JP2016186207A - Soundproof material and manufacturing method for the same, soundproof floor structure, and construction method for soundproof floor - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a soundproof material having excellent recyclability.SOLUTION: There is manufactured a soundproof material including a damping layer, an adhesion layer 2 including thermoplastic resin, and a hard layer 1 including metal or plastic. The damping layer may include a damping core layer 4 including asphalt. The hard layer may be formed from metal. The melting point or softening point of the thermoplastic resin may be lower than the softening point of the damping core layer. Fiber layers 3a, 3b including fiber assemblies may be stacked on both sides of the damping core layer. The average thickness of the hard layer is about 0.2 to 1.2 mm. A soundproof floor may be constructed by fixing the hard layer to a flooring material through an adhesive layer after laying the soundproof material on an underfloor material so that the hard layer's rear side is in contact with the underfloor material.SELECTED DRAWING: Figure 1

Description

  INDUSTRIAL APPLICABILITY The present invention is useful for reducing floor impact noise from an upper floor in a multi-storey building (multi-storey building) and has excellent recyclability, a method for manufacturing the same, and the soundproofing. The present invention relates to a soundproof floor structure provided with a material and a construction method of the soundproof floor.

  Conventionally, as countermeasures against impact noise from the upper floor, there are various methods such as laying asphalt damping material and cushioning material on the floor base, and using a dry double floor that supports the floor base with rubber support legs The method is used. In particular, soundproofing materials such as asphalt vibration damping materials and floor materials (especially flooring mainly composed of wood material) are usually constructed by using a nail and fixed to a floor base material. However, in the case of collective housing, especially rental housing, interior renovation is performed by moving the borrower for a certain period of time, but flooring such as flooring and floor base material are fixed with nails, so The intervening soundproofing material was destroyed, and it was necessary to change to a new material for each reform. Further, when the floor base material is also greatly damaged by the nail, it is necessary to update to a new floor base material.

  Japanese Patent Laid-Open No. 2002-227382 (Patent Document 1) discloses a sound insulating sheet in which a waterproof adhesive layer in which a metal powder for sound insulation is applied with asphalt is provided on one side of a base sheet made of nonwoven fabric. A floor base material obtained by adhering to a surface plywood is disclosed. In this floor base material, peeling at the adhesive interface is suppressed by adhering the waterproof adhesive layer to the surface plywood. Further, in this floor base material, a moisture-permeable soundproof substrate formed of a particle board is laminated on the other side of the sound insulation sheet via an adhesive such as vinyl acetate.

  However, the details of the construction method are not described in this document. Furthermore, it can be presumed that the face material laminated on the sound insulation sheet is a wood-based board material and is assumed to be constructed using nails.

JP 2002-227382 A (Claims, paragraph [0019])

  Accordingly, an object of the present invention is to provide a soundproof material excellent in recyclability, a method for manufacturing the same, a soundproof floor structure including the soundproof material, and a method for constructing the soundproof floor.

  Another object of the present invention is to provide a soundproof material excellent in handleability and workability, a method for producing the same, a soundproof floor structure provided with the soundproof material, and a method for constructing the soundproof floor.

  Still another object of the present invention is to provide a soundproofing material capable of reducing heavy floor impact sound from the upper floor in a multi-storey building, a method for manufacturing the same, a soundproofing floor structure equipped with the soundproofing material, and a method for constructing the soundproofing floor. It is to provide.

  As a result of intensive studies to achieve the above-mentioned problems, the inventors have formed a soundproof layer by combining a vibration damping layer, an adhesive layer containing a thermoplastic resin, and a hard layer containing metal or plastic, The inventors have found that the recyclability of the soundproofing material can be improved and have completed the present invention.

  The soundproofing material of the present invention includes a soundproofing layer having a vibration damping layer, an adhesive layer containing a thermoplastic resin, and a hard layer containing metal or plastic. The damping layer may include a damping core layer containing asphalt. The hard layer may be made of metal. The melting point or softening point of the thermoplastic resin may be lower than the softening point of the damping core layer. A fiber layer containing a fiber assembly may be laminated on both surfaces of the damping core layer. The fiber layer may be a spunbond long fiber nonwoven fabric.

In the soundproofing material of the present invention, the hard layer may be disposed on the surface layer. The soundproof layer may have an adhesive layer interposed between the vibration damping layer and the hard layer. In this soundproof layer, the adhesive strength between the vibration damping layer and the hard layer may be 0.1 N / mm ² or more. The soundproofing material may further include a buffer layer, and a vibration damping layer may be interposed between the buffer layer and the adhesive layer.

  In the soundproofing material of the present invention, the hard layer may have an average thickness of about 0.2 to 1.2 mm.

  The present invention also includes a method for producing the soundproof material including a soundproof layer forming step of laminating a vibration damping layer, an adhesive layer, and a hard layer. In the soundproof layer forming step, the adhesive layer of the laminate of the vibration damping layer and the adhesive layer may be brought into contact with the hard layer heated to a temperature equal to or higher than the melting point or softening point of the thermoplastic resin of the adhesive layer.

