JP4874592B2 - Spacer for floor base material and manufacturing method thereof - Google Patents

Description

The present invention relates to a spacer for a floor base material and a method for producing the same , and more specifically, is lightweight and excellent in cutability, water resistance, and load resistance, in which a fiber assembly is laminated on the surface of a foam, and suitable for recycling and reforming. The present invention relates to a spacer for a floor base material comprising a composite resin foam for a floor base material and a method for producing the same .

  Conventionally, many resin foams have been used as building materials. Further, in floor finishing materials for apartment houses, detached houses, public facilities, commercial facilities, etc., wooden flooring and polymer flooring are mainly used as floor surface finishing materials. Furthermore, in the case of slab direct stretch structure, double floor structure, and joist, it is well known that construction methods and structures are being studied to eliminate the level difference between floors in consideration of the recent barrier-free structure. is there.

As a method for eliminating a step in a barrier-free structure or the like, for example, dropping a slab, a method using a fiberboard or plywood as a spacer material (for example, refer to Patent Document 1), or a double floor system is used. A method of eliminating the level difference by adjusting the leg length of the double floor is used.
However, when plywood or fiberboard is used as the spacer material as described above, there are the following problems. (I) The weight is heavy and the handling is poor. For example, a plywood with a thickness of 12 mm can carry only about 2 sheets / person at a time. (Ii) It is difficult to perform cut adjustment on site, and an electric saw or the like is required, which causes safety and noise problems. (Iii) When the finishing material is a polymer flooring, the cloth craftsman usually performs the construction, but if the plywood is used as the base, the tools used by the cloth craftsman (mainly the cutter) cannot be constructed, and the wooden floor construction craftsman Is required, and multiple craftsmen from different industries are required at the construction site, resulting in a high construction unit price. (Iv) Even if it is a water-resistant plywood, complete water-absorbing performance cannot be maintained, and deformation, warpage, and the like due to corrosion tend to occur. (V) When the finishing material is subjected to a polymer finishing material such as a cushion floor, the appearance is affected. (Vi) The amount of insect repellent used is regulated by the recent revision of the Building Standards Law, and the insect repellent components contained in the plywood are reduced, so that insects are easy to eat. In addition, when an insect repellent component is blended, the possibility of indoor emission of volatile harmful substances is increased, which can cause house sick syndrome. (Vii) When fixing using a nail, the possibility of becoming a nail occurs due to secular change due to friction with the nail. In addition, for the double floor system, the step adjustment of the double floor can be eliminated by adjusting the length of the legs, but since the weight is heavy, the burden of adjustment man-hours is increased, so it is better to adjust the step with a spacer. It is rather simple. In addition, when using a cushion floor as the finishing material, a double-floor particle board will be mistaken, so it is necessary to use plywood or a special spacer material for the base, and when the floor finishing material is fixed with an adhesive When renovating the floor by renovation or the like, problems such as difficulty in separating the spacer material and the finishing material occur.

  As a method for solving such problems, for example, in a floor renovation method having a structure in which a floor material is attached to the upper surface of a base material with an adhesive, an old adhesive without destroying the base material by simple peeling means A method of peeling off and removing a layer, applying a new adhesive, and sticking a flooring to the surface of a base material (for example, see Patent Document 2) has been proposed. Has not been resolved.

For such problems, resin foams that are lightweight and have the necessary compressive strength and good workability are attracting attention. In the building field, when resin foam is used as a floor base spacer, the adhesive strength that can cancel the stress generated in the shear direction, which is thought to be generated by heat shrinkage of the resin foam, is regarded as important, and the adhesive strength in the shear direction is stable. Of course, the adhesive interface also needs a function to easily peel off the surface finish material in the vertical direction without damaging the finish material or the base material during refurbishment or repair. For example, using a polyolefin resin, a nonwoven fabric is laminated on the surface where the average aspect ratio Dz / Dxy of the internal bubbles is 1.1 to 4.0, the expansion ratio is 3 to 20 times, and the compression modulus is 5 MPa or more. A floor base material (for example, refer to Patent Document 3) has been proposed. By using this method, as long as the minimum necessary adhesive strength is satisfied, when peeling off the surface finishing material joined to the resin foam, the non-woven fabric layer is peeled off, and the finishing material is hardly broken. I can expect. However, when the entire surface of the floor adhesive is applied with an adhesive brush used at the time of normal application, the surface is worn due to friction, and pills are generated. Further, there is a problem that the workability is remarkably lowered, such as a fuzzy ball being pinched during bonding with another material to create a gap and lowering the adhesive strength per area, or generating dust and causing deterioration of the working environment.
This is not a problem limited to the use as a floor base spacer, but also a problem related to the use of foams in general laminated with non-woven fabric that needs to be fixed with an adhesive. For example, when fixing a foam to a wall material or a ceiling material, it can be easily considered that the same problem occurs. For example, when a foam is fixed to a wall material or a ceiling material, it can be easily considered that the same problem occurs.
JP 2003-293563 A Japanese Patent Laid-Open No. 10-88818 JP 2004-339757 A

