JPH04351538A - Cushioning material and soundproof flooring using said material - Google Patents

Abstract

PURPOSE:To obtain a cushioning material and a soundproof flooring, in which excellent soundproof performance and required compressive strength are made compatible with each other. CONSTITUTION:An irregular synthetic resin sheet 4 is laminated and bonded onto the rear of a foamed synthetic resin sheet 1 having a high expansion ration, thus manufacturing a cushioning material. The irregular synthetic resin sheet 4 has recessed sections 2 brought to a low foamed state or a non-foamed state by compression and foamed projecting sections 3 projected and formed on the rear side or both surface and rear sides of said sheet. The foamed projecting sections 3 have an expansion ratio lower than the foamed synthetic resin sheet 1. A non-foamed coating layer having high specific gravity coating covering the foamed projecting sections 3 and the recessed sections 2 under the low foamed state can be formed on the rear side of the irregular synthetic resin sheet 4. Such a cushioning material is laminated and bonded on the rear of a floor substrate through a nonwoven fabric properly, thus manufacturing a soundproof flooring.

Description

[Detailed description of the invention]

0001

[Field of Industrial Application] The present invention relates to flooring materials, and in particular to a cushioning material that is used in the upper floors of a house to prevent solid sound from propagating to the lower floors due to impact from the floor, and a method using the cushioning material. Regarding soundproof flooring materials.

0002

2. Description of the Related Art The following are known examples of soundproof building materials that can prevent the propagation of solid sound caused by impact. (a) Utility Model Application No. 50-49917 The flooring material of this known example has foaming ratios of 3 to 3 on the back side of the flooring material body.
Foaming ratio 1.5 with 10x soft and highly foamed layer and convex parts
It is made by sequentially laminating soft, low-foam layers of less than 3 times the size. (b) Utility Model Application Publication No. 61-47339 This known example of sound-insulating wooden flooring has a plurality of layers of sound-insulating foam adhered to the entire lower surface of the wooden board, and the foaming ratio of the adjacent upper and lower layers is are considered to be different from each other.

[0003] These known examples all use a composite of foams with different expansion ratios, and are cushioning materials with low rigidity, and when subjected to impact force, the foam deforms. During this period, the buffering time becomes longer, and even if the change in momentum, that is, the time integral value of the impulse and buffering force, is constant, the peak value of the impact force and the natural frequency of the impact decrease, and the impact input energy to the foundation is reduced. It is possible to reduce the impact and prevent the propagation of sound and vibration caused by impact. Furthermore, when these cushioning materials are combined on the back surface of a building material, the impact force is absorbed by the expansion and contraction deformation of the cushioning material caused by bending vibration of the building material.

0004

[Problems to be Solved by the Invention] However, the soundproofing function is greatly influenced by the thickness ratio of the building material and the cushioning material, and in order to sufficiently improve the soundproofing function, it is necessary to increase the thickness ratio of the cushioning material to the building material by It needs to be tripled. As a result, the cushioning material becomes too thick, which causes problems such as severe bending of the entire building material, causing damage to the joints of the building material, and causing a sense of uneasiness when walking when used for flooring. I'm leaving it behind.

[0005]

[Means for Solving the Problems] In view of the current situation, the present inventor has completed the present invention as a result of repeated research in order to solve the problems of the above-mentioned prior art.

That is, the cushioning material according to the present invention has a foamed synthetic resin sheet having a foaming ratio higher than that of the foamed projections on the surface side of a textured synthetic resin sheet having depressions made of foamed or unfoamed regions and a large number of foamed projections. It is characterized in that the sheets are laminated and bonded together.

[0007] The foamed convex portions are formed protruding from the back side of the textured synthetic resin sheet. Alternatively, protrusions are formed from both the front and back sides of the uneven synthetic resin sheet, and the uneven synthetic resin sheet and the foamed synthetic resin sheet are laminated and bonded with the protruding portion on the front side fitted into the foamed synthetic resin sheet.