  The present invention is a soundproof floor structure including a floor base material, a floor finish material, and the soundproof material interposed between the floor base material and the floor finish material, and the hard layer of the soundproof material includes: Also included is a soundproof floor structure that is disposed on the side in contact with the floor finish material and in which the hard layer and the floor finish material are fixed via an adhesive layer. The floor finish may be a flooring material.

  In the present invention, on the floor base material, the back side of the hard layer is brought into contact with the floor base material, the soundproof material is laid, and then the hard layer and the floor finish material are fixed via the adhesive layer. Also includes floor construction methods.

  In the present invention, since the soundproof layer is formed by combining the vibration damping layer, the adhesive layer containing the thermoplastic resin, and the hard layer containing metal or plastic, the hard layer is used without using a nail. It can be integrated with the floor finish through the adhesive layer. Therefore, even if the floor finishing material is peeled off during renovation or the like, the soundproofing material is not destroyed and the recyclability is excellent. In particular, if an adhesive layer is interposed between the vibration damping layer and the hard layer, the hard layer and the vibration damping layer are firmly integrated with the adhesive layer, so that even if the floor finish is peeled off, it will peel off between the layers. It is possible to improve the handleability of the soundproofing material and the workability of the soundproofing floor. Furthermore, if a damping core layer containing asphalt is used as the damping layer, heavy floor impact sound from the upper floor in a multi-storey building can be reduced.

FIG. 1 is a schematic cross-sectional view showing an example of a soundproof material of the present invention. FIG. 2 is a schematic cross-sectional view showing another example of the soundproofing material of the present invention. FIG. 3 is a schematic cross-sectional view showing an example of a soundproof floor structure. FIG. 4 is a schematic diagram for explaining an adhesion test between the soundproofing material and the floor finishing material in the example.

[Soundproof material]
Hereinafter, the soundproofing material of the present invention will be described with reference to the drawings as necessary. FIG. 1 is a schematic cross-sectional view showing an example of a soundproof material of the present invention. As shown in FIG. 1, the soundproofing material of the present invention has a laminated structure in which fiber layers 3a and 3b containing a fiber assembly are laminated on both surfaces of a damping core layer 4 containing asphalt. The adhesive layer 2 made of thermoplastic resin and the hard layer 1 made of metal are sequentially laminated, and the vibration-damping layer and the hard layer are formed as a soundproof layer firmly integrated by the adhesive layer. Forming. Therefore, in this soundproofing material, the heavy floor impact sound can be reduced by the damping core layer, and the handling property is improved by integrating the soft damping core layer having low form stability with the hard layer.

  The laminated structure of each layer in the soundproof layer is not limited to the laminated structure shown in FIG. 1 as long as the soundproof layer has a vibration damping layer, an adhesive layer, and a hard layer, and the order in which the layers are laminated is not limited. Among these, a structure in which an adhesive layer is interposed between the vibration damping layer and the hard layer is preferable from the viewpoint that the soundproofing material is easy to handle and the construction of the soundproofing floor is excellent. Furthermore, it is preferable to dispose a hard layer as the outermost layer of the soundproofing material from the viewpoint of excellent peelability from the adhesive layer.

  FIG. 2 is a schematic cross-sectional view showing another example of the soundproofing material of the present invention. In this example, a buffer layer 5 formed of a nonwoven fabric or the like is further laminated on the side where the hard layer of the vibration damping layer of the soundproof material in FIG. 1 is not laminated. By combining with a buffer layer, not only heavy floor impact sound but also light floor impact sound can be reduced, floor cushioning can be improved, and safety during a fall can be improved.

(Vibration control layer)
The vibration damping layer only needs to contain a vibration damping material having a vibration damping function, and is not limited to the vibration damping layer shown in FIGS. The structure of the damping layer is not limited to the laminated structure in which the fiber layers are laminated on both sides of the damping core layer including the damping material, and may be formed by a single layer structure formed by the damping core layer alone. .

(A) Damping core layer As the damping material, a mixture of a binder component and a filler is usually used. Examples of the binder component include bituminous substances such as asphalt, synthetic resins, rubbers, and elastomers. These binder components can be used alone or in combination of two or more. In order for the binder component to exhibit a damping effect, it is usually preferable that the mass per unit area is 4 kg / m ² or more, and has such a high specific gravity and high density to reduce the weight floor impact sound. The binder component preferably contains asphalt from the viewpoint of great effect. The asphalt is not particularly limited, and general asphalt, for example, petroleum asphalt such as natural asphalt, straight asphalt, blown asphalt, and the like can be used. These asphalts can be used alone or in combination of two or more.