Depending on the main raw material of the resin foam, there are many cases in which the chemical adhesive force due to the adhesive does not appear due to the difference in polarity. For example, polyethylene and polypropylene that are excluded from olefin resins among the resin raw materials used for general purposes Is a class that is unlikely to generate chemical adhesive force unless it is improved by product cotton, such as corona treatment, heating (burning) treatment, chemical treatment using hydrochloric acid, sulfuric acid, etc. Otherwise, a special blended adhesive must be used, which is unrealistic for construction in the building material field where the unit price is high and requires a large amount of adhesive. Moreover, although it can be assumed that a hot-melt adhesive with a low unit price is used, in practice, a melting device and a coating device are required at a construction site, and the construction becomes complicated. Also, the method of melting and fusing the material itself by heat treatment is complicated in the process and requires a skillful technique, so that it is not practical in field construction. The purpose of the present invention is to reduce the generation of pills when applying an adhesive, in light of the light and cutting properties, water resistance, and load resistance that can be used for building materials in view of the above-mentioned problems of the prior art. and to provide a underfloor member for spacers and a manufacturing method thereof comprising a composite resin foam which has both stable and functionally required adhesive strength and removability.

As a result of intensive studies to solve the above problems, the present inventors can use as a building material by laminating a fiber assembly having a specific restraint point density and a fiber restraint portion on the surface of the resin foam, lightweight cutting resistance, water resistance, load capacity superior bearing properties, suppress the occurrence of pill when applying the adhesive, combines stable and functionally required adhesive strength and removability floor comprising a composite resin foam The present inventors have found that a spacer for ground materials can be obtained and completed the present invention.

That is, according to the first aspect of the present invention, at least one surface of the resin foam, a spacer underfloor member of fiber aggregate is present the fiber restraining portion is made of a composite resin foam ing is laminated ,
In the composite resin foam, the fiber assembly has an average shortest distance from an arbitrary point to the fiber restraint portion of 0.5 mm or less, and a point density of the fiber restraint portion (hereinafter referred to as “constraint point density”) of 30. Point / cm ² or more,
The resin foam is provided with a spacer for a floor base material characterized in that the average value of Dz / Dx of the aspect ratio of the air bubbles is 1.1 to 4.0 and the expansion ratio is 3 to 20 times. The

According to a second aspect of the present invention, there is provided a spacer for a floor base material characterized in that, in the first aspect, the fiber assembly is a nonwoven fabric.

According to the third invention of the present invention, there is provided a floor base material spacer characterized in that, in the first or second invention, the resin foam is a foam using an olefin resin as a main raw material. Provided.

According to a fourth aspect of the present invention, there is provided a method for manufacturing a spacer for a floor base material according to any one of the first to third aspects,
A step of laminating the fiber assembly on at least one side of the raw fabric before foaming of the resin foam;
And heating the laminated body at a temperature equal to or higher than the foaming temperature of the original fabric to foam the original fabric in the thickness direction. .

Since the composite resin foam in the spacer for floor base material of the present invention and the method for producing the same is formed by laminating a fiber assembly having specific restraint point density and fiber restraint portion on the surface of the resin foam, the adhesive strength is lowered. Therefore, it is an inexpensive composite resin foam that can be reused by improving adhesion workability and maintaining the peelability of the face material. In addition, the foam shape of the foam of the resin foam is a spindle type, and by using an olefin resin as the main raw material, it is a composite resin foam with high compressive strength and easy to recycle performance. In particular, it can be used as a spacer for a floor base material.

The present invention relates to a spacer for a floor base material comprising a composite resin foam in which a fiber assembly is laminated on at least one surface of a resin foam and a method for producing the same. Hereinafter, the fiber assembly, the resin foam, and the composite resin foam will be described in detail.

