JP5312963B2 - Flooring - Google Patents

Description

  The present invention relates to a soundproof flooring provided with a decorative layer on the surface of a base material and a sound insulating layer on the back surface.

Conventionally, as a flooring material that can be directly pasted on a flat floor substrate such as a wooden board or concrete slab without using nails, using epoxy adhesive, urethane adhesive, etc. A soundproofing direct pasting floor material provided with a sound insulation layer is known (see Patent Documents 1 to 3). The apartment floor impact sound, but light floor impact sound (L _L) and heavy floor impact sounds (L _H) is known, soundproof straight cemented flooring largely reduce light floor impact sound (L _L) It is known to contribute to

  In particular, in Patent Documents 2 and 3, sound insulation is used for the purpose of preventing problems such as a decrease in sound insulation performance caused by solidification of a sound insulation layer by an adhesive and warping of flooring caused by moisture from a concrete slab. A technique for providing a moisture-proof layer on the back surface of the layer is disclosed.

Japanese Utility Model Publication No. 1-94530 Japanese Patent Publication No. 7-9113 JP-A-10-299234

  In Patent Document 2, for the purpose of preventing moisture derived from the concrete slab, “a moisture-proof sheet having a moisture-proof layer as a core layer and a paper layer formed on the front and back surfaces thereof” is adhered to the back surface of the sound-insulating layer. As the moisture-proof sheet, only a synthetic resin foam or a rubber foam such as a polyethylene resin, a polypropylene resin, a polyurethane resin, and a polystyrene resin is illustrated. In Patent Document 3, only a sheet is pasted, and even its material is not described. None of the documents mentions the moisture permeability of the moisture-proof layer.

  Directly soundproof flooring is applied on concrete slabs under various circumstances. That is, usually, when constructing a directly-attached soundproof flooring material, a concrete curing period is provided to dry the concrete slab after the mortar is placed, and after the curing period has elapsed, the flooring material is dried. Although it is recommended to start construction, the curing period may not be observed. Moreover, the construction of the flooring may be started when the weather during construction is bad, the moisture content of the concrete slab is large, and the drying is insufficient.

  In view of such circumstances, the present inventors obtained the following knowledge as a result of further research.

  (A) In the directly-pounded soundproof flooring, the formation of grooves on the back surface of the base material tends to cause problems such as warping and undulation, and is particularly affected by the number of grooves.

  (B) In the case of the decorative layer using the synthetic resin sheet as compared with the decorative layer using the veneer, the above-mentioned problem becomes remarkable because there is no release of moisture from the floor material surface.

  (C) From the viewpoint of soundproof performance, a soundproof layer composed of a nonwoven fabric is preferable to a foamable resin. However, from the viewpoint of moisture-proof performance, a soundproof layer made of a foamable resin is preferable to a nonwoven fabric. Therefore, if a moisture-proof layer having sufficient moisture-proof performance in relation to the number of grooves on the back surface of the base material is provided, the defects of the nonwoven fabric can be compensated for, so that a flooring material that is less prone to malfunction and has particularly excellent sound-proof performance. Can be manufactured.

  The present invention has been made based on such knowledge, and an object thereof is to provide a directly bonded soundproofing flooring material that is excellent in soundproofing performance and that does not cause problems due to moisture derived from concrete slabs.

  This invention is made | formed in order to solve said subject, and makes the summary the flooring shown to following (a)-(d).

(A) a flooring material having a decorative layer, a base material layer having a plurality of grooves formed on the back surface, a sound insulation layer, and a moisture-proof layer, and the number of grooves formed on the back surface of the base material layer; the relationship between the moisture permeability of the moisture barrier meets the following expression (1), wherein the sound insulation layer is formed of a nonwoven fabric, moisture permeability, as measured in accordance with JIS Z0208 of said moisture barrier, 5 g / (m ² · 24h) flooring is less than or equal to.
N × W ≦ 200 (1)
However, the meaning of each symbol in the above formula (1) is as follows.
N: Number of grooves on the back surface of the base material layer per 0.9 m length [lines / 0.9 m]
W: Moisture permeability of moisture-proof layer measured in accordance with JIS Z0208 [g / (m ² · 24h)]

(B) The flooring material according to (a), wherein the decorative layer, the base material layer, the sound insulating layer, and the moisture-proof layer are sequentially laminated .

  (C) The flooring according to (a) or (b), wherein the decorative layer is formed of a resin sheet.

