JPH10231613A - Floor member and apartment house built by using the same - Google Patents

Abstract

PROBLEM TO BE SOLVED: To improve the walking feeling while satisfying a soundproof function, by specifying the peak value, the half width and the deflection at the time when the variation with time of acceleration at the time when a hammer to be used for the measuring collides with the floor face, is measured, when the level of the impulse sound of the floor is measured by a specified generator of impulse sound of the floor. SOLUTION: An adhesive or the like such as vinyl acetate emulsions is applied on both faces of a rigid foamed body B such as a rigid polyurethane foamed body with a foaming expansibility of 5-25 times and a rigid board A such as veneer or plywood and a soft foamed body C such as polyethylene foamed body with a foaming expansibility of 10-30 times as a surface layer, are laminated on both faces thereof to form a floor member. The impulsion sound level of the floor is measured by a floor-impulse sound generator made on the basis of JIS A1418 and the variation of acceleration at the time when the hammer used for the measuring collides with the floor face is measured. The peak value of the measured figures is made 15G or smaller and the half width is made 2ms or higher and further, the strain is made 3mm or smaller against the compressive stress of 4kg/cm<2> .

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a floor material and a condominium using the same, and more particularly, to a floor material having good soundproofing performance and excellent walking sensation and a condominium using the same.

[0002]

2. Description of the Related Art Conventionally, a grain of wood has been applied to the surface.
A sound-insulating flooring is one in which a buffer layer such as a resin foam or a nonwoven fabric is laminated and integrated on the back surface of a plywood having a thickness of about 8 to 10 mm for sound insulation. The superiority of the soundproofing performance depends on the buffer layer. In particular, in the case of apartments, since the driving body is often constructed of concrete, the vibration of the flooring material is easily transmitted to the outdoor as it is, and a flooring material with good soundproofing performance has been desired.

[0003] However, if the thickness of the buffer layer is sufficiently large, there is no problem in terms of soundproofing. However, when heavy objects such as heavy furniture are placed, the floor sinks locally, and every time the user walks, the floor sinks and sinks. This causes a problem that walking comfort is reduced.

Therefore, 1) a method of stacking two types of foams having different magnifications as a buffer layer to provide a flooring material which satisfies the soundproofing performance and has a small floor deformation under load (actually 3─21395) 2) A method of providing a groove in a wooden floor material to reduce the apparent elastic modulus and improve the soundproofing performance (Japanese Patent Laid-Open No. 7-4011, etc.) has been proposed. I have.

[0005]

However, according to the method (1), a buffer layer of about 5 mm is required to satisfy the soundproofing performance simply by changing the expansion ratio, and the soundproofing performance is improved. However, when a person walks on the flooring material, a so-called "sickness sickness phenomenon" of "fluffy" occurs, and there is a problem that walking feeling is deteriorated. Originally from 70000 to 1200
There 00kg / cm ^2, cut grooves, the apparent modulus of elasticity be lowered (the thickness of the sample, the elastic modulus of the time that is calculated assuming that no cut grooves), since there is a break in question, deep It can not be cut, after all 5000-7000kg / c
The limit was to reduce the flexural modulus to m ² (measured value of a commercial product), and the soundproofing performance was also insufficient.

An object of the present invention is to solve the above-mentioned problems and to provide a flooring material which satisfies the soundproofing performance and has an excellent walking feeling and an apartment using the same.

[0007]

The flooring material according to claim 1 (the present invention 1) is used for measuring a floor impact sound level when the floor impact sound level is measured by a floor impact sound generator in accordance with JIS A1418. The peak value when measuring the time change of acceleration when the hammer collides with the floor surface is 15 G or less, the half width is 2 ms or more, and the amount of strain when a compressive stress of 4 kg / cm ² is given is 3 mm or less.

[0008] In the first aspect of the present invention, the first satisfying of the flooring material.
The condition is that when a floor impact sound level is measured by a floor impact sound generator in accordance with JIS A1418, a time change of acceleration when a hammer used for the measurement collides with a floor surface is measured. The peak value is 15 G or less, and the half value width is 2 ms or more.

If the peak value of the time change of the acceleration is too large, the impact sound from the flooring material is increased and the soundproofing performance is reduced. Therefore, the acceleration is limited to 15 G or less, and preferably 12G or less.
G or less, usually 7 G or more (If the peak value is too small, the half width described later tends to be too large, or the amount of strain when compressive stress is applied tends to be too large).