  Further, the binder component may contain a soft resin or an elastomer component in addition to asphalt in order to impart flexibility to the vibration damping material. Examples of the soft resin or elastomer component include polyolefin, vinyl polymer (polyvinyl chloride, ethylene-vinyl acetate copolymer, ethylene-vinyl alcohol copolymer, ethylene-acrylic acid copolymer, ethylene-methyl acrylate). Copolymer, ethylene-ethyl acrylate copolymer, etc.), polyamide, polyester, synthetic rubber (polybutadiene, polyisoprene, styrene-butadiene copolymer, etc.), natural rubber, rosin resin (natural rosin, modified rosin, etc.) Etc. These soft resins or elastomer components can be used alone or in combination of two or more. Of these soft resins or elastomer components, styrene-diene copolymers such as styrene-butadiene block copolymers are preferred.

  In the damping material containing asphalt, the ratio of the soft resin or elastomer component is, for example, 0 to 100 parts by weight, preferably 1 to 80 parts by weight, and more preferably about 3 to 50 parts by weight with respect to 100 parts by weight of asphalt. is there.

  The filler may be an organic filler, but is preferably an inorganic filler from the viewpoint of high specific gravity. Examples of the inorganic filler include metal particles (powder) such as iron, copper, tin, zinc, nickel, and stainless steel, iron oxide, iron sesquioxide, iron tetroxide, ferrite, tin oxide, zinc oxide, zinc white, Metal oxide particles such as copper oxide, aluminum oxide, metal salt particles such as barium sulfate, calcium sulfate, aluminum sulfate, calcium sulfite, calcium carbonate, calcium bicarbonate, barium carbonate, magnesium hydroxide, steelmaking slag, mica, clay, Examples include mineral particles such as talc, wollastonite, diatomaceous earth, silica sand, and pumice powder.

  These inorganic fillers can be used alone or in combination of two or more. Among these inorganic fillers, iron particles, various iron oxide particles, steelmaking slag particles, (heavy) calcium carbonate particles and the like are preferable.

  Examples of the shape of the inorganic filler include a particle shape or a powder shape, an indefinite shape, a fiber shape, and the like. The average particle diameter of the inorganic filler is, for example, about 0.5 mm or less (for example, 0.01 to 0.5 mm), preferably about 0.2 mm or less (for example, 0.05 to 0.2 mm). Use of such a finely divided inorganic filler improves molding processability when producing a vibration damping material and allows a large amount of inorganic filler to be uniformly dispersed and blended in the asphalt base material. The surface density and thermal stability of the vibration material can be improved.

The proportion of the inorganic filler is, for example, 100 to 2000 parts by weight, preferably 200 to 1800 parts by weight, and more preferably about 300 to 1500 parts by weight with respect to 100 parts by weight of asphalt. If the amount of the inorganic filler is too small, the vibration-damping and sound-insulating effect is lowered. Conversely, if the amount is too large, the whole becomes brittle and molding becomes difficult and workability is lowered. The amount of the inorganic filler is preferably adjusted so that the surface density of the damping core layer is 4 kg / m ² or more (particularly 8 kg / m ² or more).

  The damping material is not particularly limited, and can be obtained by a method in which a binder component and an inorganic filler are mixed by heating and formed into a plate shape. When blending a soft resin or an elastomer component, an inorganic filler may be added to a mixture in which asphalt and a soft resin or an elastomer component are mixed in advance.

  The thickness (average thickness) of the damping core layer is, for example, about 1 to 15 mm, preferably 2 to 12 mm, and more preferably about 3 to 10 mm (particularly 5 to 10 mm). The specific gravity of the damping core layer is, for example, about 2 to 4, preferably about 2.2 to 3.6, more preferably about 2.3 to 3.5 (especially 2.5 to 3.4).

(B) Fiber layer The vibration damping layer may have a laminated structure in which a fiber layer is laminated on at least one surface of the vibration damping core layer. In particular, when the vibration damping core layer contains asphalt, the handling property, etc. From the viewpoint, a laminated structure in which a fiber layer is laminated on at least one surface (preferably both surfaces) of the vibration damping core layer is preferable.

  The fiber layer only needs to contain a fiber assembly, but is usually a fabric formed of the fiber assembly. Examples of the fabric include woven fabric, knitted fabric, net, paper, and non-woven fabric. Of these, non-woven fabrics are preferred from the standpoints of productivity and adhesion to the damping core layer.

The non-woven fabric only needs to contain fibers. Examples of the fibers include natural fibers (cotton, hemp, etc.), regenerated fibers (rayon, etc.), semi-synthetic fibers (cellulose ester fibers, etc.), synthetic fibers [polyolefin fibers (polyethylene -Based fibers, polypropylene fibers, etc.), styrene fibers, tetrafluoroethylene fibers, acrylic fibers, vinyl alcohol fibers (ethylene vinyl alcohol fibers, etc.), polyester fibers (polyethylene terephthalate, polyethylene naphthalate, etc.) _2-4 alkylene arylate fibers, wholly aromatic polyester fibers such as liquid crystal polyester fibers), polyamide fibers (aliphatic polyamide fibers such as polyamide 6 and polyamide 66), wholly aromatic polyamide fibers such as aramid fiber, etc. ), Polyurethane Examples thereof include inorganic fibers (such as carbon fibers and glass fibers).

