JPH084261A - Woody soundproof floor material and manufacture thereof - Google Patents

Abstract

PURPOSE:To provide a woody soundproof floor material which can be directly laid on a concrete slab surface. CONSTITUTION:In a woody soundproof floor material 10 obtained by laminating and integrating a woody base material 2 and a reverse cushioning material 4 together, the reverse cushioning material 4 is formed of a continuously foamed soft or semi-hard synthetic resin foamed sheet which is thinned by the compression by thermal press and also has a number of protruding parts 5, 6 on one surface or both the surfaces. A water shielding layer 7 by the coating of a synthetic resin sol is formed on the reverse surface. By applying the coating of the synthetic resin sol, the water shielding layer 7 can be integrally molded easily and simultaneously with the molding of the reverse cushioning material 4, and the reduction in sound insulating property by absorption of moisture can be surely prevented after the laying onto a concrete slab.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a wooden soundproofing floor material and a method for producing the same, and more particularly to a wooden soundproofing floor material having excellent soundproofing performance which can be directly laid on the surface of a concrete slab or the like and a method for producing the same.

[0002]

2. Description of the Related Art Laying a wooden floor material directly on a concrete slab or on a waste plywood laid on the concrete slab has been conventionally performed as so-called flooring construction. Many structures of wooden floor materials have been proposed and used from the viewpoint of soundproofing or improvement of walking feeling.

For example, as shown in FIG. 4, a wooden decorative board 4
1. A wooden flooring material formed by sticking a backside cushioning material such as a rubber sheet 45 to the back surface of a wood-based base material obtained by laminating and integrating 1 with a soft sheet 42 and a wood-based board 43.
In addition to the cut grooves 44, the rubber sheet 45 has concave and convex portions on the front and back surfaces, that is, a concave portion 47 having a concave surface portion corresponding to a convex portion 46 protruding downward and a concave portion 48 on the rear surface.
In order to cope with the above, there has been proposed one in which a projecting portion 49 having a projecting surface is formed (see JP-A-63-241264).

Further, as shown in FIG. 5, a vibration damping sheet 52 and a perforated wood board 53 are laminated on the back surface of a wood material 51 to form a wood base material, and a polyolefin foam is further formed on the back surface thereof. , A flat cushioning material 54 made of a rubber-based foam or the like is attached as a back cushioning material (actually 1-10144
As shown in FIG. 6, as shown in FIG. 6, a vibration damping sheet 62 and a perforated wood board 63 are laminated on the back surface of the wood material 61 to form a wood base material, and the back surface thereof has a high foaming rate. A cushioning member 64 made of a rubber foam having a soft hollow hollow convex portion 65 and a convex portion 66 having a low foaming rate and a higher hardness on the back surface.
There is also proposed a back surface cushioning material (see Japanese Utility Model Publication No. 5-5988).

Each of the wooden soundproof flooring materials having the above-mentioned structure is effective in reducing the propagation of sound from the upper floor to the lower floor.
As described in Japanese Patent Application Laid-Open No. 63-241264, the structure in which the kerf is provided on the substrate has an advantage of being able to follow the irregularities on the surface of the concrete slab, but there is still room for improvement from the viewpoint of soundproofing. I have left. Actual Kaihei 1-1
As shown in Japanese Patent Laid-Open No. 0144, the one in which a flat cushioning material is adhered to the back surface of the base material has an advantage that the structure is simple, but the cushioning material vibrates because of a large area in contact with the base material and the concrete slab surface. It has the inconvenience that there is a limit to the reduction of transmissibility. What is disclosed in the above-mentioned Japanese Utility Model Laid-Open No. 5-5988 is a rubber foam cushioning material having convex portions having different shapes and different foaming ratios as a cushioning material to be attached to the back surface in order to eliminate the inconvenience. However, in this case, it is undeniable that it is difficult to manufacture the rubber foam cushioning material. In addition, all of these have a drawback that the price is high because a sheet is interposed between the wood materials.

The present inventors have conducted many experiments and studies for the purpose of eliminating the above-mentioned disadvantages of the conventional wooden soundproof flooring materials, and as shown in FIG.
A wood-based soundproofing floor material 10 in which a surface decorative board 1, a wood-based material 2, and a back surface cushioning material 4 are laminated and integrated, and the wood-based material 2 has a kerf 3 formed on its back surface. Further, the back cushioning material 4 is a wooden soundproof flooring material in which a continuous foaming type soft or semi-rigid synthetic resin sheet is compressed by hot pressing to reduce its thickness and at the same time a large number of convex portions 5 and 6 are formed on both front and back surfaces. Developed and already proposed (Japanese Patent Application No. 5-328017)
issue).