The fiber aggregate that can be used in the present invention means an aggregate of fiber materials, and is not particularly limited. For example, a surface mat obtained by making glass fibers and glass roving are woven. And the like. Incidentally, in the Safei scan mat may contain a binder for binding the glass short fibers, as the binder, polyvinyl alcohol resins, saturated polyester resins, thermosetting resins such as an acrylic resin Is mentioned. Furthermore, glass fiber, carbon fiber, polyester fiber, acrylic fiber, nylon fiber, aramid fiber and other long fiber materials are consolidated into a sheet with a resin binder or the like, a prepreg sheet, polypropylene or other thermoplastic resin and a glass long fiber mat. A stampable sheet, a cold chill, a woven or non-woven fabric, a needle punch, and the like. In addition, as a material for cold chill, woven or non-woven fabric, needle punch, mainly natural fibers such as cotton, wool, silk, semi-synthetic fibers such as rayon, synthetic fibers such as polyester, polyamide, polyolefin, PVA, vinylon, Examples thereof include high modulus fibers such as high-strength polyethylene fibers and alamod fibers. The woven fabric includes those made of general natural fibers and synthetic fibers. Paper is also included as one of the fiber assemblies.

Among the above fiber aggregates, nonwoven fabrics are preferable in that they are excellent in anchoring (anchor effect) effect at the time of lamination, and nonwoven fabrics of polyester fibers such as polyethylene terephthalate that hardly adversely affect people and the environment are more preferable. Used for.
Polyester fibers include not only polyethylene terephthalate, polybutylene terephthalate, but also copolyesters of copolymerization components such as isophthalic acid, adipic acid, diethylene glycol, trimethylene glycol, and fibers made of these copolymers. Further, it may be a composite fiber such as a core-sheath structure or side-by-side.

Furthermore, the fiber restraint part of the fiber assembly used in the present invention needs to have an average shortest distance from an arbitrary point to the fiber restraint part of 0.5 mm or less. When the fiber restraint part is within 0.5 mm from any point of the fiber assembly, the composite resin foam is used as the floor base material, and when applying adhesive, the generation of fuzz due to the friction of the face material due to friction Is suppressed.
Here, the fiber restraint portion refers to a portion in which the fiber aggregate is subjected to point-like partial heat pressure welding or the like and the fibers are fixed to each other by heat fusion or adhesive, and there is a fiber material. A range where two-dimensional or three-dimensional arrays overlap at an angle and are fixed at the overlapping part.

The restraint point density of the fiber assembly used in the present invention is 30 points / cm ² or more, preferably 50 points / cm ² or more. When the density of restraint points is less than 30 points / cm ² , the composite resin foam is used as a floor base material, and fluff is likely to occur when an adhesive is applied, which impairs workability.
Here, the restraint point density of the fiber assembly is expressed by the following equation as the density at the entire surface area of the point constrained area, that is, the restraint point density B, when the fiber assembly is subjected to point-like partial heat pressure welding or the like. The
B (points / cm ² ) = number of restraint points (points) / total surface area of the fiber assembly (cm ² )]

In the present invention, the area ratio (hereinafter referred to as “restrained area ratio”) of the fiber restraint portion of the fiber assembly is not particularly limited, but is preferably 5 to 80%. When the restraint area ratio is less than 5%, the composite resin foam is used as a floor base material, and fluff is likely to occur when the adhesive is applied, and when it exceeds 80%, the anchor effect necessary to develop the adhesive strength is obtained. There is a possibility that the required adhesive strength per unit area will not be reached.
Here, the restraint area ratio of the fiber assembly is expressed by the following expression as an area ratio of the entire restraint area to the total surface area of the heat restraint portion, that is, the restraint area ratio A, when the fiber assembly undergoes partial heat pressure welding or the like. .
A (%) = [area of total fusion area of fiber assembly (cm ² ) / total surface area of fiber assembly (cm ² )] × 100

  Furthermore, the thickness of the fiber assembly used in the present invention is not particularly limited, but when considering the adhesive workability, if the thickness is too thick, the possibility of inadvertent peeling in the fiber assembly increases. Within 0.5 mm is preferable.

Moreover, when using a nonwoven fabric as a fiber assembly used by this invention, the basis weight is 10-100 g / m < ² >. When the basis weight of the non-woven fabric is less than 10 g / m ² , the anchor effect is not exhibited, and when it exceeds 100 g / m ² , pills are generated during the bonding work using the composite resin foam as a floor base spacer material, and the workability is remarkably improved. This is undesirable.