  These fibers can be used alone or in combination of two or more. Among these fibers, cellulose fibers such as cotton and rayon, polyolefin fibers such as polyethylene fibers and polypropylene fibers, polyester fibers such as polyethylene terephthalate fibers, polyamide fibers such as polyamide 6 fibers, etc. are widely used from the viewpoint of strength and the like. Polypropylene fibers and polyester fibers (particularly polyester fibers) are preferred.

  The average fineness of the fiber is about 0.1 denier or more, for example, 0.1 to 5 denier, preferably 0.2 to 4 denier, more preferably about 0.5 to 3 denier. If the fineness is too small, the strength may decrease.

  The average fiber length of the fibers may be, for example, about 10 to 150 mm, preferably about 20 to 80 mm, and more preferably about 30 to 60 mm. In direct spinning methods such as spunbond, meltblowing, and flash spinning, the average length is infinite. May be. From the viewpoint of strength and the like, the nonwoven fabric is preferably a long fiber nonwoven fabric.

Basis weight of the nonwoven fabric may be a 10 g / ^{m 2} or more (e.g., 10 to 500 g / ^{m 2} or so), for example 10 to 100 g / ^{m 2,} preferably 20 to 80 g / ^{m 2,} more preferably 25~60g / m ² (particularly 30 to 50 g / m ² ). If the basis weight is too small, even if a fiber layer is provided, the effect of improving the handleability of the damping core layer containing asphalt may be reduced.

  The nonwoven fabric can be prepared through a conventional method, for example, a web forming step including the fibers and a web adhering step, specifically, spunbond, meltblowing, flash spinning, chemical bond, thermal bond, hot embossing. It can be prepared by processing, spunlace, needle punch, stitch bond method and the like. Of these, the spunbond method is preferable in terms of strength and the like. In particular, the nonwoven fabric may be a polyester spunbond nonwoven fabric.

  The fiber layer may contain an additive inside the fiber or on the fiber surface. Examples of additives include stabilizers (heat stabilizers such as copper compounds, ultraviolet absorbers, light stabilizers, antioxidants, etc.), fillers (fine particles, etc.), thickeners, foaming agents, flame retardants, plastics, etc. Agent, antistatic agent, colorant, surfactant, dispersant, lubricant, crystallization rate retarding agent, lubricant, antibacterial agent, insecticide (anticide, acaricide, etc.), antiseptic (antifungal agent, etc.) ), Matting agents, heat storage agents, fragrances, fluorescent brighteners, wetting agents, and the like. These additives can be used alone or in combination of two or more. The ratio of the additive is 50% by mass or less, preferably 0.01 to 30% by mass, and more preferably about 0.1 to 10% by mass with respect to the entire fiber layer.

  The thickness (average thickness) of the fiber layer (when laminated on both sides) may be 0.05 mm or more, for example, 0.1 to 1 mm, preferably 0.15 to 0.7 mm, and more preferably 0.00. It is about 2 to 0.5 mm. If the fiber layer is too thin, the handleability of the damping core layer may be reduced.

(Adhesive layer)
In the present invention, since the vibration damping layer and the hard layer are integrated via an adhesive layer containing a thermoplastic resin, the floor finish material and the hard layer are fixed via an adhesive layer such as a double-sided tape. Even if the floor finish is removed by renovation after construction of the soundproof floor, the soundproof material is not destroyed and can be recycled (reused).

  The adhesive layer only needs to contain a thermoplastic resin, but the ratio of the thermoplastic resin to the entire adhesive layer is usually 50% by mass or more, preferably 80% by mass or more, and more preferably 90% by mass. That's it.

  As the thermoplastic resin, a conventional adhesive resin (binder resin) can be used, and a hot melt adhesive resin is preferable from the viewpoint of excellent productivity and high adhesive strength. Examples of hot melt adhesive resins include olefin resins, vinyl resins, (meth) acrylic resins, styrene resins, polyesters (aliphatic polyesters, amorphous polyesters, etc.), aliphatic polyamides, urethane resins, heat Examples thereof include plastic elastomers. These thermoplastic resins can be used alone or in combination of two or more. Of these thermoplastic resins, polyethylene resins are preferred because they are excellent in adhesiveness and have a low melting point and excellent soundproofing material productivity.

  Examples of the polyethylene resin include low density polyethylene (LDPE), linear low density polyethylene (LLDPE), medium density polyethylene (MDPE), high density polyethylene (HDPE), ethylene-propylene copolymer, ethylene-butene- 1 copolymer, ethylene-propylene-butene-1 copolymer, ethylene- (4-methylpentene-1) copolymer, ethylene-vinyl acetate copolymer, ethylene-methyl methacrylate copolymer, and the like. These polyethylene resins can be used alone or in combination of two or more. Among these polyethylene-based resins, polyethylene such as LDPE and LLDPE, ethylene-vinyl acetate copolymer, and the like are preferable from the viewpoint of low melting point and excellent adhesiveness.