The soundproof flooring material according to the present invention is made by adhering a substrate to the surface of the foamed synthetic resin sheet of the cushioning material, if necessary, with a nonwoven fabric interposed therebetween.

[0009]

[Embodiment] Fig. 1 shows the structure of a cushioning material according to an embodiment of the present invention. On the back side of a foamed synthetic resin sheet 1, a recess 2 consisting of a compressed foamed portion or an unfoamed portion and the recessed portion 2 are formed. A textured synthetic resin sheet 4 on which a large number of foamed convex portions 3 are formed is laminated and bonded on its flat side.

The foamed synthetic resin sheet 1 is preferably made of open cell foam. By making it an open cell type,
Foaming synthetic resin sheet 1 that absorbs energy applied from the surface
In addition to being absorbed by the synthetic resin itself,
It can be effectively absorbed by the viscous resistance of gas flowing in and out of the porous body as it deforms, ie, by air damping. Examples of open cell synthetic resins include polyurethane resins, but are not limited thereto.

The expansion ratio of the open-cell synthetic resin constituting the foamed synthetic resin sheet 1 is preferably 40 to 60 times. If the expansion ratio is less than 40 times, the number of pores contained will be small and the ability to absorb energy applied from the surface will be insufficient. On the other hand, when the foaming ratio exceeds 60 times, although the energy absorption ability is excellent, the sheet becomes too soft and its compressive strength against loads applied from the surface rapidly decreases. This is not desirable because it causes shrinkage.

The textured synthetic resin sheet 4 has a concave portion 2 consisting of a foamed portion or an unfoamed portion, and a large number of foamed convex portions 3 connected by the concave portion.

The foamed convex portions 3 have a foaming ratio lower than that of the foamed synthetic resin sheet 1, and preferably have a foaming ratio of 20 to 30 times. If the foaming ratio is less than 20 times, the convex portions 3 will become too hard and will not be able to fully demonstrate their energy absorption ability, and the impact energy that could not be fully absorbed due to the shrinkage of the foamed synthetic resin sheet 1 will be transferred directly to the floor below. This results in insufficient soundproofing performance. On the other hand, if the expansion ratio exceeds 30 times, the convex portion 3 becomes too soft and sinks due to expansion and contraction, which is undesirable because it causes a feeling of anxiety and fatigue when walking on the floor due to it being too soft. .

Regarding the foaming form of the foamed convex portions 3, unlike the open cell type of the foamed synthetic resin sheet 1, it is preferable that the foam is a closed cell type foam. In this way, the foamed convex portion 3
has a lower foaming ratio than the foamed synthetic resin sheet 1 and is a closed cell type, so although its ability to absorb impact energy is slightly inferior to that of the foamed synthetic resin sheet 1, it compensates for the energy that could not be fully absorbed by the foamed synthetic resin sheet 1. In addition, it has an extremely high strength against compressive loads, so it can provide the necessary rigidity as a floor surface, and even if it is compressed and absorbed, It has excellent restoring power to return to its shape.

The shape of the foamed convex portion 3 is arbitrary, and can be formed into a circular, triangular, or rectangular cross section. FIG. 1 shows a foamed convex portion 3 having a substantially truncated pyramid shape.

Since the foamed convex portions 3 are formed on the back side of the uneven synthetic resin sheet 4, when this is installed, for example, on a concrete floor subsurface, the top surface of the foamed convex portions 3 will come into contact with the concrete floor subsurface. It will support the floorboards,
Air chambers are formed between the foamed convex portions 3, and the soundproofing function is further improved.

The recesses 2 in the uneven synthetic resin sheet 4 are as follows:
It exists between the foamed convex parts 3 to connect the foamed convex parts 3, and even if it is made of an unfoamed part as shown in FIG. 2, or it is made of a foamed part as shown in FIG. It's okay to have one. When the concave portion 2 is formed of a foamed portion, the foaming ratio thereof is preferably lower than that of the foamed convex portion 3 (for example, 8 times or less). Further, the concave portion 2 may include foamed portions and non-foamed portions.

