JPH02266060A - Composite sound insulating floor material - Google Patents

Abstract

PURPOSE:To improve sound insulating performance by a method wherein a wood flow material and foam having an uneven surface pattern are alternately laminated to form a composite color member, the height of the protrusion of the foam layer of a lowermost layer is divided into the given number of stages or more, and a difference in height between maximum protrusion and recess is limited. CONSTITUTION:A wood floor member 1 and a foam 2 having a uneven surface pattern are alternately laminated in two or more layers, the height of the protrusion part of the foam layer of a lowermost layer is divided into two or more stages, and a difference in height between a maximum protrusion part and recessed part is set to 1mm or more. The lowermost layer of the foam is hardmost and softer than an upper laver, and the uneven surface pattern of the foam exhibits uninterrupted free entrance and exit of air during compression caused by the falling of an object. In the foam 2, a factor by which an influence is exercised on sound insulating capability is not a kind of resin and the composition of a filler but constitution of a void and a most suitable plan of flexibility of the foam. This constitution enables governing of two factors of sound insulating performance without specifying a kind of a soft high molecular foam.

Description

[Detailed Description of the Invention] "Industrial Application Field" The present invention relates to a composite soundproof flooring material.Wood-based flooring materials are the same as carpets that were previously used in condominiums, public housing, etc. due to dust mite pollution. As an alternative to carpet, demand for this product has been rapidly increasing in recent years due to its cleanliness and luxurious feel.

[Prior Art] As a wood-based composite system, a type in which an ethylene-vinyl acetate copolymer foam is bonded to the back side of a wood flooring member has been proposed (for example,
6224), and in fact, foams of ethylene-vinyl acetate copolymer or polyethylene filled with a considerable amount of carbonic acid are mainly used. These foams have good moisture resistance and adhesion, and are also effective in retaining heat, so they form the mainstream of current wood-based composite flooring materials.

However, in housing complexes such as condominiums and public corporations, problems such as the sound of falling dishes and bowls, and light impact noise from movable platforms such as chairs and tables, which were not a problem with conventional carpets, have become a major issue. It has reached the point where it is lost. Since the surface of the flooring material is made of a hard material such as wood, it is unavoidable that such light impact noise will be louder than that of a carpet. Another major cause is the low soundproofing performance of current composite flooring materials, which are made by laminating ethylene-vinyl acetate copolymer or polyolefin resin foam made of polyethylene filled with a considerable amount of calcium carbonate on the back side of wooden flooring materials. .

In addition, a hard polyolefin resin foam or flexible rubber material is sandwiched between the wooden floor components, and then a polyolefin resin or polyvinyl chloride foam is bonded to the back side of the wooden floor component. Multilayer composite flooring has been proposed. However, although this type of flooring material is thin and exhibits some soundproofing performance, it is difficult to say that it is necessarily at a sufficient level.

Multilayer composite materials have also been proposed in which foam or flexible rubber materials are sandwiched between wooden flooring materials, and several layers of glass wool, rock wool, or cross-linked rubber materials are laminated on the back side of the flooring materials. However, these do not have high soundproofing performance or are too thick for use as flooring materials, making them difficult to work with.In addition, as modern apartment complexes become more high-rise, floating floors are becoming more difficult to work with.
Although it is thinner than the method and floor construction method, there is a problem in that it does not meet the demand for reducing the thickness of the floor.

Recently, as a result of active attempts to improve the soundproofing performance of wood systems, so-called L-55 has been found to be somewhat satisfactory in terms of soundproofing, texture as a wood floor, durability, and thickness. Products that meet the required standards are also being put into practical use. However, most of the higher-performance flooring materials such as L-50 (2nd grade accepted by the academic society) and Li2 (grade 1 recommended by the academic society) sacrifice one of the above four performance points. There was no product that could be called a soundproofing system in the true sense of the word.

In particular, when attempts were made to improve soundproofing performance by simply softening the cushion layer, the texture could no longer be called a wood floor.

[Problems to be Solved by the Invention] An object of the present invention is to provide a composite soundproof flooring material with excellent soundproofing performance, which improves the drawbacks of conventional flooring materials.

