JP2013249606A - Buffer sheet having sound insulating property and construction method of flooring material using the same - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a buffer sheet having sound insulating properties, which has a high sound insulation effect and superior workability.SOLUTION: The sound insulating buffer sheet is formed by stacking a nonwoven fabric having a thickness of 0.3-1.0 mm and a basis weight of 100-250 g/m, on at least one face of a vinyl chloride foam sheet containing a vinyl chloride resin, a plasticizer and a chemical foaming agent.

Description

  The present invention relates to a cushioning sheet having sound insulation properties and a method for constructing a floor finish using the same.

  In general, in a building, the sound of daily life generated is transmitted downstairs, which interferes with the independence of each room, particularly in a housing complex, and must be eliminated as much as possible. Therefore, the development of a unique underfloor structure for reducing floor impact noise has been carried out.

  So far, in the underfloor structure, it has been extremely effective and cost effective to install a sound-insulating cushioning sheet (floor sheet material) on the floor as a sound-insulating means for blocking impact sound and the like. Are also known to be advantageous. As such a buffer sheet material, for example, a cushion material made of urethane (Patent Document 1) and a resin foam (Patent Document 2) have been reported.

Japanese Utility Model Publication No. 8-1054 Japanese Utility Model Publication No. 5-34922

  However, the conventional buffer sheet still does not have a sufficient sound insulation effect, and there is a demand for a product having a higher sound insulation effect.

  Furthermore, an excellent product is desired from the viewpoint of workability.

  This invention is made | formed in view of this situation, Comprising: It aims at providing the buffer sheet which has the sound insulation property which has a high sound insulation effect and the outstanding construction property.

  As a result of intensive studies, the present inventor has found that the above problem can be solved by a buffer sheet having the following configuration, and has further completed the present invention by further studying based on such knowledge.

The sound-insulating buffer sheet according to one aspect of the present invention has a thickness of 0.3 to 1.0 mm on at least one surface of a vinyl chloride foam sheet containing a vinyl chloride resin, a plasticizer, and a chemical foaming agent. A non-woven fabric having an amount of 100 to 250 g / m ² is laminated.

  According to such a configuration, it is possible to provide a buffer sheet having both a high sound insulation effect for reducing impact sound and excellent workability. In addition, since the cushion sheet having the above-described structure also has an impact mitigating effect, it is possible to reduce the risk of injury due to falling in an apartment house, particularly an elderly care facility and a child welfare facility. Furthermore, when replacing the floor finishing material, it is possible to peel only the floor finishing material while leaving the cushioning sheet of the present invention, so that the cushioning sheet can be reused.

  Moreover, in the said buffer sheet, it is preferable that the said vinyl chloride foam sheet further contains at least 1 among the carboxylic acid zinc salt and the partial ester compound of a carboxylic acid condensate. Thereby, the said effect of this invention is acquired more reliably.

  Another aspect of the present invention is a method for constructing a floor finishing material using the sound insulating cushioning sheet, the step of laminating the sound insulating cushioning sheet on a floor base, and the sound insulating cushioning sheet. The method further comprises a step of laminating a vinyl-based floor finish through an adhesive layer.

  By using such a construction method, a floor finish can be constructed efficiently and simply, and a floor having excellent sound insulation and impact properties can be installed. Further, according to this construction method, the buffer sheet can be reused even when the floor finishing material is replaced, which is beneficial in terms of cost and environment.

  Further, it is preferable to use an adhesive for vinyl flooring as the adhesive layer. Thereby, workability improves more.

  ADVANTAGE OF THE INVENTION According to this invention, the buffer sheet which has the high sound-insulation effect which reduces an impact sound, and the outstanding construction property can be provided.

FIG. 1 is a schematic view showing a cross-sectional view of a laminated structure of a floor foundation, a buffer sheet, and a floor finish obtained by the construction method of the present invention.

  Hereinafter, although the embodiment concerning the present invention is described, the present invention is not limited to these.