The recesses 2 have a much higher specific gravity than the foamed convex portions 3 and the foamed synthetic resin sheet 1 due to their unfoamed state or low foamed state.
It is possible to reflect the energy that could not be completely absorbed due to the contraction of the membrane, and exhibits a sound insulation effect. This effect is
The lower the foaming ratio of the recesses 2, the larger the foaming ratio, and this is most noticeable in the unfoamed state.

The uneven synthetic resin sheet 4 having such concave portions 2 and foamed convex portions 3 can be produced, for example, by heating a uniformly foamed foamed synthetic resin sheet, preferably a closed-foam synthetic resin sheet, with a molded plate having an uneven surface. The part formed by pressing and hot-pressed on the flat part of the molding plate is left as a foam convex part 3 with the original foaming ratio, and the part hot-pressed on the convex part of the molding plate is crushed. By appropriately setting the pressing temperature and pressing time, the concave portions 2 are formed in a low foaming state or a non-foaming state.

[0020] When the uneven synthetic resin sheet 4 is manufactured by such a pressing method, the surface portion is melted during pressing to form an unfoamed molten coating layer 5. This molten coating layer 5 is formed on the surface of the foamed convex part 3 when the concave part 2 is pressed to an unfoamed state (FIG. 2), and when the concave part 2 is formed in a low foamed state, it is formed on the surface of the foamed convex part 3. and cover the entire concave portion 2 (FIG. 3). As described above, the molten coating layer 5 formed on the surface of the foamed convex portion 3 or the surface of the convex portion 3 and the recessed portion 2 in a low foaming state has a higher specific gravity than the foamed convex portion 3 (and the recessed portion 2). , has a function of reflecting energy that is not absorbed by the foamed convex portions 3 (and concave portions 2),
At the same time, it has the function of preventing moisture absorption from the subfloor after construction.

Another method for producing the textured synthetic resin sheet 4 is to contact an unfoamed sheet or a low-foamed sheet with a mold having convex portions and heat and foam the sheet to form the foamed convex portions 3. Also good. In this case, by increasing the heating and foaming time, the recesses 2 in a low foaming state can be
Also, an unfoamed molten coating layer 5 can be formed on the surface of the foamed convex portion 3 .

The uneven synthetic resin sheet 4 having the above structure is bonded to the foamed synthetic resin sheet 1 by any means such as heat fusion or adhesive.
The cushioning material of this example is obtained by laminating and adhering the material to the back surface of the material. In this cushioning material, the energy applied from the surface is first absorbed by the expansion and contraction deformation of the foamed synthetic resin sheet 1, and the energy that is not absorbed even by this, is
It is effectively absorbed by the expansion and contraction deformation of the foamed convex portions 3 of the uneven synthetic resin sheet 4, and by the sound insulation function of the high specific gravity concave portions 2 and the fused coating layer 5. Furthermore, since the foaming ratios of the foamed synthetic resin sheet 1 and the foamed convex portions 3 are different, energy is transferred from the foamed synthetic resin sheet 1 with a high foaming ratio (low specific gravity) to the foamed convex portions 3 with a low foaming ratio (high specific gravity). When propagating, energy absorption is also achieved by the difference in specific gravity between them.

In the obtained cushioning material, a nonwoven fabric may be attached to the surface side of the foamed synthetic resin sheet 1. This prevents the adhesive used for adhering to the floorboard substrate from penetrating into the foamed synthetic resin sheet 1.

FIG. 4 shows a non-woven fabric 6 further adhered to the surface of the cushioning material shown in FIG. 1, which is then adhered to the back surface of a floor substrate 7 to form a soundproof flooring material. As the substrate 7, for example, plywood, particle board, hardboard, L. V
．． L. (parallel plywood) etc. may be used, and in order to improve the soundproofing effect, for example, a foamed synthetic resin sheet 8 having an excellent cushioning effect may be laminated between plywood sheets. Furthermore, grooves extending in any direction can be formed on the back surface of the substrate 7, thereby reducing the rigidity of the substrate 7 and allowing the substrate 7 to absorb impact energy applied to the surface. Since the substrate 7 is partially divided, sound is less likely to propagate, and the soundproofing effect can be further improved. The surface of the substrate 7 is optionally decorated, for example, surface decorative materials such as veneer, synthetic resin or synthetic resin foam decorative sheet, decorative paper or synthetic resin-impregnated decorative paper are laminated and adhered, or an undercoat is applied. After that, the desired pattern will be printed.