The resin foam in the composite resin foam of the present invention preferably has an average value of the aspect ratio Dz / Dxy of the internal bubbles of 1.1 to 4.0. When the average value of the aspect ratio Dz / Dxy of the bubbles is less than 1.1, the bubbles are almost spherical, and the improvement in compression modulus and compressive strength due to the spindle shape cannot be obtained. It becomes difficult to obtain a good walking feeling. When the average value of the aspect ratio Dz / Dxy exceeds 4.0, the foam tends to break when subjected to an impact, and cracks and chips are likely to occur.
By setting the aspect ratio of the bubbles contained in the resin foam within the above range, when the resin foam in the present invention receives a compressive force in the thickness direction, a force is exerted in the major axis direction of the spindle-shaped bubbles that are long in the thickness direction. Therefore, high compressive strength is shown in the thickness direction.
Moreover, it is preferable that the average value of Dxy of the bubble inherent in the said resin foam is 500 micrometers or more.

Here, the aspect ratio is the number (arithmetic) average value of the ratio of the maximum diameter in the fixed direction in the bubbles in the foam, and is expressed as the ratio Dz / Dxy between the diameter Dz in the sheet thickness direction and the diameter Dxy in the in-plane direction. Is done.
That is, as shown in FIG. 1, an enlarged photograph 10 times the arbitrary cross section (b) parallel to the sheet thickness direction (referred to as z direction) of the foam (a) is taken and randomly selected in this photograph. It can be obtained by measuring the following two maximum directional diameters (Dz, Dxy) in at least 50 bubbles and calculating a number average value.
Dz: Maximum diameter parallel to z direction of bubbles in hard foam Dxy: Maximum sheet width or length direction of bubbles in hard foam, that is, maximum parallel to plane direction perpendicular to z direction (referred to as xy direction) Diameter

In addition, the resin foam used in the present invention preferably has an expansion ratio of 3 to 20 times. If the expansion ratio is less than 3 times, a sufficient ratio between the major axis and the minor axis of the bubbles cannot be obtained, and the desired strength may be obtained. If the expansion ratio exceeds 20, the cell walls in the individual bubbles become thin and sufficient. Compressive strength may not be expressed.
Here, the expansion ratio is a value obtained by measuring the apparent density according to JIS K6767 and setting the reciprocal expansion ratio (times).

Furthermore, the resin foam used in the present invention preferably has a compression modulus of 5 MPa or more. If the compression modulus is less than 5 Mpa, sufficient rigidity as a floor base material may not be obtained. The upper limit of the compressive elastic modulus is not particularly recognized. However, if it exceeds 50 MPa, it becomes brittle, and care must be taken because chipping and cracking may easily occur during construction.
Here, the compression modulus is a value measured according to JIS K7220.

  Further, the resin material used for the resin foam of the present invention is not particularly limited. For example, polyolefin, polystyrene, polyurethane, polyphenol, polyvinyl chloride, vinyl chloride copolymer, polyvinylidene chloride, polyamide, polycarbonate, polyethylene Examples include thermoplastic and thermosetting resins such as terephthalate, polyimide, polyacryl, EVA, ABS, epoxy resin, unsaturated polyester, melamine resin, urea resin, diallyl phthalate resin, and xylene resin, preferably polyolefin resin. Certain polyethylene and polypropylene resins are preferred in that they are excellent in soundproofing and are excellent in recyclability and incineration disposal.

  Examples of the polyolefin resin include low density polyethylene, medium density polyethylene, high density polyethylene, linear low density polyethylene, isotactic or syndiotactic homopolypropylene, block propylene copolymer, random propylene copolymer, Examples include polybutene, ethylene-propylene copolymer, ethylene-propylene-diene copolymer, ethylene-butene copolymer, ethylene-vinyl acetate copolymer, and ethylene-acrylic acid ester copolymer. These may be used singly or in combination of two or more.

  Moreover, the melt flow rate (MFR) of polyolefin resin is a value measured based on JIS K-7210, and 0.1-20 g / 10min is preferable. If the MFR is too large, or conversely too small, the foaming stability is lowered, which is not preferable.

  Furthermore, the polyolefin resin may be cross-linked as necessary. The crosslinking method is not particularly limited. For example, an electron beam crosslinking method in which ionizing radiation such as an electron beam is irradiated, a chemical crosslinking method using an organic peroxide, or a silane-modified resin is used. And the silane crosslinking method.

If the degree of crosslinking of the polyolefin-based resin is too high, the foaming ratio is reduced and the thermoformability is lowered. If it is too low, the thermal stability is lowered and the cell during foaming (bubble wall) May break, and uniform bubbles may not be obtained. Therefore, the gel fraction serving as an index for crosslinking is preferably 10 to 30% by weight, more preferably 15 to 25% by weight.
Here, the gel fraction is a value expressed as a percentage (weight) of the weight of the polyolefin resin foam after immersion in xylene at 120 ° C. for 24 hours with respect to the weight of the polyolefin resin foam before xylene immersion. is there.