(D) The flooring material according to any one of (a) to (c), wherein the moisture permeability measured according to JIS Z0208 of the moisture-proof layer is 3.3 g / (m ² · 24 h) or less.

  According to the present invention, it is excellent in soundproofing performance, and since it is possible to prevent the occurrence of defects such as warpage and undulation caused by moisture derived from concrete slabs, it is possible to provide a flooring material that is optimal for directly pasted soundproofing flooring materials. .

The longitudinal cross-sectional view which shows the example of the flooring of this invention

  Hereinafter, embodiments of the present invention will be described with reference to the drawings.

  FIG. 1 is a longitudinal sectional view showing an example of the flooring of the present invention. As shown in FIG. 1, for example, the flooring of the present invention is configured by adhering a decorative layer 1, a base material layer 2, a sound insulating layer 3 and a moisture-proof layer 4 in this order.

  As the decorative layer 1, a commonly used decorative sheet can be used. For example, in addition to a wooden board such as a natural veneer and an artificial veneer, a synthetic resin sheet such as polyethylene and polypropylene, a paper sheet such as resin-impregnated paper and printed paper, or a composite sheet thereof can be exemplified. Moreover, the coating material comprised by urethane type resin etc. is apply | coated to the surface of the decorative layer 1 as needed. For joining the base material 2 and the decorative layer 1, for example, an adhesive such as urea melamine, ethylene vinyl acetate, PUR (polyurethane reactive) is used.

  As the base material layer 2, a wood board, an inorganic board, a synthetic resin board, or these composite materials can be used. As the wood board, for example, plywood such as lauan plywood, wood fiber board such as MDF, HDF, particle board, oriented strand board, solid wood, laminated wood, and further, wood board and wood fiber board Can be mentioned. As an inorganic board, a fiber mixed calcium silicate board, a fiber mixed slag gypsum board, a glass fiber mixed inorganic phenol board, a fiber mixed aluminum hydroxide molded board, a volcanic glassy multilayer board, etc. are mentioned. Examples of the synthetic resin plate include a melamine resin plate and an acrylic resin plate.

  For example, a male seed 2a and a female seed 2b as shown in FIG. 1 are formed on the base layer 2 at the edge facing the adjacent floor material, and the male seed 2a is fitted into the female seed 2b. Construction of the flooring is performed by A large number of back grooves are formed on the back surface of the base material layer 2. The purpose of this is to improve the familiarity of the floor base by giving flexibility as a flooring material, enabling construction using only an adhesive, and improving the sound insulation of the flooring material. It is.

  As the sound insulation layer 3, for example, a synthetic resin foam, a nonwoven fabric, a rubber foam, or a composite of these can be used. Examples of the synthetic resin foam include a continuous foam of polyurethane resin, and an independent foam such as polyethylene resin and polypropylene resin. Among these, it is an independent foam that has low moisture permeability. Therefore, when a synthetic resin foam is used as the sound insulation layer 3, it is preferable to use a composite of a continuous foam and an independent foam so that the continuous foam is on the upper surface side and the independent foam is on the lower surface side. It is more preferable to arrange in the above.

  Examples of the material for the nonwoven fabric include polyester and rayon. The sound insulation layer using a nonwoven fabric is superior in soundproofing performance than that using a synthetic resin foam. However, a nonwoven fabric has a problem that moisture permeability is large. Examples of the rubber foam include foams such as natural rubber and styrene butadiene rubber.

  In addition, it is preferable to perform adhesion | attachment with the base material layer 2 and the sound-insulation layer 3 using adhesives which do not contain formaldehyde, such as a water-based vinyl urethane type adhesive agent and a rubber-type adhesive agent, for example. Moreover, although there is no restriction | limiting in particular in the thickness of a sound-insulation layer, when it is too thin, sufficient sound-insulation property will not be acquired, but when too thick, construction will become difficult. Therefore, the thickness of the sound insulation layer is preferably 3 to 6 mm when any material is used.

  As the moisture-proof layer, for example, a polyolefin film such as polyethylene or polypropylene, a film having a low moisture permeability such as a PET film, a sheet obtained by bonding these resin film and a metal sheet, or a composite of these can be used. . In addition, there is no restriction on the positional relationship between the moisture-proof layer and the sound insulation layer, but if the adhesive used for bonding to the concrete slab penetrates into the sound insulation layer, the sound insulation performance may be lowered. It is preferable to arrange so as to be located on the lowermost surface. Examples of the metal sheet include aluminum oxide and aluminum foil.