<Sound insulation cushioning sheet>
The sound insulating buffer sheet according to this embodiment has a thickness of 0.3 to 1.0 mm and a basis weight of at least one surface of a vinyl chloride foam sheet containing a vinyl chloride resin, a plasticizer, and a chemical foaming agent. characterized in that formed by laminating a non-woven fabric is 100 to 250 g / ^{m 2.}

  First, the vinyl chloride foam sheet will be described.

  Examples of the vinyl chloride resin contained in the vinyl chloride foam sheet of this embodiment include polyvinyl chloride, vinyl chloride-vinyl acetate copolymer resin, vinyl chloride-ethylene copolymer resin, and the like. The polymerization method for obtaining these resins is not particularly limited, and can include usually used polymerization methods (for example, suspension polymerization, emulsion polymerization, etc.).

  Examples of the plasticizer that can be used in this embodiment include phthalic acid such as di-n-octyl phthalate, di-2-ethylhexyl phthalate, diisooctyl phthalate, isoheptyl phthalate, diisononyl phthalate, and diisodecyl phthalate. Ester plasticizers, trimellitic acid ester plasticizers such as tri-2-ethylhexyl trimellitic acid, dibasic acid ester plasticizers such as di-2-ethylhexyl adipate, diisononyl adipate, diisodecyl adipate, Examples thereof include phosphate plasticizers such as tri-2-ethylhexyl phosphite, isodecyl diphenyl phosphite, and tricresyl phosphite, chlorinated paraffins, and polyester plasticizers. These can be used alone or in combination of two or more.

  As for the compounding quantity of the plasticizer with respect to 100 weight part of vinyl chloride resin, about 30-120 weight part is preferable.

  As the chemical foaming agent that can be used in the present embodiment, a pyrolytic organic foaming agent is used. Specific examples include azodicarbonamide, azobisisobutyronitrile, benzenesulfonyl hydrazide, p-toluenesulfonyl hydrazide, dinitrosopentamethylenetetramine, and the like.

  The compounding amount of the chemical foaming agent with respect to 100 parts by weight of the vinyl chloride resin is preferably about 0.1 to 8 parts by weight.

  Furthermore, in addition to the above, the vinyl chloride foam sheet of this embodiment preferably contains at least one of a carboxylic acid zinc salt and a partial ester compound of a carboxylic acid condensate. Preferably, both the carboxylic acid zinc salt and the partial ester compound of the carboxylic acid condensate are contained.

  Examples of the carboxylic acid zinc salt that can be used in the vinyl chloride foam sheet of the present embodiment include, for example, a carboxylic acid zinc salt, a basic carboxylic acid zinc salt, and a carboxylic acid zinc salt and an overbased carboxylic acid zinc salt. Mention may be made of mixtures. Of these, preferred carboxylic acid zinc salts are basic carboxylic acids obtained by reacting 2 mol of carboxylic acid with 1 mol of zinc oxide and reacting 1 mol of zinc oxide with excess zinc oxide with respect to carboxylic acid. It consists of a mixture of subsalts.

  As for the compounding quantity of the carboxylic acid zinc salt with respect to 100 weight part of vinyl chloride resin, about 0.01-5 weight part is preferable.

  The zinc carboxylate used in the present embodiment is preferably obtained by reacting a carboxylic acid and zinc oxide in a molar ratio of 2.0: 1.0 to 1.5: 1.0.

  Examples of carboxylic acids that can be used here include carboxylic acids having 2 to 22 carbon atoms, such as saturated fatty acids, unsaturated fatty acids, and carbocyclic carboxylic acids. More specifically, acetic acid, propionic acid, valeric acid, caproic acid, caprylic acid, 2-ethylhexylic acid, tridecanoic acid, isodecane, neodecanoic acid, undecanoic acid, lauric acid, myristic acid, palmitic acid, stearic acid, isostearic acid 12-hydroxystearic acid, oleic acid, linoleic acid, ricinoleic acid, erucic acid, behenic acid, thioglycolic acid, mercaptopropionic acid, lauryl mercaptopropionic acid, benzoic acid, para-t-butylbenzoic acid, dimethylbenzoic acid, Aminobenzoic acid, salicylic acid, aminoacetic acid, brutamic acid, oxalic acid, glutaric acid, succinic acid, malonic acid, adipic acid, phthalic acid, fumaric acid, maleic acid, malic acid, citric acid, tartaric acid, thiodipropionic acid, tri Merit acid, pyromellitic acid, merit acid And the like. Of these, acetic acid, 2-ethylhexylic acid, neodecanoic acid, oleic acid, and ricinoleic acid are preferred.