  The polyolefin-based resin may be mixed with other thermoplastic resin, for example, a compatible thermoplastic resin such as polystyrene, an elastomer, or the like within a range of 30% by weight or less.

  The production method for obtaining the resin foam used in the present invention is not particularly limited, but preferably, a polyolefin resin and a modifying monomer are melt-blended to obtain a modified polyolefin, and a thermally decomposable chemical foaming agent is dispersed in the modified polyolefin. In this method, the obtained foamable resin composition is once formed into a sheet-like raw material, and then the obtained foamable sheet is heated to a temperature equal to or higher than the decomposition temperature of the pyrolyzable chemical foaming agent for chemical foaming.

The modifying monomer is a compound having two or more functional groups capable of radical reaction in the molecule. Examples of the functional group include an oxime group, a maleimide group, a vinyl group, an allyl group, and a (meth) acryl group. The modifying monomer is preferably a dioxime compound, a bismaleimide compound, divinylbenzene, an allyl polyfunctional monomer, or a (meth) acrylic polyfunctional monomer. The modifying monomer may be a cyclic compound having two or more ketone groups in the molecule, such as a quinone compound.
By adopting the resin modification method as described above, it is possible to foam the foamed sheet at normal pressure despite the low degree of crosslinking of the molded foam sheet.

  The resin foam used in the present invention may be either one obtained by chemical foaming or one obtained by physical foaming, but when the resin foam is laminated to another material by thermal fusion, The former method is preferred.

  In the foam by chemical foaming, for example, a thermal decomposition type chemical foaming agent that generates a decomposition gas by heating is dispersed in a polyolefin resin composition in advance, and the obtained foamable composition is once applied to a sheet-like raw fabric. After forming, it is manufactured by heating and foaming with a gas generated from a foaming agent. Representative examples of the pyrolytic chemical foaming agent include azodicarbonamide, benzenesulfonyl hydrazide, dinitrosopentamethylenetetramine, toluenesulfonyl hydrazide, 4,4-oxybis (benzenesulfonyl hydrazide) and the like. The addition amount of the chemical foaming agent is preferably 2 to 20 parts by weight with respect to 100 parts by weight of the resin composition.

As a method for shaping the sheet-like foamable raw material, methods generally performed in plastic molding processes such as press molding, blow molding, calendering molding, injection molding, etc. can be applied in addition to extrusion molding. A method of immediately forming a foamable resin composition discharged from a screw extruder is preferable from the viewpoint of productivity. In this method, a continuous original fabric sheet having a constant width can be obtained.

  The chemical foaming of the sheet-shaped original fabric is usually performed in a temperature range not lower than the decomposition temperature of the pyrolytic chemical foaming agent and not higher than the thermal decomposition temperature of the thermoplastic resin. In particular, as a continuous foaming apparatus, in addition to a take-off type foaming machine that foams while taking out a foam on the outlet side of a heating furnace, a belt type foaming machine, a vertical or horizontal type foaming furnace, a hot air thermostat, or a hot bath Foaming oil baths, metal baths, salt baths, etc. are used.

The resin foam having a specific aspect ratio used in the present invention has spindle-shaped bubbles because the average value of the bubble aspect ratio Dz / Dxy is 1.1 to 4.0. A method for obtaining a resin foam having such spindle-shaped bubbles is not particularly limited, and for example, has a strength capable of suppressing the foaming force in the in-plane direction (xy direction) of the original fabric during foaming. A method of laminating the face material on at least one side of the original fabric before foaming is preferable.
By laminating face materials on at least one side of the original fabric before foaming, foaming in the two-dimensional direction (xy direction) in the surface of the original fabric during foaming is suppressed, and foaming is performed only in the thickness direction (z direction). The bubbles in the foam sheet thus obtained become spindle-shaped bubbles whose major axis is oriented in the thickness direction.

The face material is capable of withstanding a temperature equal to or higher than the foaming temperature of the original fabric, that is, a temperature equal to or higher than the melting point of the resin for foams, for example, a polyolefin resin, and a temperature equal to or higher than the decomposition temperature of the pyrolytic chemical foaming agent. Although it is not particularly limited, for example, paper, cloth, wood, iron, non-ferrous metal, woven or non-woven fabric made of organic fiber or inorganic fiber, cold water bottle, glass fiber, carbon fiber, etc. are suitable. Used. Further, for example, a sheet having releasability such as a Teflon (registered trademark) sheet is used as a face material, and after foaming the raw material in the thickness direction, the releasable sheet is peeled off to obtain a foam sheet. You may get.
However, when using a face material made of a material other than the polyolefin-based resin, it is preferable to keep the amount used to a minimum from the viewpoint of recyclability.
Since the composite resin foam of the present invention is obtained by laminating a fiber assembly on the surface of the resin foam, by using the fiber assembly as the face material, the step of laminating the resin foam and the fiber assembly is performed. The fiber assembly described above is particularly preferred because it can be omitted.