[0010] The half width is a peak of the ordinate (acceleration axis) in a curve obtained by measuring a floor impact sound level and smoothing a curve showing the relationship between acceleration and time, which is obtained within a predetermined time. The absolute value of the time width measured at half the value. If the half width is too short, the energy of the impact sound source (hammer in this measurement) is rapidly absorbed or transmitted to the floor material, and the energy is transmitted to the outside as an impact sound from the floor material. It is limited to 2 ms or more because the soundproofing performance is reduced, and is preferably 3 ms or more, and usually 5 ms or less (if the half width is too long, vibration is generated for a long time, which is not preferable).

[0011] The above floor impact sound is given according to JIS A141.
In accordance with No. 8, a lightweight floor impact sound generator shall be used as the floor impact sound generator in principle. It should be noted that a heavy floor impact sound generator may be used as long as it does not significantly affect the evaluation of the sound insulation performance of the flooring material, or may be improved and simplified as necessary as described below. You may.

In accordance with JIS A1418, a lightweight floor impact sound generator, the test is performed under the following conditions.

1) As a principle, a light-weight impact source is provided with five hammers arranged at equal intervals on a straight line, and the center distance between the hammers at both ends is 40 cm. However, depending on the size of the test piece, the number of hammers is at least good.
In addition, when using a plurality of hammers to affect the measurement of the half width (that is, when the half width is very long), the number of hammers may be one,
The time interval to be described later may be lengthened (as described above, if the half width is too long, vibration is generated for a long time, which is not preferable).

2) The effective mass of each hammer is 500 ±
12.5 g.

3) The hammer (each) falls vertically and collides with the floor surface.
It is equivalent to the case of free fall from a height of ± 0.1 cm.

4) The time interval between impacts that are continuously generated by the (hammer) hammer is, in principle, 100 ± 5 ms. However, when the measurement of the half width is affected (that is, when the half width is very long), as described above, the number of hammers may be one or the time interval may be long.

5) Each of the hammers is cylindrical and made of steel having a diameter of 3 cm, and the impact surface of the head of the hammer against the floor is, in principle, a convex spherical surface having a radius of curvature of 50 cm. However, when the peak value of the time change of the acceleration is small or the half width is large, when the hammer collides with the floor, the hammer bounces off the floor and collides twice with this radius of curvature. If this affects the measurement of the half width, the radius of curvature may be reduced.

Other conditions are JIS A1418 (method of measuring floor impact sound level at building site) 2.2.
Follow (1).

Time change of acceleration The method of measuring the time change of acceleration is not particularly limited, and 1 ms
Any commercially available accelerometer (e.g., a change in the relative position of the mass with respect to the case that can be measured by a potentiometer) can be appropriately used as long as the following time change can be measured. The measurement terminal is fixed to a location other than the impact surface), and the change in acceleration from the fall of the hammer to the impact on the floor surface to the stop is measured.

The obtained acceleration-time curve is smoothed as necessary to obtain a peak value and a half width, and it is determined whether or not the obtained peak value and the half width are included in the above range. Select the flooring materials contained in the building as appropriate.

According to the first aspect of the present invention, the second satisfactory flooring material is used.
Is that the amount of strain when a compressive stress of 4 kg / cm ² is given is 3 mm or less.

If the amount of distortion is too large, walking comfort is reduced. Therefore, the amount of distortion when a compressive stress of 4 kg / cm ² is applied is limited to 3 mm or less, and usually 1.0 mm or more (distortion). If the amount is too small, the above-described soundproofing performance tends to decrease), preferably 1.5 to 2.5 m
m, more preferably 1.8 to 2.2 mm.

The method of applying the above-mentioned compressive stress is not particularly limited, but it is preferable to conform to JIS K7220 (a compression test method for hard foamed plastic). Note that the strain amount here is obtained by extending the steepest straight line portion of the compressive stress / strain curve to the zero pressure stress line using a straight line ruler, as in the case of obtaining the compressive strain and the proportional limit strain in JIS K7220. , The amount of distortion from the zero deformation point when the zero deformation point is plotted. Therefore, it does not include distortion due to unevenness given to the flooring surface in order to increase the apparent distortion amount.

The flooring material may be provided with irregularities, if necessary, for preventing slippage, projections for visually impaired persons, and for locking furniture and the like. However, it is needless to say that these projections are not included when calculating the amount of distortion.