  The melting point or softening point of the thermoplastic resin is preferably lower than the softening point of the damping core layer, for example, 3 ° C. or more (eg, 5 to 100 ° C., preferably 10 to 50 ° C.) than the softening point of the damping core layer. It may be low. Specifically, the melting point or softening point of the thermoplastic resin may be 130 ° C. or less, for example, 60 to 130 ° C., preferably 65 to 125 ° C., more preferably about 70 to 120 ° C. If the melting point or softening point of the thermoplastic resin is too high, the temperature at which the thermoplastic resin is melted or softened increases, so when the damping core layer contains asphalt, the damping core layer melts and deforms or is hard When the layer is a thin metal plate or a low melting point plastic plate, the hard layer may be deformed or distorted.

  The adhesive layer may also contain the additive exemplified in the section of the fiber layer. The said additive can be used individually or in combination of 2 or more types. The ratio of the additive is 50% by mass or less, preferably 0.01 to 30% by mass, and more preferably about 0.1 to 10% by mass with respect to the entire adhesive layer.

  The thickness (average thickness) of the adhesive layer is about 5 μm or more, for example, 5 to 100 μm, preferably 8 to 50 μm, and more preferably 10 to 30 μm (particularly 12 to 20 μm). If the thickness of the adhesive layer is too thin, the adhesive strength is reduced, and the vibration damping layer and the hard layer may not be integrated.

(Hard layer)
In the present invention, since the hard layer containing metal or plastic is laminated and integrated on the soundproofing material via the adhesive layer, the recyclability of the soundproofing material can be improved as described above. In contrast, when a conventional soundproofing material (a laminate of a fiber layer and a damping core layer) that does not include an adhesive layer and a hard layer is fixed to the floor base material with an adhesive layer, the adhesive layer and the fiber layer are separated. Is difficult, and the fiber layer and the damping core layer are damaged.

  The hard layer includes metal or plastic, and these materials are difficult to nail unlike wood materials, but are hard and have excellent peelability to the adhesive material. Even if fixed to the floor base material, it can be easily peeled off without breaking. The hard layer may contain metal or plastic, but is usually a single layer (single layer plate) made of metal or plastic.

  The material of the metal is not particularly limited, and examples thereof include aluminum, iron, nickel, copper, and chromium. The metal may be the single metal or an alloy of the metal (for example, stainless steel or steel). Furthermore, the metal surface may be subjected to plating treatment such as galvanization for rust prevention treatment. Of these, metals containing iron are widely used, and plated iron is preferred.

  Examples of the plastic include conventional hard plastics such as (meth) acrylic resins, polypropylene resins, hard vinyl chloride resins, polyesters, polycarbonates, polyamides, and polyacetals. Among these plastics, (meth) acrylic resins such as poly (meth) methyl acrylate, polypropylene resins such as polypropylene, and the like are widely used.

  The melting point or softening point of the plastic is preferably higher than the melting point or softening point of the thermoplastic resin of the adhesive layer. For example, the melting point or softening point of the thermoplastic resin is 3 ° C. or higher (eg, 5 to 100 ° C., preferably (About 10-50 degreeC) may be high. Specifically, the melting point or softening point of the plastic may exceed 130 ° C., for example, 135 to 300 ° C., preferably 140 to 250 ° C., and more preferably about 150 to 200 ° C. If the melting point or softening point of the plastic is too low, the hard layer may be deformed if the thermoplastic resin of the adhesive layer is melted or softened.

  The thickness (average thickness) of the hard layer can be selected from the range of about 0.1 to 5 mm (particularly 0.2 to 3 mm), but preferably 0.2 to 1.2 mm when the hard layer is formed of metal. More preferably, it is about 0.3-1 mm, and when the hard layer is formed of plastic, it is preferably 0.5-2 mm, more preferably about 0.7-1.5 mm. If the thickness of the hard layer is too thin, it is difficult to adhere to the floor finish, and if it is too thick, the workability of the work may be lowered, such as difficult to cut.

(Buffer layer)
The buffer layer is laminated in order to improve the vibration proof property of the soundproof material, and may have elasticity and shock absorption, and a conventional buffer material can be used. As the buffer material, for example, plastic foam (for example, foamed styrene, foamed urethane, foamed polyolefin, etc.), rubber or elastomer, fiber structure (structure composed of woven or knitted fabric, non-woven fabric, etc.) can be used. Among these, a non-woven fiber structure (nonwoven fabric) is preferable because it has moderate voiding properties and excellent vibration proofing properties.

  In the non-woven fiber structure, the fibers exemplified in the fiber layer can be used as the fiber material. Of the fibers, polypropylene fibers, polyester fibers, polyamide fibers and the like are preferable from the viewpoint of strength and the like, and polyester fibers such as polyethylene terephthalate fiber are particularly preferable.

  The average fineness of the fiber is about 0.03 denier or more, for example, 0.05 to 15 denier, preferably 1 to 13 denier, more preferably about 2 to 9 denier. If the fineness is too small, the strength may decrease.