  In the production of the composite foam of the present invention, when a fiber assembly is used as the face material, the production process can be simplified by simultaneously performing the foaming step and the face material laminating step, and the resin melted in the foaming step can be obtained. Due to the flow characteristics, the fiber aggregate is firmly laminated to the resin foam by solidifying into the fine gaps of the fiber aggregate that is the face material, and only the face material that is the fiber aggregate unless the resin foam is destroyed. Can not be peeled off, and when the surface material in use is peeled off, delamination of the fiber aggregate is caused, and the effect of peeling off the surface material without destroying the resin foam is likely to occur.

  In addition, lamination | stacking with a resin foam and the said fiber assembly may be the adhesion | attachment which uses not only the method of laminating | stacking directly at the time of foaming as mentioned above but a normal adhesive agent. As an adhesive, it can be used without any particular limitation. For example, vinyl acetate resin emulsion adhesive, acrylic emulsion adhesive, vinyl acetate copolymer emulsion adhesive, polyvinyl alcohol adhesive, vinyl acetate resin mastic adhesive, dope cement, monomer Cement, vinyl chloride resin adhesive, chloroprene rubber adhesive, natural rubber adhesive, urea resin adhesive, melamine resin adhesive, phenol resin adhesive, epoxy resin adhesive, polyurethane adhesive, and the like can be used.

The use of the composite resin foam of the present invention is not particularly limited, but it is preferably used as a building material from the viewpoint of thermal conductivity characteristics, compressive strength, and light weight as the performance of the foam. Here, the building material means a material used for various structural constructions such as apartment houses, detached houses, commercial facilities, public facilities, multi-purpose facilities, etc. Flooring materials for flooring, for example, wooden flooring spacer materials; spacer materials for resin-based floor surface finishing materials such as carpets and cushion floors; various fiber-based floor surface finishing materials such as goza and hemp mats Spacer material for double floors and standing floors; Spacer material for tatami mats; Various underfloor heat insulating materials; joist foam materials; Various base heat insulation materials such as base heat insulation materials, ceiling heat insulation materials, inner wall heat insulation materials, outer wall heat insulation materials, heat insulation materials for partitioning, core materials for partitioning, and various remodeling materials. . Among these, the use as a floor base material is most preferable.
The shape of the composite resin foam of the present invention is not particularly limited, but in view of utilization, shapes such as a panel shape, a block shape, and a long sheet are preferable.

In addition, when using as a floor base material, you may use a composite resin foam as a single-piece | unit, for example, may be laminated | stacked and combined with another hard plate-shaped body.
It does not specifically limit as said hard plate-shaped object, For example, what is shown to the following (i)-(v) is mentioned.
(I) Single plate (single material strip)
(Ii) Plywood, etc. [Veneer, particle board, fiber board (also called fiber board: MDF, etc.) conventionally used as flooring]
(Iii) Synthetic resin plates [polyethylene resin plates (preferably ultrahigh molecular weight polyethylene plates), polypropylene resin plates, vinyl chloride resin plates, etc.]
(Iv) Fiber reinforced synthetic resin plate (polyester resin plate, epoxy resin plate, rigid polyurethane resin plate, etc. reinforced with glass fiber)
(V) Inorganic board (porcelain tile, stone board, etc.)

  In order to describe the present invention in more detail, examples will be given below, but the present invention is not limited to these examples. The evaluation methods used in the examples are as follows.