[Means for Solving the Problems] The present invention has discovered that when a light impact is applied to a wooden floor member, the area of the wooden part that responds to the impact is extremely small, and the present invention provides a soft polymer foam having unevenness with the wooden part. It originated from the confirmation that the soundproofing effect can be improved by laminating layers and effectively designing the voids. Further studies revealed that increasing the flexibility of the foam and reducing the number of protrusions that come into contact with the wood could further improve the soundproofing performance.Also, even with the same light impact, a fall on the edge would be more effective than the center. By optimally designing each performance required for a flooring material based on the fact that the impact on soundproofing performance is less than when it falls, it is possible to achieve a high level of soundproofing performance of L-50 and L-45 as a wooden floor. The present invention was achieved by successfully creating a design that maintains the texture of the product.

That is, the gist of the present invention is that in a composite floor member having a structure in which a wooden floor member and a foam material having an uneven pattern are alternately laminated in two or more layers, or a total of four or more layers, at least the bottom foam layer has a convex portion. It has a structure in which the height is divided into two or more levels, and the difference in height between the highest convex part and the concave part is less than 1 inch, and the foam is the lowest layer or the hardest one.
”It is characterized by the fact that the second layer is softer,
Furthermore, the composite soundproof flooring material is characterized in that the uneven pattern of the foam is configured so that it does not obstruct the inflow and outflow of air when compressed by a falling object.

The present invention will be explained in detail below.

FIG. 1 is a side view of one embodiment of the composite soundproof flooring material of the present invention, and FIG.
The figure shows a perspective view of it from above.

The foam (2) used in the present invention is basically not limited to its type of resin or composition of fillers.

The reason for this is that the factors that affect soundproofing performance are the configuration of the voids and the optimal design of the flexibility of the foam, so it is not possible to control these two factors without specifying the type of flexible polymer foam. This is because it is possible.

The physical properties required of soft polymer foam include cushioning properties that softly absorb the impact of falling objects such as plates under normal flooring conditions, and soundproofing performance deteriorates if the convex parts become flat. Because of its resistance to repeated compression, it also has the ability to withstand normal light and
Even if the convex part does not collapse under heavy load, if a large load is applied per unit area such as on a grand piano or a chair with casters, the convex part will sink and the four parts will take on the function of sharing the load. Compression creep resistance and other properties are required, and the required properties listed here are basically physical properties that can be achieved by ordinary flexible polymer foams.

Therefore, the types of foams used in the present invention are not particularly limited, but include polyethylene, ethylene-vinyl acetate copolymer, polyvinyl chloride, polypropylene, polyurethane, styrene-butadiene copolymer, and butadiene-vinyl acetate copolymer.
Easy to use foams of soft polymers such as acrylonitrile copolymer, butyl rubber, chloroprene rubber, or blends thereof. However, in the case of polymers having a low glass transition temperature, such as polyethylene, ethylene-vinyl acetate copolymer, rubber, etc., crosslinking can be performed. In addition, inorganic fillers such as calcium carbonate, talc clay, mica lath balloon, glass fiber, flame retardants, powdered rubber, etc. can also be included as required.

The structure of the unevenness of the foam is such that the area of each protrusion is 3 cJ or less, preferably 2 cJ or less, and the space between the protrusions is 1. 5
It is desirable that the distance be at least cm. The reason for this is that the weight of 500g is used for evaluation as a typical example of lightweight impact.
4 hammers with a radius of curvature of 50 cm at the tip.
This is because our studies have revealed that when a product is dropped naturally from a height of 1.5 cm, the effect of the impact decreases rapidly when the range of the impact is 1.5 cm or more away from the point of fall.

However, this is not the case for the ends, as they have little effect on the soundproofing effect. Specifically, if the area of the convex portion at the end is within 25% of the area of the entire floor, there is no need to consider the restriction on the end. This improves durability.
I can hope for two.

The soundproofing effect will be enhanced if the heights of the convex portions of at least the bottom layer foam are divided into several levels, at least two or more levels, rather than being made uniform. The reason for this is basically that the smaller the area of the convex part in contact with the wooden part (1), the smaller the propagation path of solid sound. In addition, by dividing the height of the convex portion into several levels, the necessary amount of convex portions can correspond to the impact force of the applied lightweight impact, and the soundproofing effect is also improved. On the other hand, reducing the area of the convex portions that come into contact with the woody portion causes the convex portions to wear out prematurely during actual use, leading to deterioration of durability.