  The average fiber length of the fibers may be, for example, about 10 to 150 mm, preferably about 20 to 80 mm, and more preferably about 30 to 60 mm. In direct spinning methods such as spunbond, meltblowing, and flash spinning, the average length is infinite. May be. Short fibers may be used from the viewpoint of versatility.

Nonwoven basis weight of the fiber structure may be a 50 g / ^{m 2} or more (e.g., 50 to 2000 g / ^{m 2} or so), for example 80~1500g / ^{m 2,} preferably 100 to 1000 g / ^{m 2,} more preferably 200 it is a ~800g / ^{m 2} about. If the basis weight is too small, the effect of improving vibration isolation may be reduced.

Apparent density of the nonwoven fibrous structure, for example 0.01~0.20g / cm ^3, preferably 0.03~0.15g / cm ^3, more preferably at about 0.05~0.13g / cm ³ is there. If the apparent density is too small, the effect of improving vibration isolation may be reduced.

  The manufacturing method of a nonwoven fiber structure can also be manufactured with the manufacturing method similar to the manufacturing method of the nonwoven fabric of the said fiber layer. Among the manufacturing methods, a manufacturing method including an adhesion step by needle punching may be used from the viewpoint of simplicity.

  The buffer layer may also contain the additive exemplified in the section of the fiber layer. The said additive can be used individually or in combination of 2 or more types. The ratio of the additive is 50% by mass or less, preferably 0.01 to 30% by mass, and more preferably about 0.1 to 10% by mass with respect to the entire buffer layer.

  The thickness (average thickness) of the buffer layer is 0.5 mm or more, for example, 0.5 to 20 mm, preferably 0.8 to 10 mm, more preferably about 1 to 5 mm (particularly 2 to 4 mm). If the thickness of the buffer layer is too thin, the effect of improving vibration isolation may be reduced.

(Method for manufacturing soundproofing material)
The method of manufacturing the soundproofing material is not particularly limited as long as it includes a soundproofing layer forming step of laminating the vibration damping layer, the adhesive layer, and the hard layer, but the adhesive layer is interposed between the vibration damping layer and the hard layer. When forming a soundproof layer, from the viewpoint of productivity, the adhesive layer of the laminate of the vibration damping layer and the adhesive layer, and a hard material heated to a temperature higher than the melting point or softening point of the thermoplastic resin of the adhesive layer It may be a production method including a contact step of contacting the layer.

  In the contacting step, the heating method of the hard layer is not particularly limited, and for example, an induction heating method, a warm air heating method, an infrared heating method, or the like can be used. The heating temperature only needs to be higher than the melting point or softening point of the thermoplastic resin of the adhesive layer, and can be selected according to the type of the thermoplastic resin, but from the point that distortion and deformation of the thin hard layer can be suppressed, 130 ° C. or less May be sufficient, Preferably it is 60-120 degreeC, More preferably, 65-100 degreeC (especially 70-90 degreeC) grade may be sufficient.

  The lamination method of the laminate of the vibration damping layer and the adhesive layer is not particularly limited, and for example, after laminating the heat-melted adhesive layer on the vibration damping layer, the laminate may be cooled and solidified by cooling. Good.

  When the soundproofing material includes a buffer layer, the buffer layer may be bonded to the vibration damping layer using a conventional adhesive or pressure-sensitive adhesive. As the adhesive, in addition to the adhesive resin exemplified in the adhesive layer, natural polymer adhesives such as starch and casein, thermosetting resin adhesives such as epoxy resins, and the like can be used. For example, an olefin adhesive, a (meth) acrylic adhesive, a polyester adhesive, a urethane adhesive, a rubber adhesive, or the like can be used.

[Soundproof floor structure and construction method]
The soundproof floor structure of the present invention has a structure in which the soundproof material is interposed between a floor base material and a floor finish material, and the hard layer of the soundproof material is on the side in contact with the floor finish material. It is arrange | positioned and the said hard layer and the said floor finishing material are being fixed through the adhesion layer. FIG. 3 is a schematic cross-sectional view showing an example of a soundproof floor structure. In this example, a soundproofing material is disposed on the floor base material 8, and more specifically, the soundproofing material is formed from the side in contact with the floor base material by the fiber layer 3b, the damping core layer 4, and the fiber layer 3c. The adhesive layer 2 and the hard layer 1 are laminated and integrated in this order. Furthermore, a floor finish 6 is fixed on the hard layer 1 via an adhesive layer 7.

  The soundproof material may be laid on the floor base material with the back side of the hard layer (fiber layer, buffer layer, etc.) in contact with the floor base material, and the soundproof material and the floor base material are adhesive or adhesive. It may be fixed via, or may not be fixed. When the back side of the hard layer is a buffer layer formed of a fiber layer or a fiber structure, and is fixed via an adhesive or a pressure-sensitive adhesive, the fiber layer or the buffer layer is an adhesive layer in the same manner as the opposite surface. A hard layer (second hard layer) may be laminated via the (second adhesive layer).

