JPH07165962A - Polyolefinic foam and floor covering material integrated with the same - Google Patents

Abstract

PURPOSE:To obtain the foam useful for a soundproofing floor, a ceiling structure, etc., having excellent soundproofing properties, durability and lightness, containing a specific amount of urethane elastic yarn. CONSTITUTION:This foam is obtained by adding 0.1-30wt.% of urethane elastic yarn such as one having 0.3-1.0mm length and 10-500mum thickness to a polyolefinic resin such as PE, PP, an ethylenevinyl acetate copolymer.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a polyolefin foam having excellent sound absorbing properties and good compression recovery, and a floor material incorporating the foam.

[0002]

2. Description of the Related Art In recent years, in condominiums and other condominiums, wooden floor materials are often used, and the noise from the upper floors is transmitted to the lower floors to generate noise, which causes a serious problem of deterioration of the housing environment. Therefore, various elastic bodies have been developed as soundproofing means for effectively absorbing the impact sound, and using a foam material having a high open cell ratio and a high elasticity as a floor base material under the wood finishing material. Is preferred, and rubber foams and the like have begun to be used as a material suitable for this purpose. However, when a soft and thick elastic body is laid on the floor base and a relatively hard wood-based material is used as the finishing material, the weighted part is distorted when standing on the floor,
I was worried about the softness of the floor, such as the sinking of the floor, resulting in a loss of the original hardness of the wood-based material. Moreover, when porous fibers such as felt are used for the elastic body, moisture under the floor may cause the felt or the like to absorb moisture, resulting in a decrease in cushioning property and creep or the like, which may cause sinking of the floor. Further, as one of soundproofing means, Japanese Patent Laid-Open No. 1-2908
The floor material to which the chip-shaped rubber-based elastic material described in JP-A-73 is adhered has high soundproofing performance, but is difficult to construct,
In addition, there are restrictions such as the need for a large amount of adhesive, which makes it unsuitable for general housing.

[0003]

SUMMARY OF THE INVENTION It is an object of the present invention to provide a plastic foam which is excellent in soundproofness, lightweight, and does not cause creep, and which is excellent in durability. Another object of the present invention is to provide a soundproof flooring material which is excellent in soundproofing property, lightweight, and excellent in durability.

[0004]

DISCLOSURE OF THE INVENTION The present invention is based on the finding that a foam obtained by dispersing a specific amount of urethane elastic yarn in a polyolefin foam matrix can efficiently solve the above problems. It was done. That is, the present invention uses the urethane elastic yarn in an amount of 0.1 to 30% by weight (hereinafter,%
Abbreviated). The present invention also provides the above foam,
There is also provided a floor material in which a surface plate is laminated, and a floor material in which the surface plate, the foam, the base material, and the foam are laminated in this order. The urethane elastic yarn used in the present invention may be of any length, but the length is preferably 0.1 mm to 10 mm. This is because if the thickness is less than 0.1 mm, the foam shape of the foam is unlikely to be fibrous, and if it exceeds 10 mm, the gas easily escapes immediately after foaming. Furthermore, it is preferably 0.3 to
It is 1.0 mm. Moreover, the thickness of the urethane elastic thread is 5 to
1000 μm is preferable. If it is less than 5 μm, the foam shape of the foam is unlikely to be fibrous, and if it exceeds 1000 μm, the foam state tends to be nonuniform and coarse, and the compression creep property of the foam deteriorates. Furthermore, preferably, 10 to 5
It is 00 μm. That is, by using the urethane elastic yarn, the bubbles in the foam can be easily made into open cells.

The content of urethane elastic yarn in the polyolefin resin foam is 0.1 to 30%, and 0.5 to 10%.
Is preferred. If it is less than 0.1%, the open cell property is low, and it is 30%.
If it exceeds, the bubble state is not uniform and there is a strong tendency to coarsen,
Variations in apparent density increase. Examples of the polyolefin resin foam matrix in which the urethane elastic yarn is dispersed include, for example, 40 to 95% of polyolefin resin, 0 to 20% of rubber, 0 to 40% of inorganic filler, and the balance of a foaming agent and a crosslinking agent. One that is crosslinked and foamed up to 100 times. Of these, polyolefin resin 55-
95%, rubber 0 to 10%, preferably 0 to 5%, inorganic filler 0 to 35%, preferably 25 to 35%, the balance being a foaming agent and a cross-linking agent and the like, which is 8 to 20 times cross-linked and foamed. Is preferred. Here, examples of the polyolefin-based resin include low-density polyethylene, linear low-density polyethylene, high-density polyethylene, polypropylene, ethylene-vinyl acetate copolymer (vinyl acetate content: 2 to 35%), and these are used alone or Used in combination with one or more species. The polyolefin resin preferably has a melt flow rate of 0.5 to 10 g / 10 min. A melt flow rate of less than 0.5 / 10 minutes tends to cause unevenness during kneading because of high viscosity during melting, and a flow rate of more than 10 g / 10 minutes tends to cause excessive fluidity and uneven air bubbles. Is. Furthermore, preferably 1 to 3 g / 10
Minutes.