  Examples of the partial ester compound of the carboxylic acid condensate include a compound obtained by esterifying a dimer acid or trimer acid having 30 to 60 carbon atoms or an anhydride thereof with a monoalcohol or a monoepoxy compound. it can. The esterification rate is preferably 10 to 90%, and the acid value is preferably 10 mg / KOH or more. When the esterification rate is outside this range, open cells are difficult to obtain. Further, the molecular weight (weight average molecular weight in terms of GPC polystyrene) of the partial ester compound of the carboxylic acid condensate is preferably about 1000 to 20000.

  Here, examples of monoalcohols and monoepoxy compounds include saturated aliphatic, unsaturated aliphatic, alicyclic compounds, aromatic alcohols and epoxy compounds. Alcohols and epoxy compounds containing an ether group in the molecule may be used. Specific examples include stearyl alcohol, oleyl alcohol, alkyl glycidyl ethers having 12 or more carbon atoms, branched alkyl alcohols having 12 or more carbon atoms, oxo alcohol polyethylene oxide ethers, alkoxyoxypolyalkylene glycols having a molecular weight of about 200 to 1200, and the like. be able to. Here, examples of the alkoxyxypolyalkylene glycol include methoxypolyethylene glycol and methoxypolypropylene glycol.

  A commercial item can be used for the partial ester compound of a carboxylic acid condensate. Examples of commercially available products include BYK-P4100 (manufactured by Big Chemie Japan).

  As for the compounding quantity of the partial ester compound of the carboxylic acid condensate with respect to 100 weight part of vinyl chloride resin, 0.1-15 weight part is preferable.

  It is possible to add other than the above components to the vinyl chloride foamed sheet of the present embodiment as long as the object of the present invention is not impaired. Preferably, further, alkali metal salts and alkaline earth metal salts, basic carboxylic acid alkaline earth metal salts, cell regulators, fillers, foaming accelerators, viscosity reducers, flame retardants, antifungal agents, antibacterial agents, pigments Etc. may be mixed.

  Alkali metal salts and alkaline earth metal salts are added as necessary to impart heat resistance during heat processing. Examples include alkaline earth metal salts of carboxylic acids such as carboxylic acid alkali metal salts, carboxylic acid magnesium salts, carboxylic acid calcium salts, carboxylic acid barium salts, such as carboxylic acid kalimu salts and carboxylic acid sodium salts. Can do. Examples of the carboxylic acid used as the raw material include those similar to the carboxylic acid exemplified above as a raw material for producing the carboxylic acid zinc salt.

  The basic carboxylic acid alkaline earth metal salt is added as necessary to impart heat resistance, and basic carboxylic acid barium salts, calcium salts, and magnesium salts are preferred. Examples of the carboxylic acid used as the raw material of the basic carboxylic acid alkaline earth metal salt include the same carboxylic acids exemplified above as the raw material for producing the carboxylic acid zinc salt. Moreover, what is marketed can also be used as basic carboxylic acid alkaline-earth metal salt. For example, there is a plastis stub 2116, a plastis stub 2508, a plastis stub 2513, and a plastis stub 2106, 2117 of Hammond, USA. Heat resistance imparting agents other than the above metal salts, color tone improvers, anti-coloring agents and the like may be blended as necessary.

  Cell regulators are added as necessary to make the cell diameter small and uniform, and include butyl methacrylate polymer, methacrylic acid isobutyl ester polymer, methacrylic acid-2-ethylhexyl ester polymer having an average molecular weight of 1,000 to 1,000,000. be able to.

  The filler is added as necessary to impart strength, and examples thereof include calcium carbonate, magnesium carbonate, calcium sulfate, calcium oxide, titanium oxide, aluminum hydroxide, clay, and silica. When the filler is contained, the blending amount is preferably 10 to 100 parts by weight with respect to 100 parts by weight of the vinyl chloride resin.