Therefore, taking advantage of the fact that increasing the area of the convex part has little effect on the soundproofing effect, by increasing the area of the convex part at the end and setting the height high, durability and soundproofing performance can be improved. It is possible to achieve both. Furthermore, when a large load is applied, such as in a grand piano, the convex portion sinks and shares the load with the concave portion, thereby improving the durability of the layer. Note that the height of the convex portion or the height of the four portions in the present invention refers to the height from the lower end of the foam, respectively.

It is desirable that the difference in height between the highest height of the convex portion and the height of the concave portion be 1 mm or more. The reason for this is that when a normal light impact is applied, the wooden part deflects by about 0.2mm to 0.5mm+, so the difference in height between the convex part and the concave part must be at least 0.2mm. Considering that it is divided into at least two stages, a value of 1■ or higher is appropriate. Also, the upper limit of the height difference is 75% of the total thickness of the foam.
is preferred.

It is most desirable to provide such a structure in the lowest foam layer. Of course, a similar configuration can be provided in the foam of the intermediate layer, but the effect will not be as efficient as in the lower layer. The reason for this is that the foam layer in the middle layer is designed from the viewpoint of receiving shocks softly, and the foam layer in the bottom layer is designed to ensure that even if an impact is applied, there will be sufficient air gaps to allow solid-borne sound to propagate. This is because our studies have made it clear that designing from the perspective of reducing the route size brings about the best effects. Therefore, it is desirable that the bottom layer of the foam is the hardest, and the upper layers have softer physical properties. Specifically, it is related to the size of the flooring and the thickness of the board, so it cannot be determined exactly, but for example, if the width is 303 mm and the length is 909 mm, the top board thickness is 3.5non, and the middle layer is 303 mm wide and 909 mm long. Foam thickness 3m
m, base plate thickness 5.5 mm, lower layer foam thickness 3 mm 4
In the case of a wooden floor member with a layered structure, the stress required for the convex part to deform by 30% is approximately 4.9N in the middle layer and approximately 1N in the lower layer.
A foam having a hardness of about 5N is desirable.

In addition, if the convex structure of the foam is designed to prevent air from entering and exiting from the sides of the flooring material, for example, as the most obvious example, if all four edges of the edge are convex, it will be trapped inside. The soundproofing performance deteriorates due to a phenomenon thought to be resonance of the trapped air. Therefore, it is desirable that the structure of the convex pattern of the foam is such that when the plate is deformed due to an impact, the internal air can move in and out accordingly.

Further, in the present invention, such a flexible foam and a fiber aggregate such as glass wool or a smooth flexible foam can be used together to form a composite flooring material.

Further, it is also possible to further improve workability by laminating a sheet on top of the convex portion.

The soft polymer foam used in the present invention can be produced by a chemical foaming method using a chemical foaming agent, which is a conventional method for manufacturing foams, or a gas injection method in which a gas such as nitrogen is forcibly mixed in.
Furthermore, products manufactured using methods such as solvent extraction, in which components soluble in a specific solvent are mixed into the resin and the soluble components are extracted with a solvent after molding, are shaped to match the size of the wooden flooring material. It can be obtained by embossing it with voids.

The composite soundproof flooring material of the present invention can be obtained by laminating the obtained foam body alternately with wooden flooring materials using an adhesive while paying attention to the positions of the convex portions.

[Example] The present invention will be explained below with reference to Examples.