As the rubber, natural rubber, polybutadiene rubber, polyisoprene rubber, styrene-butadiene copolymer rubber, nitrile rubber, butyl rubber, chloroprene rubber, acrylonitrile-butadiene copolymer rubber, ethylene-propylene copolymer rubber. , Silicone rubber and the like, and these may be used alone or in combination of two or more kinds. Examples of the inorganic filler include calcium carbonate, talc, clay, silica, aluminum hydroxide, magnesium hydroxide, zeolite and the like. As a cross-linking agent,
Organic peroxides such as 1,3-bis (tert-butylperoxyisopropyl) benzene, 2,5-dimethyl-2,5-di (tert-butylperoxy) hexane, and dicumyl peroxide, and sulfur and sulfur Compounds. As the foaming agent, azodicarbonamide, azobisisobutyronitrile, dinitrosopentamethylenetetramine, 4,4′-oxybisbenzenesulfonyl hydrazide, diphenylsulfone-3,3′-disulfohydrazide, benzylsulfonic acid diphenylhydrazide Etc. Furthermore, antioxidants, colorants, foaming aids,
Various additives such as a crosslinking aid, a lubricant, and a flame retardant can be added if necessary.

The polyolefin resin foam of the present invention has an open cell ratio of 60 to 95% by volume, and the variation in the apparent density of the foam is 0 between the surface vicinity and the center of the foam. It is preferably less than 0.02 g / cm ³ , and such a foam has low compression creep and excellent soundproofing. The foam of the present invention can be easily produced, for example, by the following method. First, resin, urethane elastic thread,
Foaming agent, cross-linking agent, filler, and further rubber if necessary,
Various additives, pressure kneader, internal mixer,
The mixture is kneaded with a device such as a Banbury mixer and further with a roll and an extruder to form a sheet having a thickness of 0.5 to 3.0 mm.
The sheet prepared in the above step is heated at a temperature of 140 to 1 by a pressure heating foaming method using a pressure press device or the like.
Crosslinking foaming is performed at 90 ° C. and a pressure of 100 to 200 kg / cm ² . In this way, the foam of the present invention is obtained. The foam thus obtained can be used as it is or after being sliced to a predetermined thickness. When the polyolefin resin foam of the present invention is provided between the upper wooden floorboard and the floor substrate, an excellent soundproof floor can be obtained.

Here, the surface plate provided on the polyolefin resin foam of the present invention, for example, the upper wood floor plate is a wood plate, a plywood, a laminate of a plastic sheet and a plywood,
Examples include decorative boards, inorganic composite wood, wood-plastic composite (WPC), and the like. The thickness of the surface plate can be arbitrary, but it is 2 to 15 mm, preferably 2 to 10 mm.
It is preferable to use the one of mm. Examples of the floor substrate include conventionally known floor substrates such as concrete slab, stone material, ALC and the like. Also, from the top to the floor,
5 mm surface plate / the plastic foam of the present invention 1 to 3 m
m / base plate 5 to 15 mm / plastic foam 1 of the present invention
It can be a multilayer laminate of 10 mm. here,
As the base plate, a wood plate, a plywood, an inorganic composite wood, a laminated plate of a plastic sheet and a plywood, or the like can be used. In the laminate having the above structure, a moistureproof layer or the like can be provided between the upper wooden floorboard or floor substrate and the foam or the like. In addition, the respective layers constituting the above-mentioned laminated body may be formed by an arbitrary method, for example, an adhesive (a vinyl adhesive, a rubber adhesive,
It can be fixed by using an epoxy adhesive or the like or a mechanical joining means.