  As foaming accelerators, zinc compounds represented by zinc oxide, fine zinc oxide, zinc hydroxide, zinc chloride, urea, thiourea dioxide, monoethanolamine, diethanolamine, triethanolamine, triethylamine, diethylamine, monoethylamine And a nitrogen-containing compound.

  Examples of the flame retardant include organic metal salt systems such as aluminum hydroxide, magnesium hydroxide, antimony trioxide, and boric acid.

  The vinyl chloride foamed sheet of the present embodiment can be obtained by mixing the above-mentioned composition by a conventional method and processing appropriately. Specifically, in the paste sol obtained by mixing the above-mentioned compositions, open cells are formed by a conventional method to obtain a vinyl chloride foam sheet.

  In the present embodiment, the expansion ratio of the vinyl chloride foam sheet is preferably about 4 to 10 times. Further, the thickness of the vinyl chloride foam sheet is preferably about 1 to 10 mm.

  By using the vinyl chloride foam sheet as described above, it is possible to obtain a sound insulating cushioning sheet having a very excellent sound insulating property.

  Next, the nonwoven fabric used in this embodiment will be described.

  The sound insulation buffer sheet in this embodiment is a sheet formed by laminating the nonwoven fabric on at least one surface of the above-mentioned vinyl chloride foam sheet. In particular, it is preferable to laminate a non-woven fabric on the side to be an adhesive surface with the floor finish. By laminating the nonwoven fabric on the top surface in this way, when peeling the floor finish material to be stuck on it, the floor finish material does not damage the foam sheet by breaking the interface with this nonwoven fabric or the nonwoven fabric itself. Can be peeled off.

The nonwoven fabric used in this embodiment has a thickness of 0.3 to 1.0 mm, a basis weight of 100 to 250 g / m ² , and a thickness and a basis weight of the above ranges. For example, it can be used without particular limitation. By making the thickness and basis weight within the above ranges, it is possible to secure a sufficient material fracture thickness in peeling, and to reduce as much as possible dent marks when casters run on the floor finish due to its high strength. Is also possible. In addition, when the thickness of a nonwoven fabric exceeds 1.0 mm or a fabric weight exceeds 250 g / m <2>, since it will become very expensive, it is unpreferable.

  Specific examples of the nonwoven fabric that can be used include a glass fiber nonwoven fabric, a polyester fiber nonwoven fabric, and an aramid nonwoven fabric. Preferably, when a glass fiber nonwoven fabric is used, there is an advantage in terms of obtaining strength performance at low cost.

  There is no limitation in particular about the method of laminating a nonwoven fabric, It can laminate by the method used normally. Specifically, for example, they are laminated together with an adhesive. Or, after applying the vinyl chloride paste sol to the nonwoven fabric, it is heated, gelled and foamed to integrate the vinyl chloride foam sheet and the nonwoven fabric.

  Such a sound insulation cushioning sheet according to the present embodiment is very excellent in sound insulation and workability, and is also excellent in impact resistance, so that it is possible to reduce the impact when it falls.

  Furthermore, since the buffer sheet according to the present embodiment is very excellent in workability and can be easily peeled off when the floor finish material is peeled off, for example, when replacing the floor finish material, It is possible to leave it as it is and reuse it.

  Moreover, it is preferable to use the sound-insulating cushion sheet according to this embodiment in combination when a vinyl flooring is used. Particularly preferred is a vinyl chloride flooring. Since the buffer sheet according to the present embodiment has a vinyl chloride foam sheet, it is easy to specify the type of adhesive used between the same vinyl-based floor finish and the buffer sheet. For example, a vinyl-based floor material There is also an advantage that only one type of adhesive can be used.

<Construction method>
Next, the construction method of the floor finishing material using the sound-insulating buffer sheet in this embodiment will be described.

  The construction method of the present embodiment includes a step of laminating the sound insulating buffer sheet of the present embodiment on a floor base, and a vinyl floor material as a floor finish material is laminated on the sound insulating buffer sheet via an adhesive layer. Including the step of:

  FIG. 1 is a schematic view showing a laminated structure of floor foundation + buffer sheet + flooring material obtained by the construction method of the present embodiment.