The peak value of the time change of the acceleration of the hammer is 15 G or less, and the half width is 2 ms or more.
The amount of strain when applying a compressive stress of kg / cm ² is 3 mm
As the floor material below, for example, a specific hard plate-like body,
Specific examples thereof include those formed of a laminate having a two-layer structure with a hard thermoplastic resin foam, and a hard plate-like body is used as a surface layer shown below, and a hard foam and a soft foam are laminated. Are preferred.

The flooring material according to claim 2 (the present invention 2) is the flooring material of the present invention 1, wherein a hard plate-like body is used as a surface layer, and a hard foam and a soft foam are laminated.

The hard plate is not particularly limited as long as it does not easily break or be damaged when subjected to a load. For example, a single plate, a plywood, a resin plate, a fiber reinforced synthetic resin plate and the like can be used. No. These may be used alone, but are generally used by decorating the surface.

Single veneer Normally, it is a single veneer called a "bare board", which can be made into a decorative board excellent in wood texture only by applying varnish or oil.

Plywood Conventionally used floor materials (including those called medium density fiberboard "MDF") can be used.

Resin plate A plate made of a so-called hard resin such as a polyethylene plate (ultra-high molecular weight polyethylene plate is particularly preferable), a polypropylene plate, or a polyvinyl chloride plate is preferably used.

Fiber reinforced synthetic resin plate Thermosetting polyester resin plate, epoxy resin plate reinforced with glass fiber, hard polyurethane plate (foamed 2-3 times if necessary), polyvinyl chloride plate Etc. can be used.

If the thickness of the hard plate is too thin, the strength and rigidity are insufficient, and if it is too thick, the floor impact sound insulation performance is reduced. Therefore, the thickness is preferably 1 to 5 mm, more preferably 2 to 4 mm.
It is.

Surface Decoration The surface of the hard plate may be decorated by printing a wood grain pattern, a marble pattern, a granite pattern, etc. in order to enhance the design.

Decorative sheet-like material In order to decorate the surface, a decorative sheet-like material for enhancing the design may be further laminated on the surface of the hard plate-like body. As the decorative sheet, a synthetic resin sheet on which a wood grain pattern, a marble pattern, a granite pattern, or the like is printed, for example, a vinyl chloride sheet can be used. Alternatively, a veneer made by slicing a commercially available wood may be adhered to the surface of the hard plate as a decorative sheet.

As the adhesive or pressure-sensitive adhesive for bonding the decorative sheet to the hard plate, a commonly used acrylic adhesive or a natural or synthetic rubber adhesive can be used. .

Surface Coating In the present invention 2, if necessary, a surface (a surface of a hard plate or a decorative sheet is further laminated on the surface in order to enhance the abrasion resistance of the surface or develop a color and gloss). In this case, a coating may be applied on the surface of the decorative sheet. As such a coating method, a method generally called a ceramic coating can be adopted, and thereby, the abrasion resistance of the surface can be enhanced. The ceramic coating can be performed by applying and drying a paint such as an acrylic silicon-based, an acrylic urethane-based, or an alkyl silicate-based containing an alkyl group having 10 or less carbon atoms containing inorganic fine particles such as colloidal silica.

The hard foam is a material having a relatively high compression modulus and flexural modulus relative to a soft foam described later. When the hard plate and the soft foam are laminated,
What satisfies the conditions of the present invention 1 may be appropriately selected.

As the rigid foam, JIS K72
It is preferable that the compression modulus measured according to JIS 20 is 4 kg / cm ² or more and the flexural modulus measured according to JIS K7203 is 3000 kg / cm ² or less.

If the compressive modulus is too small, the material will float and sink due to the weight of a person or the load of furniture, and the amount of distortion when a compressive stress of 4 kg / cm ² is applied will often be 3 mm or less. If the flexural modulus is too large, the floor impact sound insulation performance is deteriorated, and the peak value when measuring the time change of the acceleration often exceeds 15 G, or its half-value width is less than 2 ms in many cases.

As the above-mentioned rigid foam, JP-A-8-11
No. 2873, a rigid polyurethane foam having a magnification of 5 to 25 times, and a polystyrene foam having a magnification of 10 to 30 times, and the like, as shown below, a continuous foam layer made of a thermoplastic resin and A high-foamed body made of a thermoplastic resin disposed on at least one side of the continuous foam layer, and a low-foamed thin film made of a thermoplastic resin covering the outer surface of the high-foamed body, wherein the plurality of high-foamed bodies Is preferably a thermoplastic resin foam which is thermally fused to each other via the low foaming thin film.