Here, in the flooring according to the present invention, the relationship between the number of grooves formed on the back surface of the base material layer 2 and the moisture permeability of the moisture-proof layer 4 needs to satisfy the following formula (1).
N × W ≦ 200 (1)
However, the meaning of each symbol in the above formula (1) is as follows.
N: Number of grooves on the back surface of the base material layer per 0.9 m length [lines / 0.9 m]
W: Moisture permeability of moisture-proof layer measured in accordance with JIS Z0208 [g / (m ² · 24h)]

The moisture permeability of the moisture-proof layer 4 is useful as an index for preventing the occurrence of problems such as warpage and undulation of the base material layer 2 due to moisture from the concrete slab. From this viewpoint, it is preferable that the moisture permeability of the moisture-proof layer is 10.0 g / (m ² · 24 h) or less. More preferred is 5.0 g / (m ² · 24 h) or less, and further more preferred is 4.0 g / (m ² · 24 h) or less. More preferable is 3.0 g / (m ² · 24 h) or less.

  On the other hand, even when a moisture-proof layer whose moisture permeability is adjusted to the above range is used, the flooring may be warped or wavy. And it became clear by the research of the present inventors that even when the same moisture-proof layer was used, the above-mentioned problems were more likely to occur as the number of grooves formed on the back surface of the base material layer 2 increased. .

That is, according to experiments conducted in advance by the present inventors, the moisture permeability is 5.0 g / (m ² · 24 h when the groove on the back surface of the base material layer has a length of 40 m per 0.9 m. ), The flooring will not be warped or corrugated, but if the floor material has 50 grooves on the back surface of the base material layer per 0.9 m in length, using the same moisture-proofing layer will Occurred. Furthermore, even when the groove on the back surface of the base material layer per length of 0.9 m is a flooring of 50, if the moisture-proof layer having a water vapor transmission rate of 3.0 g / (m ² · 24 h) is used, Did not occur.

  Based on such experimental results, the present inventors have found that there is a certain correlation between the number of grooves on the back surface of the base material layer per 0.9 m in length and the moisture permeability of the moisture-proof layer. It was. And when satisfy | filling the relationship shown to said (1) Formula, it confirmed that the malfunction, such as a curvature and a wave, did not generate | occur | produce in a flooring.

  In particular, when a non-woven fabric is used, it is preferable to limit “N × W” to a smaller value because moisture easily moves from the back surface of the flooring to the base material layer. In addition, when using a wood material such as a veneer veneer as a decorative layer, there is a possibility of troubles due to the passage of moisture from the atmosphere, but when using a resin sheet with low moisture permeability, In this case, “N × W” is preferably limited to a smaller value. Therefore, “N × W” is preferably limited to 180 or less. More preferred is 180 or less, and even more preferred is 150 or less. More preferred is 120 or less.

  As described above, the groove on the back surface of the base material layer is intended to improve the sound insulation of the flooring material while improving the familiarity with the floor base and enabling the construction with only the adhesive. However, for example, when a nonwoven fabric is used, although the moisture permeability increases, the sound insulation performance is greatly improved, so even if the number of grooves on the back surface of the base material layer is reduced, sufficient sound insulation performance, specifically Can obtain L45. Accordingly, when a nonwoven fabric is used as the sound insulation layer, the number of grooves on the back surface of the base material layer can be reduced to 40 or less, so that the number of man-hours required for groove processing can be significantly reduced.

  Although there is no restriction | limiting in particular in the manufacturing method of the flooring which concerns on this invention, For example, it can manufacture by the following methods.

  First, for example, an adhesive is applied to the upper surface of the base material layer 2 using a roll coater or the like, and the decorative layer 1 is attached thereon, and dried and solidified by hot pressing. Thereafter, for example, a male fruit 2a and a female fruit 2b for bonding are formed on the floor material, and a groove 2c is further formed. Thereafter, for example, an adhesive such as an aqueous vinyl urethane-based adhesive is applied to the lower surface of the base material layer 2, the sound insulating layer 3 is attached, and is crimped and solidified by a cold press. At this time, the moisture-proof layer 4 is pasted on the sound insulating layer 3 in advance. In the case where the decorative layer 1 is a flooring composed of a veneer veneer or the like, the surface of the decorative layer 1 is colored as necessary, and a coating film is formed to obtain a product.