  As shown in FIG. 1, the sound-insulating cushioning sheet 1 of this embodiment is usually laminated on a floor base 6 with an adhesive layer 5 interposed therebetween. As the sound insulating cushioning sheet 1, the cushioning sheet of the present embodiment as described above is used.

  The adhesive that can be used for the adhesive layer 5 can be used without particular limitation as long as it is an adhesive for a polymer-based upholstery flooring as shown in JIS A 5536 (adhesive for floor finishing). Specific examples include rubber latex adhesives, acrylic resin emulsion adhesives, urethane resin adhesives, and the like.

  When the buffer sheet 1 has the nonwoven fabric 4 on one side, it is preferable to laminate the floor sheet 6 with the surface having the nonwoven fabric 4 facing up. By doing so, the floor finishing material 2 can be easily peeled off, and the sound insulating cushioning sheet can be reused when the floor finishing material is replaced.

  After the buffer sheet 1 is laminated, a floor finishing material 2 is laminated on the buffer sheet 1 with a vinyl chloride foam layer.

  In the present embodiment, the floor finishing material 2 can be used without particular limitation as long as it is a vinyl floor material, but in particular, a vinyl chloride floor material can be used. For example, various floor finishing materials such as a cushion floor, a vinyl floor sheet, a vinyl floor tile, an inlay vinyl floor tile, and a tile carpet can be used, and the thickness is not particularly limited. In particular, as shown in FIG. 1, a cushion floor formed by laminating a nonwoven fabric 4 and a surface layer 7 on a foam layer 3 is preferable as a finishing material.

  As the nonwoven fabric 4 used for the floor finish material 2, the same nonwoven fabric as that of the buffer sheet 1 can be used, or another type of nonwoven fabric can be used.

  The adhesive that can be used as the adhesive layer 5 between the buffer sheet 1 and the floor finish 2 can also be used without particular limitation as long as it is an adhesive for a polymer-based upholstery floor material. The same adhesive as that used as the adhesive layer 5 of the ground 6 is preferably applied.

  According to such a construction method, a floor (floor finishing material) having excellent sound insulation and impact resistance can be easily constructed. Further, since the buffer sheet can be reused, it is very useful.

  EXAMPLES Hereinafter, the present invention will be described more specifically with reference to examples, but the present invention is not limited to the examples.

[Example 1]
A sound insulating cushioning sheet was produced by the following method.

Using the components of the foam layer shown in Table 1 (all the numerical values of the components in the table indicate parts by weight), the mixture was mixed with three propeller blades at 1000 rpm for 5 minutes to prepare a uniform vinyl chloride paste.
A glass fiber non-woven fabric (thickness 0.4 mm, basis weight 170 g / m ² ) is coated with the above-mentioned vinyl chloride paste sol uniformly at a thickness of 460 μm using a bar coater and then heated in a gear oven for 180 ° C./30 seconds. Gelled. Further, the sheet was heated in a gear oven at 210 ° C. for 150 seconds to obtain a buffer sheet having a thickness of about 3.0 mm and an expansion ratio of about 5.5 times integrated with the nonwoven fabric.

  This buffer sheet is laminated on the floor substrate (made of concrete) with an adhesive (rubber latex, “Fukubiment L” (product name), manufactured by Fukubi Chemical Co., Ltd.) on the floor base (made of concrete) ( Glued).

  Further, on the non-woven fabric side of the cushion sheet, a 1.8 mm thick vinyl chloride cushion floor ("Fukubi Rume" (product name), manufactured by Fukubi Chemical Industry Co., Ltd.) is bonded with an adhesive (rubber latex type, "Fukubimento"). L ”(product name), manufactured by Fukubi Chemical Industry Co., Ltd.).

  In this way, a sample in which the sound-insulating buffer sheet and the floor finish were laminated on the floor was manufactured.