(Example 1) Polyvinyl chloride paste resin (Lyuron Paste 1-7
Based on 100 parts by weight of 25 (manufactured by Tosoh ■), 60 parts by weight of DOP (di-2-ethylhexyl phthalate, manufactured by Kao Corporation) as a plasticizer, 20 parts by weight of mica (Sujirite Mica 40S, manufactured by Kuraray Corporation), whitebait. Balloon (Zanki Light Y
-02: manufactured by Sanki Kogyo Co., Ltd.) 3 parts by weight 1 azodicarbonamide as a foaming agent (Vinihole #AC-3M: manufactured by Eiwa Kasei Kogyo Co., Ltd.) 3 parts by weight 1 volume as a foaming aid and stabilizer
3 parts by weight of Mark FL-21 (manufactured by Adeka Argus Chemical Co., Ltd.), a composite system of lithium and zinc, is mixed and stirred in a mixer to form a sol, which is then made into a non-woven fabric with a basis weight of 100 g/c♂. Apply at 0.7nun, temperature 190°
After heating for 4 minutes under the conditions of C, roll 3 vertically from the embossing roll.
0cm, width 90cm, inner side 1 from the edge of the four sides
A convex portion with a height of 3 mm from the bottom edge of the foam is formed in the area of 5 mm, and inside the convex portion is a circular shape with a diameter of 101 Ill, the height of the convex portion is 2n++n, and the center distance between the convex portions is 3 mm. The foam (A) has a concavo-convex pattern with a concave portion height of 1 fl 1 m and a convex portion diameter of 1.75 cm. On+m, the height from the bottom of the foam is constant 3 n++n Height difference of unevenness 2
A foam (B) was prepared which had an uneven pattern on the entire surface with a center spacing of 3.75 cm between the protrusions. Thickness 3
++++++++, the foam (B) is attached to the bottom of a wooden floor member measuring 30 cm long and 90 cm wide using adhesive, followed by a wooden floor member of the same size with a thickness of 5 nm, and then the foam (A) ) was bonded together to obtain a four-layer composite flooring material.

A perspective view of the obtained composite flooring material seen from two sides is shown in FIG.

(Example 2) The same uneven pattern was formed by using the same formulation and molding as in Example 1, except that the blending amount of the blowing agent was changed to 2 parts by weight and the blending amount of the foaming aid was changed to 2 parts by weight. Foam (C)
and the same formulation as in Example 1.

The foam (D) formed with the same uneven pattern by molding is 1! Also. As in Example 1, the thickness is 3 mm and the length is 3 mm.
Foam (D) under a wooden floor member 0cm wide and 90cm wide.
are pasted together using adhesive, and the following thickness is 5Il]I11
A composite flooring material with a four-layer structure was obtained by laminating a wooden flooring member of the same size and then a foam (C).

(Example 3) A foam of the same composition as the foam (C) of Example 2 was molded, and instead of having all four sides formed into convex portions, the sides were partially made into convex portions as shown in Fig. 4. The foam (E) was changed to a convex structure that allows more air to enter and exit, and was made with the same composition as in Example 1, with the same pattern as the foam (E) of this example, or with a constant convex height. A foam (F) with a convex structure as shown in FIG. A composite flooring material with a four-layer structure was obtained by laminating a wooden flooring material of the same size of 5++++n and then a foam (E).

FIG. 4 shows a perspective view and a side view of the obtained composite flooring material as seen from the - plane.

A 3-inch thick Bo Diolefin resin foam (Lion Board hard grade; manufactured by Lion Corporation), which is used as a cushioning material for current wood composite flooring materials, is 30 cm long and 3 cm wide.
It was cut into pieces of 0 cm, and a foam (G) having an uneven pattern as shown in Fig. 5 was made using a strainer and the same thickness was 3.
mm polyolefin resin foam (Lion Board, general grade manufactured by Lion Corporation)) with a length of 30 cm and a width of 3
A foam (H) having the same uneven pattern as the foam (B) of Example 1 was created by cutting it into 0 cm pieces.

The obtained foam is 3 mm thick, 30 cm long, and 30 cm wide.
Place foam (H) under the wooden flooring material with a thickness of 5 mm or less.
, a 6-layer structure consisting of a wooden floor member 30 cm long and 30 cm wide, a foam (G) layered underneath, followed by a wooden floor member 3 mm thick and 30 cm long and 30 cm wide, with foam (G) layered underneath. A composite flooring material was obtained.

The perspective view and side view of the obtained composite flooring material are shown in Figure 5.
As shown in the figure.