  As the floor base material, various floor base materials can be used according to the type of building. The floor base material may be, for example, a concrete slab or a lightweight foamed concrete in a reinforced concrete building, and may be a wooden floor used in a general wooden house. In addition, floor base materials are concrete slabs, wooden floors, tatami floors, plastic boards, plywood, wooden boards, paper, woven or non-woven sheets, inorganic boards (gypsum boards, calcium silicate boards, etc.), metals A board etc. may be laminated. In consideration of fire resistance, it is preferable to use a gypsum board.

  The pressure-sensitive adhesive layer is not particularly limited as long as it contains a conventional pressure-sensitive adhesive such as an olefin-based pressure-sensitive adhesive, a (meth) acrylic pressure-sensitive adhesive, a polyester-based pressure-sensitive adhesive, a urethane-based pressure-sensitive adhesive, or a rubber-based pressure-sensitive adhesive. From the viewpoint of workability, a laminate (double-sided tape) in which an adhesive is applied to both sides of the base film may be used.

  The adhesive layer may be laminated on the entire surface of the soundproofing material (particularly the hard layer) or may be partially laminated. For example, when partially laminating using double-sided tape, the interval between adjacent double-sided tapes may be, for example, about 100 to 500 mm, preferably about 150 to 450 mm, and more preferably about 200 to 400 mm.

  As the floor finishing material, a conventional floor finishing material, for example, a conventional floor finishing material used for laying finishing, flooring, soft finishing and the like can be used. Examples of the floor finish material for flooring include tatami mats, carpets, rugs, rug mats, and carpets. Flooring materials for flooring include flooring materials such as muk-wood floor finishing materials and plywood floor finishing materials. Soft finish flooring materials include cork boards, soft plastic boards and the like. The soft plastic plate may be a plastic sheet (cushion floor) having a foam layer. Among these floor finishing materials, the flooring material suitable for fixing via an adhesive layer is particularly effective.

  The thickness of the floor finishing material can be selected according to the type. For example, the thickness of the flooring material may be, for example, 2 to 20 mm, preferably 3 to 15 mm, and more preferably about 5 to 15 mm.

  The soundproof floor structure of the present invention can reduce the floor impact sound in a wide frequency range by selecting the material of the vibration damping layer and the buffer layer. When the vibration damping layer includes a vibration damping core layer containing asphalt, the weight It is effective for floor impact sound, for example, impact sound having a natural frequency of about 5 to 100 Hz, preferably 10 to 80 Hz, and more preferably about 20 to 70 Hz.

  EXAMPLES Hereinafter, the present invention will be described more specifically with reference to examples. However, the present invention is not limited to these examples. The evaluation of the examples was measured by the following method. In the examples, “parts” and “%” are based on mass unless otherwise specified.

[Adhesion test with floor finish]
As shown in FIG. 4, the flooring 12 cut in advance to 40 mm square was applied to the soundproof material 11 cut in advance to 40 mm square using a double-sided tape (“No.751” manufactured by Teraoka Seisakusho, not shown). . Adhesion test jigs 13 and 14 having attachment portions (gripping portions) 13a and 14a with a tensile tester on the flooring side and the opposite side thereof are respectively epoxy adhesives ("Bond Quick Mender" manufactured by Konishi Co., Ltd.). The tensile maximum load (N) is measured under the condition of 2 mm / min using a tensile tester ("Autograph AGS-5KND" manufactured by Shimadzu Corporation, not shown). The adhesion strength (N / mm ² ) between the flooring (floor finishing material) and the soundproofing material was measured. At that time, the test was performed three times using the same specimen.

[Adhesion test between damping layer and hard layer]
Except for fixing the adhesion test jig used in the adhesion test of the floor finish material to the damping layer and hard layer of the soundproofing material with an epoxy adhesive, respectively, the same method as the adhesion test with the floor finish material, The adhesive strength (N / mm ² ) between the damping layer and the hard layer was measured.

[Floor impact sound test]
The test was carried out in an experimental house using a joist-less construction method with a floor size of 3,640 × 3,640 mm in the central part of a semi-anechoic chamber measuring 8 m long × 8 m wide × 8 m high. The test was conducted in accordance with JIS A 1418-1 “Method for measuring floor impact sound insulation performance of buildings—Part 2: Method using standard weight impact source”. The evaluation is shown by the amount of reduction (dB) from the raw surface of the 63 Hz band.

Example 1
A polyester long-fiber nonwoven fabric (Asahi Kasei Fibers Co., Ltd. “EO-1050”, basis weight 50 g / m ² ) on one side and a polyethylene resin with a thickness of 15 μm on the other side is heat-laminated. fiber Ltd. "EO-1050", basis weight 50 g / ^{m 2)} asphalt-based damping material which is laminated (Nanao Kogyo Co., Ltd. "asphalt sheet", specific gravity 2.8, one of thickness 8 mm) Next, on the solidified polyethylene resin layer, a galvanized iron plate having a thickness of 0.38 mm heated to 120 ° C. using a warm air heating device was placed and cooled to obtain a soundproofing material.