  In order to confirm the effect of the present invention, various sound insulations were applied to a 0.16 mm olefin decorative sheet affixed to a base material (HDF + Lawan plywood or Lauan plywood, 64 or 39 back grooves) having a thickness of about 9 mm. A sheet was pasted to produce a flooring, and the anti-waving performance and sound insulation performance were confirmed. Manufacturing conditions and performance are shown in Table 1.

  In addition, “urethane + olefin” in Table 1 means a composite sheet (total thickness is 4.5 mm) of 50 times continuous foam of polyurethane and 25 times closed foam of polyethylene. “Nonwoven fabric” means a polyester fiber nonwoven fabric having a thickness of 4 mm.

The moisture permeability (W) was determined from the following formula in accordance with JIS Z0208.
W [g / (m ² · 24h)] = 240 × M / (T · S)
However, the meaning of each symbol in the above formula is as follows.
M: the sum of the last two weighing intervals and increased mass (mg)
T: Time of the last two weighing intervals in the test (= 24 h)
S: Moisture permeable area (cm ² )

  The flooring is extended by moisture from the lower side (concrete surface) and moisture from the upper side (indoor), but the soundproofing flooring has a back groove, and there is a difference in rigidity between the part with and without the back groove. In addition, undulation occurs when the elongation of the flooring material is deformed on the wave. Therefore, it is necessary to confirm the state of occurrence of undulation for both humidification from the lower surface of the flooring and humidification from the upper surface.

  Therefore, various flooring materials were constructed 3 days after mortar placement, and the occurrence of undulation due to humidification from the lower surface of the flooring material was confirmed by visual observation. In addition, various flooring materials were applied 3 weeks after mortar placement, and then wet floor towels were put on the flooring material surface, and the occurrence of undulation due to humidification from the upper surface of the flooring material was confirmed by visual observation. In all cases, the occurrence of undulation was confirmed after 30 days had passed since the flooring work. In addition, it is recommended that the flooring work be done 3 weeks after mortar placement.

  In addition, both the humidification from the lower surface of the flooring and the humidification from the upper surface were “◎” when there was no undulation, “○” when there was a sign of undulation, and slight undulation occurred. Table 1 shows “Δ” when there is no problem in quality, and “X” when there is a wave that causes a quality problem.

  The soundproofing performance was measured according to JIS A1419-2, and the case where L45 was satisfied was evaluated as “◯” and the case where it was not satisfied was evaluated as “X”.

  As shown in Table 1, no. In each of 1, 3, 5, 7, 9, 11, 13, and 15, the substrate layer was wavy. No. 1 having a moisture-proof layer and satisfying the range of “N × W” defined by the present invention. In 2, 4, 6, 8, 10, 12, 14, and 16, no corrugation occurred in the base material layer.

  ADVANTAGE OF THE INVENTION According to this invention, while being excellent in soundproof performance, generation | occurrence | production of malfunctions, such as the curvature generate | occur | produced by the water | moisture content derived from a concrete slab, and a wave, can be prevented. Therefore, the flooring of the present invention can be suitably used as a directly pasted soundproofing flooring.

1. 1. Cosmetic layer Base material layer 2a. Yumi 2b. Female seed 2c. Groove 3. Sound insulation layer4. Moisture barrier

Claims (4)

A flooring material having a decorative layer, a base material layer having a plurality of grooves formed on the back surface, a sound insulation layer, and a moisture-proof layer, the number of grooves formed on the back surface of the base material layer, and the moisture-proof material relationship between moisture permeability layers meets the following expression (1),
The sound insulation layer is composed of a nonwoven fabric,
A flooring material having a moisture permeability of 5 g / (m ² · 24 h) or less measured according to JIS Z0208 of the moisture-proof layer .
N × W ≦ 200 (1)
However, the meaning of each symbol in the above formula (1) is as follows.
N: Number of grooves on the back surface of the base material layer per 0.9 m length [lines / 0.9 m]
W: Moisture permeability of moisture-proof layer measured in accordance with JIS Z0208 [g / (m ² · 24h)] The flooring according to claim 1, wherein the decorative layer, the base material layer, the sound insulation layer, and the moisture proof layer are laminated in order .   The flooring according to claim 1 or 2, wherein the decorative layer is made of a resin sheet. The flooring material according to any one of claims 1 to 3, wherein the moisture permeability of the moisture-proof layer measured according to JIS Z0208 is 3.3 g / (m ² · 24h) or less.

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