric (thickness 1.9 mm, basis weight 400 g / ^{m 2)} except for using in the same manner as in Example 1 A lightweight waterproof sheet for building materials having a thickness of 2.6 mm was obtained.

<Comparative Example 1>
In Example 1, a 0.8 mm thick sheet was obtained in the same manner as in Example 1 except that the inorganic foaming agent was not used and 90 parts by mass of the polyethylene resin having the melt flow rate 20 was used. The basis weight of the resin layer was 300 g / m ² and the thickness was 0.3 mm.

<Comparative example 2>
In Example 1, a sheet having a foamed resin layer thickness of 0.7 mm was obtained without using a spunbonded nonwoven fabric (thickness 0.5 mm, basis weight 100 g / m ² ).

<Nail hole sealability evaluation method>
Place a lightweight tarpaulin for building material on a 12mm thick water-resistant plywood, and straighten a ring nail (diameter 3.2mm, length 32mm) until the nail head is about 10mm above the lightweight tarpaulin for building material. A pipe made of vinyl chloride with an inner diameter of 30 mm is set up on the bottom, and the bottom thereof is sealed in a watertight state with a sealing agent. Then, colored water which has been added with ink in advance and stirred is filled in the pipe, and a head pressure of 30 mm is applied. It was left still for 24 hours, and the presence or absence of water leakage through the ring nail nailed to the lightweight waterproof sheet for building materials was confirmed. A sample in which the water-resistant plywood was not wet and no water leakage was observed on the back surface of the water-resistant plywood was defined as “pass”. In addition, 20 samples each were tested about each Example and the comparative example. Table 1 shows the pass rate. “12/20” in the table indicates that 12 out of 20 samples are acceptable.

  As is clear from Tables 1 and 2, the lightweight waterproof sheets for building materials of Examples 1 to 10 of the present invention exhibited excellent needle hole sealing properties.

  Since the lightweight tarpaulin for building material of the present invention is light and easy to handle and is light after construction, the weight load can be reduced. Therefore, it is used as, for example, a building base material, and particularly preferably used as a roof base material.

DESCRIPTION OF SYMBOLS 1 ... Lightweight waterproof sheet for building materials 2 ... Foamed resin layer 3 ... Nonwoven fabric layer 4 ... Air bubbles

Claims (4)

  A lightweight waterproof sheet for building materials, comprising a nonwoven fabric layer and a foamed resin layer laminated on the non-woven layer.   2. The lightweight waterproof sheet for building materials according to claim 1, wherein the foamed resin layer is foamed 1.5 to 100 times by a foaming agent.   The lightweight waterproof sheet for building materials according to claim 1 or 2, wherein the foamed resin layer contains a thermoplastic elastomer in an amount of 5% by mass to 40% by mass with respect to the foamed resin layer.   The lightweight waterproof sheet for building materials according to any one of claims 1 to 3, wherein the nonwoven fabric layer is a spunbonded nonwoven fabric.

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