(Comparative Example 1)
Polyester long fiber nonwoven fabric ("EO-1050" manufactured by Asahi Kasei Fibers Co., Ltd., basis weight 50g / m ² ) laminated on both sides, asphalt damping material ("Asphalt sheet" manufactured by Nanao Industry Co., Ltd.), specific gravity 2 .8, thickness 8 mm) was used as a soundproofing material.

  Table 1 shows the results of the adhesion test with the floor finish of the soundproofing material of Example 1 and Comparative Example 1.

  As is clear from the results in Table 1, in the soundproofing material of Example 1, the adhesive strength between the floor finish and the soundproofing material did not decrease even when used multiple times, but decreased in the soundproofing material of Comparative Example 1. .

(Example 2)
A soundproofing material was obtained in the same manner as in Example 1 except that an ethylene-vinyl acetate copolymer (“Hyrodyne 7573” manufactured by Hirodine Co., Ltd.) was used instead of the polyethylene resin.

  Table 2 shows the results of the adhesion test between the vibration damping layer and the hard layer for the soundproofing materials of Examples 1 and 2.

  Furthermore, Table 3 shows the results of measuring the amount of reduction (dB) from the bare surface of the heavy floor impact source for the soundproofing materials of Example 1 and Comparative Example 1.

  As is clear from the results in Table 3, the soundproofing material of Example 1 had a greater reduction from the bare surface at the heavy floor impact source than the soundproofing material of Comparative Example 1.

  From these results, when replacing the flooring material, the conventional product has sufficient adhesiveness for the first time, but at the time of replacement, the face material is destroyed, the damping core layer is directly exposed, and the adhesiveness is lost.

  On the other hand, since the product of the present invention uses a metal plate, the face material is not destroyed and the strength is stable. Also, when the flooring was replaced, the tape adhesive was softened by heating the double-sided tape from above the flooring and could be easily removed.

  The soundproofing material of the present invention can be used for a floor structure of a building such as a condominium, a building, and a general house, and in particular, two or more floors in a multi-storey building (multi-storey building) such as a condominium, building, and general house. It is useful as a floor structure in the floor.

DESCRIPTION OF SYMBOLS 1 ... Hard layer 2 ... Adhesive layer 3a, 3b ... Fiber layer 4 ... Damping core layer 5 ... Buffer layer 6 ... Floor finishing material 7 ... Adhesive layer 8 ... Floor base material

Claims (16)

  A soundproofing material including a soundproofing layer having a vibration damping layer, an adhesive layer containing a thermoplastic resin, and a hard layer containing metal or plastic.   The soundproofing material according to claim 1, wherein the damping layer includes a damping core layer containing asphalt.   The soundproofing material according to claim 2, wherein the melting point or softening point of the thermoplastic resin is lower than the softening point of the damping core layer.   The soundproof material according to any one of claims 1 to 3, wherein the hard layer is formed of a metal.   The soundproofing material according to any one of claims 2 to 4, wherein a fiber layer containing a fiber assembly is laminated on both surfaces of the damping core layer.   The soundproofing material according to claim 5, wherein the fiber layer is a spunbond long fiber nonwoven fabric.   The soundproofing material according to any one of claims 1 to 6, wherein the hard layer is disposed on the surface layer.   The soundproofing material according to any one of claims 1 to 7, wherein an adhesive layer is interposed between the vibration damping layer and the hard layer. The soundproofing material according to claim 8, wherein the adhesive strength between the vibration damping layer and the hard layer is 0.1 N / mm ² or more.   The soundproofing material according to any one of claims 1 to 9, further comprising a buffer layer, wherein a damping layer is interposed between the buffer layer and the adhesive layer.   The soundproof material according to any one of claims 1 to 10, wherein an average thickness of the hard layer is 0.2 to 1.2 mm.   The method for producing a soundproof material according to any one of claims 1 to 11, further comprising a soundproof layer forming step of laminating the vibration damping layer, the adhesive layer, and the hard layer.   13. The soundproof layer forming step, wherein the adhesive layer of the laminate of the vibration damping layer and the adhesive layer is brought into contact with the hard layer heated to a temperature equal to or higher than the melting point or softening point of the thermoplastic resin of the adhesive layer. A method for producing a soundproofing material.   A soundproof floor structure comprising a floor base material, a floor finish material, and the soundproof material according to any one of claims 1 to 11 interposed between the floor base material and the floor finish material, wherein the soundproof material A soundproof floor structure in which the hard layer is disposed on a side in contact with the floor finish material, and the hard layer and the floor finish material are fixed via an adhesive layer.   The soundproof floor structure according to claim 14, wherein the floor finish is a flooring material.   On the floor base material, the back side of the hard layer is brought into contact with the floor base material, and the soundproofing material according to any one of claims 1 to 11 is laid, and then the hard layer and the floor finishing material are interposed via an adhesive layer. Construction method of soundproof floor to fix

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