(Example 4) (Comparative Example 1) A composition having the same composition as in Example 1 was heated and foamed under the same conditions, and the foams (A, ) had the same uneven pattern but the height of the convex portions The volume was kept constant at 3 ml11 from the lower end of the body, and a foam (B) having the same external shape was obtained. The obtained foam (B) has a thickness of 3+ nm and a length of 30 cm.
A 4-layer structure was created in which the foam (A) was attached to the bottom of a wooden floor member with a width of 90 cm and a wooden floor member of the same = j method with a thickness of 5 mm. A composite flooring material was obtained.

(Comparative example 2) The foam (A) used in Example 1 had a thickness of 9 mm.

It was attached to the bottom of a wooden floor member measuring 30 cm long and 90 cm wide using an adhesive to obtain a composite flooring material with a two-layer structure.

(Comparative Example 3) Density 0.0, which is currently used as a buffer shrine for wood-based composite floors. 076 g/cri1. Hardness: 55, thickness: 3
+n+n polyolefin resin foam (Lionbodo hard grade; manufactured by Lion Corporation) with a length of 30 cm.

Cut into 90cm width, 3mm thickness, 30cm length, 90cm width.
It was pasted under a wooden surface material of cm, and then a wooden floor material of 5 m + n in thickness, 3 Q cm in length, and 90 cm in width, followed by a polyolefin resin foam of 3 + n + n thickness (Lion Board general grade F manufactured by Nilion Co., Ltd.). ) were laminated together to obtain a composite flooring material having a four-layer structure.

(Comparative Example 4) A composition having the same composition as Example 1 was heated under the same conditions.
The convex portion is circular with a diameter of 1.5 n++n, the center distance between the convex portions is 3.75 cm, and the height is 1.5 mm from the bottom edge of the foam, and the convex portion is 1.2 mm in height. A foamed material having a concavo-convex pattern in which the concavities and convexities were arranged alternately and the height of the concave portions was 0.9 mm was prepared. The obtained foam was attached to the bottom of a wooden floor member with a thickness of 5 mm, a length of 30 cm, and a structure of 90 cm using an adhesive, and then a wooden floor member of the same size with a thickness of 5 mm and the same foam were attached. A composite flooring material having a four-layer structure was obtained.

(Evaluation of impact sound absorption performance of lightweight floor) Concrete floor slab with thickness of 15 cm = 1. Using double-sided adhesive tape for urine collection Example 1, 2, 3.4 Comparative Examples 1, 2
, 3.4 was fixed so that it was 90 cm square, and a tapping machine used for normal evaluation of floor impact sound was fixed so that the hitting points of the hammer were diagonal and symmetrical about the center point. The sound generated downstairs was measured when the device was installed and operated.

The volume of the sound is analyzed using a one-octave analyzer, and 125, which has the strongest influence on determining the light impact sound level,
Sound pressure levels at 250,500 Hz were measured. The results are shown in Table 1.

In comparison with Comparative Examples 1 and 23.4, Examples 1 and 2.3.4 all show a rebooking effect of 4 dB or more at 125 Hz, 4 dB or more at 250 Hz, and 9 dB or more at 500 Hz, except for Comparative Example 1. .

In addition, when looking at the L value, which is an index of the soundproofing performance of the floor, Example 1
．． ．． 2.4 is L-50 (grade 2 of the academic society's acceptance standard).

Embodiment 3 achieves L-45 (class 1 recommended by an academic society).

[Effects of the Invention] As is clear from the above description, according to the present invention, the soundproofing performance against light impact can be improved to 125 Hz by adjusting the height of the convex portion of the lowest layer at least.

Each can be improved by 4 dB or more at 250 Hz. This effect makes it possible to achieve an impact sound level of L-50° to L-45.

FIG. 2 is a side view and a front perspective view showing an embodiment of the present invention.

Claims (3)

[Claims] (1) In a composite floor component consisting of a wood floor component and a foam material with an uneven pattern, two or more layers are alternately laminated, a total of four or more layers, at least the bottom foam layer has a convex height of two or more levels. A composite soundproof flooring material having a structure in which the height difference between the highest convex part and the concave part is 1 mm or more. (2) The composite soundproof flooring material according to claim (1), wherein the foam located in the lowest layer is the hardest and the foam located in the upper layer is softer. (3) The composite soundproof floor according to claim (1), characterized in that the structure of the uneven pattern of the foam is such that when compressed by a falling object, the inflow and outflow of air is not obstructed. Material.