In addition, the detail of each component used in the present Example is as follows.
・ Vinyl chloride resin: PMS-162 (trade name), manufactured by Kaneka Corporation ・ Plasticizer: DOP (dioctyl phthalate), manufactured by Jplus Corporation ・ Foaming agent: ADCA (azodicarbonamide), manufactured by Eiwa Kasei ・ Zinc carboxylate: 2-ethylhexylic acid zinc salt, KF-711D (trade name), manufactured by Sakai Chemical Industry, partial ester compound of carboxylic acid condensate: fatty acid polyglycol ester, BYK-P4100 (trade name), manufactured by Big Chemie Japan : Heavy calcium carbonate, Maruo calcium

[Example 2]
Glass fiber non-woven fabric (thickness 0.8 mm, basis weight 240 g / m ² ) as non-woven fabric, vinyl chloride tile (“Joywood” (product name), manufactured by Fukubi Chemical Industry Co., Ltd.) with a thickness of 2.5 mm as floor finish A sample was produced in the same manner as in Example 1 except that was used.

[Example 3]
A sample was manufactured in the same manner as in Example 1 except that a glass fiber nonwoven fabric (thickness 0.4 mm, basis weight 120 g / m ² ) was used as the nonwoven fabric.

[Example 4]
A sample was produced in the same manner as in Example 1 except that a polyester fiber nonwoven fabric (thickness 0.4 mm, basis weight 170 g / m ² ) was used as the nonwoven fabric.

[Comparative Example 1]
A sample was produced in the same manner as in Example 1 except that a foam was prepared using a release paper without using a nonwoven fabric.

[Comparative Example 2]
A sample was manufactured in the same manner as in Example 1 except that a glass fiber nonwoven fabric (thickness 0.25 mm, basis weight 50 g / m ² ) was used as the nonwoven fabric.

(Evaluation)
The following evaluation tests were performed on the samples (Examples 1 to 4 and Comparative Examples 1 and 2) obtained as described above.

(Sound insulation)
This was performed in accordance with JIS A1418. Using a 150mm slab equivalent housing of the experimental house, a light floor impact sound insulation performance test was conducted using 2F as a sound source and 1F as a sound receiving room.

(Peelability)
The test body (500 mm × 500 mm) was placed in a place where the walking frequency was high, and the finishing material was peeled off after 2 weeks. And the state of the peeling surface was observed and the following evaluation was performed.
○ Reusable level × Adhesive remains on the non-woven fabric or the foamed layer is destroyed.

  The above evaluation results are shown in Table 1.

[Discussion]
As can be seen from Table 1, in the samples using the sound insulating buffer sheet of the present invention as the underlay, the sound insulating properties were all at an excellent level of L-50. Also, the releasability was at a reusable level.

  On the other hand, in Comparative Examples 1 and 2, although the sound insulation was maintained, the peelability was poor and the buffer sheet could not be reused.

  From the above, it was found that the sound insulating buffer sheet of the present invention is excellent in both sound insulating properties and peelability (constructability).

DESCRIPTION OF SYMBOLS 1 Buffer sheet 2 Floor finishing material 3 Foam layer 4 Nonwoven fabric 5 Adhesive layer 6 Floor base 7 Surface layer

Claims (5)

A nonwoven fabric having a thickness of 0.3 to 1.0 mm and a basis weight of 100 to 250 g / m ² is laminated on at least one surface of a vinyl chloride foam sheet containing a vinyl chloride resin, a plasticizer, and a chemical foaming agent. Sound insulation buffer sheet.   The sound insulating buffer sheet according to claim 1, wherein the vinyl chloride foam sheet further contains at least one of a carboxylic acid zinc salt and a partial ester compound of a carboxylic acid condensate. A construction method for a floor finish using the sound-insulating buffer sheet according to claim 1,
A step of laminating the sound insulating cushioning sheet on a floor base, and a step of laminating a floor finishing material including a vinyl chloride foam layer on the sound insulating cushioning sheet via an adhesive layer. Construction method.   The construction method of a floor finish material according to claim 3, wherein the sound insulating buffer sheet is laminated with the nonwoven fabric surface facing up. The construction method according to claim 3, wherein a rubber latex adhesive, an acrylic resin emulsion adhesive, or a urethane resin adhesive is used as the adhesive layer.

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