In the wooden soundproof flooring material proposed above, the material of the back cushioning material used is a continuous foaming type soft or semi-rigid synthetic resin foamed sheet to be thinned by compression by hot pressing and at the same time on one or both sides. Since a large number of convex portions are formed, the convex portions formed on the front and back surfaces can have a clear contour shape and a high height, resulting in good sound insulation and sound insulation. Furthermore, by having a low-density layer portion that is a convex portion as a whole and a high-density layer portion other than that, in addition to reducing the propagation of vibrations from the upper side to the lower side, either repeated short-term load or long-term load Also, it has an advantage that it exhibits high resistance to the above and does not cause deterioration of sound insulation performance and sound insulation performance for a long period of time. Further, by forming the kerf on the wood-based material, the unevenness on the surface of the concrete slab is well followed, and it is possible to prevent the rise and the like from occurring.

[0008]

SUMMARY OF THE INVENTION In the process of further conducting experiments and researches on the above-mentioned wood-based soundproof floor material, the present inventors have developed a continuous foam type soft or semi-rigid synthetic resin foam sheet as a back cushioning material. Since it is used, when laid on a concrete slab, the moisture contained in the concrete slab may reach the wood-based base material through the backside cushioning material. It has been found that there is a case in which the adhesive agent that adheres to and is adversely affected and peeling occurs, or the wood-based substrate is swollen to cause unevenness on the floor surface.

In order to avoid this, a synthetic resin film is laid in advance on a concrete slab at the time of construction, and a wood-based soundproof floor material is placed thereon, or an adhesive is applied to the back surface of the wood-based soundproof floor material. Prepared one with a synthetic resin film attached by, and arranged it on a concrete slab, etc., but in both cases, laying or It requires a sticking work and is not sufficient in terms of work efficiency.

Therefore, when the back cushioning material is formed, a synthetic resin film is laminated on one surface of a continuous foaming type soft or semi-rigid synthetic resin foamed sheet, which is a raw material, and is inserted into a hot platen press to synthesize. It is possible to fuse the synthetic resin film to the synthetic resin foam sheet side at the time of hot pressing by the hot platen press of the resin foam sheet, and form the back cushioning material with the synthetic resin film fused on one side without increasing the number of working steps. I tried. This method does not cause any particular problem in terms of work efficiency, but the synthetic resin film may be broken when the back cushion material is released from the hot platen press after fusion bonding. As a result, we have found that the yield of products is low and the manufacturing cost is affected.

An object of the present invention is to eliminate the above-mentioned inconveniences of a wood-based soundproof flooring material to which a continuous foaming type soft or semi-rigid synthetic resin foaming sheet is adhered as a back cushioning material. Provided is a wood-based soundproof flooring material and a method for producing the same that can reliably and easily form a water-impervious layer on the back surface of the back surface cushioning material, thereby effectively avoiding the inconvenience associated with absorption of moisture from a concrete slab. The purpose is to

[0012]

In order to achieve the above-mentioned object, the present invention is basically a wooden soundproof floor material obtained by laminating and integrating a wooden base material and a back cushion material. Is a continuous foam type soft or semi-rigid synthetic resin foam sheet that is compressed by hot pressing to reduce its thickness and at the same time has a large number of protrusions formed on one or both sides, and on its back surface is a water impermeable layer made of synthetic resin sol coating. Disclosed is a wood-based soundproof flooring characterized by being formed.

The present invention is also a method of manufacturing a wood-based soundproofing flooring material by laminating a wood-based base material and a back surface cushioning material, wherein the back surface of a continuous foam type soft or semi-rigid synthetic resin foam sheet is synthesized. By applying a resin sol coating and compressing it with a hot press to reduce the thickness, a back buffer material having a large number of convex portions on one surface or both surfaces and a water blocking layer on one surface is formed, and the back buffer material is formed. Also disclosed is a method for producing a wood-based soundproof flooring, which is characterized by laminating a wood-based base material.

In the present invention, the fact that the material of the continuous foaming type soft or semi-rigid synthetic resin foam sheet as the material of the back cushioning material and the synthetic resin sol material to be coated are the same material provides high fusion property. Postcard Although it is a particularly preferred embodiment, the intended purpose can be sufficiently achieved even with a combination of different materials.

[0015]

[Working] The wood-based soundproofing flooring material according to the present invention has a continuous foaming type soft or semi-rigid synthetic resin sheet as a cushioning material on the back side, which is compressed by hot pressing to reduce its thickness and at the same time, a large number of convex portions are formed on one or both sides. Since these materials are used, they have good sound insulation and sound insulation, exhibit high resistance to long-term load, and do not cause deterioration of sound insulation and sound insulation over a long period of time.