(1) Distance from an arbitrary point of the nonwoven fabric to the restraint part 20 points were previously displayed on the sample surface with a ballpoint pen, the surface was photographed with a microscope, and the image data was stored in a personal computer. . Then, it displayed on the personal computer display using the image analysis apparatus, and arbitrary points were confirmed visually. The image analysis apparatus was used from the confirmed point, the distance to the shortest restraint part edge part was measured, and the average value was computed.
(2) Restraint point density The density in the total surface area of the point-like restrained area of the fiber assembly, that is, the restraint point density B was obtained by the following equation.
B (points / cm ² ) = [number of restraint points (points) / total surface area of fiber assembly (cm ² )]
(3) Abrasion resistance According to JIS K5600, the number of rotations and the degree of wear were visually determined using a Taber abrasion tester.
(4) Adhesive workability Panel composite fat foam is cut into a 1m x 1m size panel, and the bond "KUKU2828R", an adhesive for directly attaching wooden flooring made by Konishi Co., Ltd., is attached to the panel. It apply | coated to one side and the hair ball generation | occurrence | production condition of the surface was confirmed visually.
(5) Adhesive strength In accordance with JIS A1612, the adhesive strength between concrete mortar and materials was measured using “bond KU928R”, an adhesive for directly applying wood flooring manufactured by Konishi Co., Ltd.
The test jig, concrete mortar, and data were fixed using an epoxy adhesive having high adhesive strength, an adhesion area of 25 cm ² , and a pulling speed of 5 mm / min.
(6) Recyclable moldability A recycle resin pallet having a height of 10 cm and a size of 1 m × 1 m was molded, and it was examined whether or not in-mold molding was possible by an injection molding method in which a sample was pulverized by pelletizing.
(7) Re-peeling property Adhesive “Bond KU928R”, an adhesive for directly applying wood flooring made by Konishi Co., Ltd., to a 1 m × 1 m sample was applied in a lattice shape at 15 cm intervals in a bead shape, and a wooden flooring was adhered. After leaving at room temperature (23 ° C.) for 48 hours, the flooring was peeled off and the degree of destruction of each sample was judged visually.

Example 1
(1) Preparation of modified polyolefin resin In order to prepare a modified polyolefin resin, a co-rotating twin screw extruder (Plastics Engineering Laboratory Co., Ltd., model "BT40 type") was used. This extruder is equipped with a self-wiping double thread, and its L / D is 35 and D (diameter) is 39 mm. The cylinder barrel is divided into a sixth barrel from the upstream side to the downstream side of the extruder, the forming die is a three-hole strand die, and a vacuum vent for collecting volatile matter is installed in the fourth barrel. In the following operations, the temperature of the first barrel was set to 180 ° C., the temperature from the second barrel to the sixth barrel and the temperature of the 3-hole strand die were set to 220 ° C., and the screw rotation speed was set to 150 rpm.
From the hopper provided at the rear end of the first barrel of the twin screw extruder, a random polymer type polypropylene resin (trade name “EX6” manufactured by Nippon Polychem Co., Ltd., MFR 1.8 g / 10 min, density 0 9.9 g / cm ³ ) was fed into the extruder at a feed rate of 10 kg / hour. Next, a mixture of divinylbenzene (modifying monomer) and 2,5-dimethyl-2,5-di (t-butylperoxy) hexyne-3 (organic peroxide) is injected into the extruder from the third barrel. These were uniformly melt-kneaded to prepare a modified polypropylene resin.
Next, the modified polypropylene resin was discharged from a three-hole strand die, cooled with water, and cut with a pelletizer to obtain modified polypropylene resin pellets. The amount of the modifying monomer and the organic peroxide injected was 0.5 part by weight of the modifying monomer and 0.1 part by weight of the organic peroxide with respect to 100 parts by weight of the polypropylene resin. Moreover, the volatile matter generated in the extruder was vacuumed by a vacuum vent.

(2) Production of expandable sheet In order to add unmodified polypropylene resin and a foaming agent to the modified polypropylene resin obtained above, a co-rotating twin-screw extruder (manufactured by Nippon Steel Works, model "TEX-44" Type "). This extruder is equipped with a self-wiping twin screw, and its L / D is 45.5 and D (diameter) is 47 mm. The cylinder barrel is divided from the first barrel to the twelfth barrel from the upstream side to the downstream side of the extruder, and a T die is set as a forming die at the tip of the twelfth barrel. Further, in order to supply the foaming agent, a side feeder is installed in the sixth barrel, and a vacuum vent for collecting volatile components is installed in the eleventh barrel. In the following operation, the first barrel is always cooled, the temperature of the first zone (second barrel to fourth barrel) is 150 ° C., the temperature of the second zone (fifth barrel to eighth barrel) is 170 ° C., The temperature of the third zone (9th barrel to 12th barrel) was set to 180 ° C., the temperature of the fourth zone (T die and adapter part) was set to 160 ° C., and the screw rotation speed was set to 40 rpm.
From the hopper provided at the rear end of the first barrel of the above twin screw extruder, the pellet-shaped modified polypropylene resin obtained in the previous step (1) and the unmodified homopolymer type polypropylene resin (manufactured by Nippon Polychem Co., Ltd.) , Trade name “FY4”, MFR 5.0 g / 10 min, density 0.9 g / cm ³ ) was fed into the extruder at a feed rate of 10 kg / hr (total 20 kg / hr). Also, azodicarbonamide (ADCA) as a foaming agent is introduced into the extruder at a supply rate of 1.0 kg / hour from the side feeder provided in the sixth barrel, and these are uniformly melt-kneaded and foamed. A functional polypropylene resin composition was prepared. Next, this resin composition was extruded from a T die to produce a foamable sheet having a width of 1100 mm and a thickness of 0.7 mm.