[0009]

EFFECTS OF THE INVENTION According to the present invention, there is provided a polyolefin foam which is excellent in absorbing impact noise and can reduce the impact noise peak. When this foam is used in combination with surface materials, etc., when the impact sound on the floor is transmitted through the wooden floor material, the impact sound is absorbed by the fibrous open cells of the plastic foam and the impact sound transmitted to the room below is absorbed. The impact time becomes longer and the impact sound peak decreases, and the frequency of the impact sound shifts to the low frequency side, making it difficult for the human ear to hear. Therefore, the polyolefin resin foam of the present invention can be widely used for various applications such as a ceiling structure and a partition wall structure as well as a soundproof floor. Next, the present invention will be described with reference to examples.

[0010]

【Example】

Example 1 Polyolefin-based resin foam matrix components shown in Table 1 and polyurethane elastic yarn were melted and kneaded by an internal mixer, and then foamed to have a predetermined foamed cell ratio, and polyolefin-based resin foaming. Manufactured body. The foam moldability, the open cell ratio, the compression creep and the soundproofing property of the foam of the present invention thus produced were measured by the following methods. The results are shown in Table 1. The apparent density of the foamed molded foam by the following equation to determine the apparent density difference of the central portion 100 cm ³ of foam and partial 100 cm ³ near the surface of the foam. D = W / V (according to JIS K-6767) (where D is the apparent density (g / cm ³ ), W is the mass (g) of the test piece, and V is the volume (cm ³ ) of the test piece. The obtained values were evaluated according to the following criteria. ○ Apparent density difference less than 0.02 g / cm ³ △ Apparent density difference 0.02 g / cm ^{3 to} 0.05 g / c
Less than m ³ × Apparent density difference 0.05 g / cm ³ or more

The open cell ratio was determined by the following formula according to ASTM D 2856 air pycnometer method. V = 100 × (Vs−ΔV) / Vs (In the formula, V is the open cell ratio (%), Vs is the apparent volume (cc) of the test piece, and ΔV is the true volume (c) of the test piece.
c). ) Compression creep wood flooring is 50 mm on a side (length, width), thickness is 10 to 20 m
It is a rectangular parallelepiped of m, has a horizontal fixed plate and a movable plate that can always be compressed horizontally with a constant load according to the deformation of the test piece, and uses a device with a structure that can easily measure the change in the thickness of the test piece. To measure. The initial thickness and the thickness after 168 hours when a load of 0.2 kg / cm ² was applied were measured, and the strain (%) was calculated by the following formula. Strain = 100 × (t ₀ −t ₁ ) / t ₀ (where, t ₀ is the initial thickness (mm) of the test piece, t
₁ is the thickness (mm) of the test piece after 168 hours. ) Soundproofness It is expressed by the sound insulation grade value specified in JIS A 1419.

[0012]

[Table 1] Table 1 Example 1 Example 2 Example 3 Example 4 LDPE 30 61.5 41.5 26 sLDPE 10 5 EVAc 52.5 20 20 42.5 HDPE 8 PP 2 Length 0.5 mm 2 Po diameter 0.1 mm Re-length Length 1.0 mm 3 C Diameter 0.1 mm Length 0.5 mm 3 Length 0.3 mm Length 2.0 mm 1 Diameter 0.5 mm Calcium carbonate 10 20 20 Azodicarbonamide 3 3 3 3 Crosslinking agent 1 1 1 1 Zinc oxide 1 1 1 1 1 Zinc stearate 0.3 0.3 0.3 0.3 0.3 Antioxidant 0.2 0.2 0.2 0.2 Foam moldability ○ ○ ○ ○ Open cell ratio (%) 65 79 75 61 Compression creep (%) 1.9 2.8 2.7 7.2 Soundproofing L-50 L-50 L-50 L-55 In the table, sLDPE is linear low density polyethylene, and E
VAc is ethylene vinyl acetate copolymer, crosslinker is 1,
3 Bis (tertiarybutyloxyisopropyl) benzene (hereinafter the same).

Examples 2 to 8 Polyolefin resin foams were produced in the same manner as in Example 1 except that the materials and conditions shown in Tables 2 to 3 were used, and foam molding was performed in the same manner as in Example 1. Property, open cell rate,
The compression creep and soundproofing were measured. The results are shown in Tables 2-3. Comparative Examples 1 to 6 A polyolefin resin foam was produced in the same manner as in Example 1 except that the materials and conditions shown in Tables 4 to 5 were used.
In the same manner as in Example 1, foam moldability, open cell ratio, compression creep and soundproofing were measured. The results are shown in Tables 4-5.