Further, when the kerf is formed in the wood-based material, it is possible to follow the irregularities on the surface of the concrete slab well and prevent the occurrence of floating or the like. Furthermore, by simply applying synthetic resin sol coating to the backside of the backside cushioning material, it is possible to simultaneously form an impermeable layer on the backside at the time of molding the backside cushioning material. Moisture on the concrete slab surface will not reach the wood-based base material of the wooden soundproof floor later, and when the concrete slab surface is bonded with an adhesive, the adhesive will enter the concave part of the backside cushioning material. Therefore, the sound insulation performance is not deteriorated, and the sound insulation performance is not deteriorated by the adhesive permeating the back cushioning material and hardening.

[0017]

The present invention will be described in more detail based on the following examples. FIG. 1 shows an example of a wooden soundproof flooring material according to the present invention. In the figure, reference numeral 1 denotes a surface decorative board, a wood-based base material 2 is laminated on the back surface thereof, and a back surface cushioning material 4 is further laminated on the back surface thereof to be integrated to form a wood-based soundproof floor material 10. To be done.

As the surface decorative board 1, any one used for a conventionally known wood-based soundproof flooring material such as a decorative veneer or a laminated laminated veneer on a decorative veneer can be arbitrarily used. Further, although not particularly shown, a groove may be provided in the longitudinal direction or the lateral direction. Its thickness is 0.3mm-3.0
The thing of about mm is normally used. The wood-based material 2 may be plywood, MDF (medium quality fiberboard), particle board, etc. In this embodiment, one plywood is used. The thickness is 6.0 mm to 9.0 m
Those of about m are usually used. In this example,
The wood-based board 2 is provided with a large number of kerfs 3 that do not penetrate through the back surface of the wood-based board 2 at predetermined intervals. This kerf 3
Is provided mainly for the purpose of reducing the rigidity of the wooden base material 2, and may be provided in the longitudinal direction, the lateral direction, or both directions thereof. The distance is 10m
The width may be about 1.0 mm to 3. mm.
0 mm, depth is 60-70% of the thickness of the wood-based substrate 2
It is preferably about the same. The cut groove 3 can be omitted.

The wood-based base material 2 is the wood-based soundproof floor material 1
It may be a single piece over 0, or may be a plurality of small pieces gathered together and accumulated in a predetermined size. The back surface cushioning member 4 is formed by using a continuous foaming type soft or semi-rigid synthetic resin foam sheet as a material and coating one surface thereof with a synthetic resin sol of the same material or a different material. As the resin species, polyurethane, vinyl chloride, polyvinyl acetate, etc. can be used, and polyurethane is particularly preferable.

In molding, for example, a polyurethane foam sheet having a required thickness coated on one side with urethane sol is prepared, and it is heat-compressed by a hot platen press having a large number of embosses, or the foam sheet is formed. It can be easily molded by heat-compressing it in the thickness direction with a flat plate-shaped hot platen press while sandwiching it with a punching plate. Simultaneously with molding, the water-proof layer 7 made of urethane sol is formed on the surface coated with urethane sol, and a large number of convex portions 5 and 6 are formed on both front and back surfaces. The shape of the convex portion is not particularly limited, and is circular, rhombic,
It is arbitrary such as a triangle or a quadrangle.

The amount of compression of the continuous foaming type soft or semi-rigid synthetic resin sheet in the hot platen press, the size and number of the convex portions 5 and 6 to be formed, etc., depend on the environment in which the wood-based soundproof floor material is used as a product. According to the experiments by the present inventors, a polyurethane foam sheet having a specific gravity of 0.025 to 0.05 and a thickness of 6 mm to 9 mm is 4 mm as a whole. It is compressed up to about 6 mm and the height on the front and back is 1 mm to 3 mm.
mm, an average diameter of 8 mm to 10 mm
If it is provided at a rate of about 000 to 8000 pieces / m ² , a sufficient sound insulating effect as well as a buffering effect can be achieved.

The synthetic resin sol needs to be coated in such an amount that a desired water-impervious layer is formed on the back side of the synthetic resin sheet when the synthetic resin sheet is thermocompressed to form the backside cushioning material. However, the amount thereof varies depending on the resin species of the synthetic resin sheet, the specific gravity or the bubble diameter. In the case of thermocompression molding using the above-mentioned polyurethane foam sheet, a coating having a thickness of about 1 mm was suitable.
If it is less than that, cracks occur, and if it is more than that, the sound insulation performance deteriorates.