(3) Production of Composite Resin Foam Sheet On both surfaces of the foam sheet obtained above, a polyethylene terephthalate nonwoven fabric (manufactured by Unitika Ltd., trade name “Marix 70150 WTO”, restraint point density 64 points / cm ² , arbitrary The position of the fiber restraint part from the point 0.415 mm and the weight per unit area 15 g / m ² ) are stacked and laminated using a press molding machine under a heating and pressing condition of 180 ° C., 2 m × 1 m foam composite A sheet was obtained.

(4) Foaming Next, the composite resin foamable sheet was heated in a heating furnace at 230 ° C. for about 10 minutes to be foamed to obtain a composite resin foam having a thickness of 6 mm.
The characteristics of the obtained composite resin foam were evaluated. The results are shown in Table 1.

(Example 2)
Polystyrene terephthalate non-woven fabric (product name “Marix 70150 WTO” manufactured by Unitika Co., Ltd.), restraint point density 64 points / cm ² Then, a composite resin panel in which a position where the fiber restraint portion is present from an arbitrary point 0.415 mm and a weight per unit area 15 g / m ² ) was laminated with an epoxy adhesive was manufactured.

(Comparative Example 1)
Nonwoven fabric made of polyethylene terephthalate (trade name “Spunbond Ecule 6301A”, restraint point density 25 points / cm ² , location of fiber restraint portion from arbitrary point 0.803 mm, weight per unit weight A composite resin foam was obtained in the same manner as in Example 1 except that 15 g / m ² ) was used. The evaluation results are shown in Table 1.

(Comparative Example 2)
Nonwoven fabric made of polyethylene terephthalate (trade name “Spunbond Ecule 6301A”, restraint point density 25 points / cm ² , location of fiber restraint portion from arbitrary point 0.803 mm, weight per unit weight A composite resin foam was obtained in the same manner as in Example 2 except that 15 g / m ² ) was used. The evaluation results are shown in Table 1.

  As is clear from Table 1, the composite resin foam of the present invention is excellent in wear resistance and the function of suppressing the generation of pills in the adhesive application. On the other hand, if a non-woven fabric outside the scope of the present invention is used, it is inferior in wear resistance and the function of suppressing the generation of pills in adhesive application. Moreover, when olefin resin is used as the main raw material, it is excellent in recyclability.

As explained above, the spacer for floor base material of the present invention and the composite resin foam in the production method thereof improve the adhesive workability without decreasing the adhesive strength and maintain the delamination property of the face material. The resin foam can be reused, is a composite foam that is lightweight, can be used for building materials, is lightweight, has excellent cutting properties, water resistance, and load resistance, and can be used as a spacer for floor base materials. it can be used as an industrially useful material because it can be used without any problem even when the renovation.

(A) is a schematic perspective view of a hard foam, (b) is an enlarged schematic view of a part of a cross section parallel to the z direction in (a).

Claims (4)

At least one surface of the resin foam, a spacer underfloor member of fiber aggregate is present the fiber restraining portion is made of a composite resin foam ing is laminated,
In the composite resin foam, the fiber assembly has an average shortest distance from an arbitrary point to the fiber restraint portion of 0.5 mm or less, and a point density of the fiber restraint portion is 30 points / cm ² or more,
The above-mentioned resin foam is a spacer for a floor base material characterized in that the average value of Dz / Dx of the aspect ratio of air bubbles is 1.1 to 4.0 and the expansion ratio is 3 to 20 times . The floor base material spacer according to claim 1, wherein the fiber assembly is a nonwoven fabric. The spacer for a floor base material according to claim 1 or 2 , wherein the resin foam is a foam using an olefin resin as a main raw material . It is a manufacturing method of the spacer for floor base materials given in any 1 paragraph of Claims 1-3,
  A step of laminating the fiber assembly on at least one side of the raw fabric before foaming of the resin foam;
  And heating the laminated body at a temperature equal to or higher than the foaming temperature of the original fabric to foam the original fabric in the thickness direction.

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