[0014]

[Table 2] Table 2 Example 5 Example 6 Example 7 Example 8 LDPE 5 30 40.5 40 sLDPE 10 5 EVAc 51.5 60 20 42.5 HDPE 1 3 PP 3 1 Length 0.1 mm 28 Po diameter 0.01 mm Relength Length 0.3 mm 0.5 C Diameter 0.01 mm Length 8.0 mm 1 Length 0.1 mm Length 2.0 mm 2 Diameter 0.8 mm Calcium carbonate 10 20 5 Azodicarbonamide 3 3 2 3 Crosslinker 1 1 1 1 Zinc oxide 1 1 1 1 1 Zinc stearate 0.3 0.3 0.3 0.3 Antioxidant 0.2 0.2 0.2 0.2 Foam moldability ○ ○ ○ ○ Open cell ratio ( %) 92 62 67 67 63 Compression creep (%) 2.8 2.5 2.0 2.9 Soundproofing L-50 L-55 L-55 L-55

[0015]

[Table 3] Table 3 Example 9 Example 10 Example 11 Example 12 LDPE 5 22 45 sLDPE 5 EVAc 70 60 60.5 10 HDPE 1 PP 1 Length 0.3 mm 1 1 3 Po diameter 0.05 mm Re-length 0.3 mm 1 3 C Diameter 0.1 mm Length 0.5 mm 1 Diameter 0.1 mm Length 0.8 mm 0.5 Diameter 0.1 mm Calcium carbonate 10 10 30 35 35 Azodicarbonamide 3.5 3 4 4.5 Crosslinking agent 1 1 1 1 Zinc oxide 1 1 1 1 1 Zinc stearate 0.3 0.3 0.3 0.3 Antioxidant 0.2 0.2 0.2 0.2 Foam moldability ○ ○ ○ ○ Open cell ratio ( %) 74 75 70 73 Compression creep (%) 2.1 1.8 2.3 2.1 Soundproofing L-50 L-45 L-50 L-50

[0016]

[Table 4] Table 4 Comparative Example 1 Comparative Example 2 Comparative Example 3 Comparative Example 4 LDPE 30 30 41.5 sLDPE 10 10 EVAc 54.45 19.5 20 20 Length 0.5 mm 0.05 Po diameter 0.1 mm Length 1 .0Mm 35 U diameter 0.1 mm les length 0.05 mm 3 data size 0.1mm down length 15 mm 3 size 0.1mm calcium carbonate 10 10 20 20 azodicarbonamide 3 3 3 3 crosslinker 1 1 1 1 oxide Zinc 1 1 1 1 1 Zinc stearate 0.3 0.3 0.3 0.3 0.3 Antioxidant 0.2 0.2 0.2 0.2 Foam moldability ○ × △ × Open cell ratio (%) 10 58 40 48 Compression creep (%) 3.5 15.5 4.3 8.3 Soundproofing L-65 L-65 L-65 L-65

[0017]

[Table 5] Table 5 Comparative Example 5 Comparative Example 6 Comparative Example 7 Comparative Example 8 LDPE 30 30 30 30 sLDPE 1 EVAc 51.5 51.5 51.5 51.5 49 HDPE 1 PP 0.5 Poly length 1.0 mm 3 Ure diameter 0.003 mm Tan length 1 0.0mm 3 Diameter 1.2mm Nye Length 1.0mm 3 Long Diameter 0.1mm Cotton Yarn Length 1.0mm 3 Diameter 0.1mm Calcium Carbonate 10 10 10 10 10 Azodicarbonamide 3 3 3 3 3 Crosslinking Agent 1 1 1 1 Oxidation Zinc 1 1 1 1 1 Zinc stearate 0.3 0.3 0.3 0.3 Antioxidant 0.2 0.2 0.2 0.2 Foam moldability × × × × Open cell ratio (%) 48 37 31 27 Compression creep (%) 7.5 13.4 19.8 20.3 Soundproofing L-65 L-65 L-65 L-70

Claims (5)

[Claims] 1. A polyolefin foam comprising urethane elastic yarn in an amount of 0.1 to 30% by weight. 2. The urethane elastic yarn has a length of 0.3 mm to 1.0.
The foam according to claim 1, which has a size of mm. 3. The thickness of the urethane elastic yarn is 10 to 50.
The foam according to claim 1, which has a thickness of 0 μm. 4. A flooring material, characterized in that a surface plate is laminated on the foam according to any one of claims 1 to 3. 5. A floor comprising a surface plate, a foam according to any one of claims 1 to 3, a base material and a foam according to any one of claims 1 to 3 laminated in this order. Material.