The back cushioning material molded as described above is attached to the back surface of the wood base material using a vinyl adhesive such as vinyl acetate or EVA to complete the wood soundproof flooring material 10. The wood-based soundproof flooring material 10 has a continuous foam type soft or semi-rigid synthetic resin sheet as the back cushioning material 4 whose thickness is reduced by compression by hot pressing and at the same time a large number of convex portions 5 and 6 are formed on both sides. Since it is used, it has good sound insulation and sound insulation, exhibits high resistance to long-term load, and does not cause deterioration of sound insulation and sound insulation over a long period of time. In addition, since the kerf 3 is formed in the wood-based substrate 2, it is possible to follow the irregularities on the surface of the concrete slab well and prevent the occurrence of lifting and the like.
Soundproofing is also improved.

Furthermore, since the water-blocking layer 7 made of synthetic resin sol coating is formed on the back surface of the back surface cushioning material 4, the water content of the concrete slab surface reaches the wood-based base material 2 of the wood-based soundproof floor material 10 after installation. In addition, when the adhesive is adhered to the concrete slab surface via the adhesive, the adhesive enters the concave portion of the back surface cushioning material 4 to reduce the sound insulation performance, or the adhesive penetrates into the back surface cushioning material 4. The hardening does not reduce the sound insulation performance.

Numeral 8 is a non-woven fabric layer, which is a wood-based substrate 2
By intervening between the back cushioning material 4 and the back surface cushioning material 4, the adhesive strength between the two is increased to prevent the separation between the materials. The nonwoven fabric layer 8 is not necessary and can be omitted if the wood-based base material 2 and the back surface cushioning material 4 can be firmly bonded only by the adhesive. FIG. 2 shows another embodiment of the wooden soundproof flooring material according to the present invention. In this example, a foamed sheet 4 having one surface coated with a synthetic resin sol was prepared, and was coated with the synthetic resin sol using a flat plate-shaped hot platen press having a punching plate only on one surface side. It differs from the wood-based soundproof flooring material 10 shown in FIG. 1 in that the back surface cushioning material 4 formed by thermal compression is used with the surface facing the hot platen surface on which the punching plate is arranged. The wood-based soundproof flooring material 10 has a unique effect that it is easily and firmly adhered to the base material by forming the convex portion 6 on only one surface.

FIG. 3 shows still another embodiment of the wooden soundproof flooring material according to the present invention. In this example, a synthetic resin sol coated on one surface of the foam sheet 4 is prepared, and the surface coated with the synthetic resin sol is prepared by using a flat plate type hot platen press having a punching plate only on one surface side. The backside cushioning material 4 formed by thermal compression is used with the surface on the opposite side to the hot platen side on which the punching plate is arranged, and the convex portion 5 between the wood-based substrate 2 and the backside cushioning material 4 is used. 2 is different from the wooden soundproof flooring material 10 shown in FIG. 2 in that the non-woven fabric layer 8 is interposed on the bonded surface.

In this case, since the water-impervious layer 7 made of synthetic resin sol is formed on the flat surface side of the back surface cushioning member 4, there is an advantage that the more stable water-impervious layer 7 is formed. By interposing the non-woven fabric layer 8 on the adhesive surface between the base material 2 and the back surface cushioning material 4, the adhesive strength between the base material 2 and the back surface cushioning material 4 is increased as in the case of the embodiment of FIG.
The same applies to the fact that the non-woven fabric layer 8 is not essential.

The following wooden soundproof floor materials were actually prepared. That is, as the wood-based base material 10, 4 pieces of 75 mm x 900 mm of 5-ply plywood with a thickness of 9 mm, to which a veneer board having a thickness of 0.3 mm is adhered as a surface decorative material, are used in a geese-run type hot melt. A kerf 3 having a depth of 6 mm and a width of 2 mm was engraved on the back surface thereof at a pitch of 15 mm.

The back surface cushioning material 20 has a specific gravity of 0.032.
Prepare a polyurethane foam sheet with a thickness of 9 mm coated with urethane sol on the back side, heat it with a hot platen press having embossing, and form a water impermeable layer 7 of urethane sol of almost uniform thickness on the entire back side. Have and average diameter 1
The protrusions 5 and 6 having a height of 0 mm and a height of 2 mm were formed on both surfaces at a rate of 5000 pieces / m ² and were molded.