FIG. 5 shows a soundproof flooring according to another embodiment. The difference from the soundproof flooring material in FIG. 1 is that the foamed convex portions of the uneven synthetic resin sheet 14 in the cushioning material are
4 is formed as a foamed convex portion 13 protruding from both the front and back sides. Uneven synthetic resin sheet 1 having such a structure
4 can be easily manufactured by, for example, performing hot pressing using a molded plate in the manufacturing method described above on both sides. When this uneven synthetic resin sheet 14 is laminated and adhered to the back side of the foamed synthetic resin sheet 1, since the foamed synthetic resin sheet 1 is made of a soft material with a high expansion ratio, the protruding portions on the front side of the foamed convex portions 13 are formed by the foamed synthetic resin sheet 1. By sinking into the resin sheet 1, a configuration as shown in FIG. 5 is obtained. In the soundproof flooring material of FIG. 5, the same components as those of the soundproofing flooring material of FIG.

FIG. 6 shows a state in which a compressive load is applied to the soundproof flooring material of FIG. 5 from the surface side, and the foamed synthetic resin sheet contracts when the compressive load is applied.
By abutting the front side protruding portion of the foamed convex portion 13 with the back surface of the floor substrate 7 (or the back surface of the nonwoven fabric 6), further shrinkage of the foamed synthetic resin sheet 1 is prevented. By thus limiting the contraction range of the foamed synthetic resin sheet 1 to a certain extent, it is possible to prevent the flooring from sinking without reducing the soundproofing effect.

[0027]

According to the present invention, a cushioning material with excellent soundproofing effect and sufficient compressive strength, and a soundproof flooring material using the cushioning material can be obtained.

[Brief explanation of the drawing]

FIG. 1 is a sectional view showing the structure of a cushioning material according to an embodiment of the present invention.

FIG. 2 is a partially enlarged sectional view showing the state of formation of a molten coating layer in the cushioning material of FIG. 1;

FIG. 3 is a partially enlarged cross-sectional view showing another state of formation of the molten coating layer.

4 is a cross-sectional view showing the structure of a soundproof flooring material obtained using the cushioning material of FIG. 1. FIG.

FIG. 5 is a sectional view showing the structure of a soundproof flooring material according to another embodiment of the present invention.

FIG. 6 is a sectional view showing a state in which the soundproof flooring material of FIG. 5 is compressed and deformed.

[Explanation of symbols]

1. Foamed synthetic resin sheet 2 Recess 3. Foaming convex part 4 Uneven synthetic resin sheet 5 Melt coating layer 6. Non-woven fabric 7 Floor board

Claims (5)

[Claims] Claim 1: A foamed synthetic resin sheet having a higher foaming ratio than the foamed projections is laminated and adhered to the surface side of a textured synthetic resin sheet having recesses consisting of foamed or unfoamed regions and a large number of foamed projections. A cushioning material characterized by: 2. The cushioning material according to claim 1, wherein the foamed convex portion is formed to protrude from the back side of the uneven synthetic resin sheet. 3. The foamed convex portions are formed to protrude from both the front and back surfaces of the textured synthetic resin sheet, and the textured synthetic resin sheet and the foamed synthetic resin are bonded to each other with the protruding portions on the front side fitted into the foamed synthetic resin sheet. The cushioning material according to claim 1, wherein the cushioning material is laminated and bonded to the sheet. 4. The cushioning material according to claim 1, further comprising a high specific gravity coating layer that covers the back side of the uneven synthetic resin sheet. 5. A soundproof flooring material comprising a substrate bonded to the foamed synthetic resin sheet surface of the cushioning material according to any one of claims 1 to 4.