Then, they were laminated and integrated using a modified ethylene vinyl acetate adhesive to prepare a wood-based soundproof flooring material 10. When this wooden soundproof flooring material 10 was laid on the surface of the concrete slab, the rigidity of the entire wooden soundproofing floor material was lowered due to the formation of the kerfs 3 on the back surface of the wooden material base material 2. It was possible to follow the irregularities on the surface of the concrete slab and to lay it closely. After laying, according to the test specified in JIS A1418,
An impact was applied on the surface decorative board, and a light weight floor impact sound was measured downstairs. The results showed good sound insulation as shown in FIG. Also, after a load of 4 kg / cm ² was continuously applied for 48 hours, the lightweight floor impact sound was similarly measured.
There was no particular difference in the impact sound level. This is because the backside cushioning material compressed by the hot press has sufficient resistance to long-term load and does not cause so-called "sagging", so there was little change in the physical property values. It is supposed to be.

Further, in this state, after leaving for 7 days, the wooden soundproofing floor material was taken out and ruptured, and the back surface cushioning material was observed. As a result, the presence of the adhesive applied to the concrete slab surface was not seen.

[0032]

EFFECTS OF THE INVENTION In the wood-based soundproof flooring material according to the present invention, by applying synthetic resin sol coating on the back surface of the back surface cushioning material, a water-impervious layer is simultaneously formed integrally on the back surface of the back surface cushioning material without increasing the work steps. It becomes possible to do. Furthermore, after the construction on the concrete slab due to the molded impermeable layer, the moisture of the concrete slab surface does not reach the wood-based base material of the floor material, and the adhesive enters the concave part of the back surface cushioning material. The sound insulation performance is not deteriorated, and the sound insulation performance is not deteriorated by the adhesive permeating and curing the back surface cushioning material.

Further, as the backside cushioning material, a continuous foaming type soft or semi-hard synthetic resin sheet, which is thinned by compression by hot pressing and at the same time has a large number of convex portions formed on one or both sides, is used. It has good sound insulation and sound insulation, shows high resistance to long-term load, and does not cause deterioration of sound insulation and sound insulation over a long period of time. In addition, when the kerf is formed on the wood-based material, it is possible to follow the irregularities on the surface of the concrete slab well and prevent the rise of the concrete slab.

[Brief description of drawings]

FIG. 1 is a cross-sectional view showing an embodiment of a wooden soundproof flooring material according to the present invention.

FIG. 2 is a cross-sectional view showing another embodiment of the wooden soundproof flooring material according to the present invention.

FIG. 3 is a cross-sectional view showing still another embodiment of the wooden soundproof flooring material according to the present invention.

FIG. 4 is a cross-sectional view showing an example of a conventionally known wooden soundproof flooring material.

FIG. 5 is a cross-sectional view showing another example of a conventionally known wooden soundproof floor material.

FIG. 6 is a cross-sectional view showing still another example of a conventional wooden soundproof floor material.

FIG. 7 is a cross-sectional view showing a wooden soundproof flooring material which is a basis of the wooden soundproofing floor material according to the present invention.

FIG. 8 is a graph showing the test results prescribed in JIS A1418 for one example of the wooden soundproofing flooring material according to the present invention.

[Explanation of symbols]

DESCRIPTION OF SYMBOLS 10 ... Wood-based soundproof flooring material, 1 ... Surface decorative board, 2 ... Wood-based base material, 3 ... Cutting groove, 4 ... Back cushioning material, 5 ... Front side convex part, 6 ...
Back side convex part, 7 ... Water impermeable layer by synthetic resin sol coating

Claims (4)

[Claims] 1. A wooden soundproofing floor material comprising a wooden base material and a back cushioning material laminated and integrated, wherein the back cushioning material is a continuous foaming type soft or semi-rigid synthetic resin foamed sheet that is compressed by hot pressing to a thickness. A wood-based soundproof flooring material, characterized in that a plurality of convex portions are formed on one surface or both surfaces at the same time as a thin layer, and a water barrier layer formed by a synthetic resin sol coating is formed on the back surface thereof. 2. The wood-based soundproof flooring material according to claim 1, wherein the continuous foaming soft or semi-rigid synthetic resin foam sheet is a urethane foam sheet and the synthetic resin sol coating is a urethane sol coating. 3. The wood-based soundproof flooring material according to claim 1, wherein the wood-based base material has a kerf formed on the back surface thereof. 4. A method for producing a wood-based soundproofing flooring material, which comprises laminating a wood-based base material and a back surface cushioning material, wherein the back surface of a continuous foam type soft or semi-rigid synthetic resin foam sheet is coated with synthetic resin sol. And then compressing it with a hot press to reduce the thickness and at the same time form a backside cushioning material with a large number of protrusions on one or both sides and a water-impervious layer on one side. A method for producing a wood-based soundproof flooring, which comprises laminating it on a wood-based base material.