The thermoplastic resin used for the continuous foamed layer and the thermoplastic resin used for the low foamed thin film and the high foamed body do not need to be the same resin, but have a high heat fusion force and improved bending strength. Therefore, it is preferable to use the same type of resin.

The expansion ratio of the hard foam is usually 2 to 20 times, preferably 5 to 15 times, more preferably 5 to 15 times when a polyolefin resin is used for both the continuous foam layer, the low foam thin film and the high foam. It is 7 to 12 times.

The method for producing the thermoplastic resin foam is not particularly limited. For example, foamable thermoplastic resin granules containing a foaming agent are arranged substantially uniformly in a plane. A foamable thermoplastic resin sheet in which the foamable thermoplastic resin granules are integrally connected via a foamable thermoplastic resin thin film is obtained by heating and foaming at a temperature equal to or higher than the decomposition temperature of a foaming agent. Can be.

The thermoplastic resin used for the expandable thermoplastic resin granules and the expandable thermoplastic resin thin film constituting the expandable thermoplastic resin sheet is not particularly limited as long as it is a foamable thermoplastic resin. It is not something to be done. As such a thermoplastic resin, for example, low-density polyethylene, high-density polyethylene, linear low-density polyethylene (hereinafter, “polyethylene” refers to low-density polyethylene, high-density polyethylene, linear low-density polyethylene,
Or a mixture thereof. ), Random polypropylene, homopolypropylene, block polypropylene (hereinafter, “polypropylene” refers to random polypropylene, homopolypropylene, block polypropylene, or a mixture thereof), and ethylene vinyl acetate resin. Olefin copolymers of polyvinyl chloride, chlorinated polyvinyl chloride, AB
Examples include S resin, polystyrene, polycarbonate, polyamide, polyvinylidene fluoride, polyphenylene sulfide, polysulfone, polyether ketone, and copolymers thereof, and these may be used alone or in combination.

Among the above thermoplastic resins, an olefin resin such as polyethylene or polypropylene or a mixture thereof is preferable because the surface smoothness of the obtained thermoplastic resin foam can be enhanced, and both the surface smoothness and the compressive strength are satisfied. For this purpose, high-density polyethylene, homopolypropylene or a mixture containing at least one of these is particularly preferred.

The thermoplastic resin used for the foamable thermoplastic resin granules and the thermoplastic resin used for the foamable thermoplastic resin thin film do not need to be the same resin. From the viewpoint of the above, it is preferable to use the same type of resin.

As the thermoplastic resin used for the foamable thermoplastic resin sheet, it is preferable to use a crosslinked thermoplastic resin in order to improve the expansion ratio and reduce the weight of the obtained thermoplastic resin foam. . As a crosslinking method,
The method is not particularly limited. For example, after melt-kneading a silane graft polymer with a thermoplastic resin, a water treatment is performed, and a method of crosslinking, and a thermoplastic resin is melt-kneaded with a peroxide at a temperature lower than the decomposition temperature of the peroxide. Thereafter, a method of crosslinking by heating to a temperature equal to or higher than the decomposition temperature of the peroxide, a method of crosslinking by irradiating radiation, and the like can be given. However, a cross-linking method using a silane graft polymer is preferable in order to obtain a high cross-linking resin and a low (no) cross-linking resin described later.

The silane-grafted polymer is not particularly limited, and examples thereof include silane-grafted polyethylene and silane-grafted polypropylene.

The above-mentioned water treatment methods include a method of immersion in water and a method of exposure to water vapor.
When the treatment is performed at a temperature higher than 00 ° C., the treatment may be performed under pressure.

If the temperature of water and water vapor in the above-mentioned water treatment is low, the rate of the crosslinking reaction decreases, and if the temperature is too high, the foamable thermoplastic resin sticks with heat.
0 ° C is preferred, and 90 to 120 ° C is particularly preferred.

If the time of the water treatment is short, the crosslinking reaction may not proceed completely. Therefore, the water treatment time is preferably in the range of 0.5 to 12 hours.

The method of mixing the silane graft polymer is as follows:
There is no particular limitation on the method as long as it can be uniformly mixed. For example, a method in which a thermoplastic resin and a silane graft polymer are supplied to a single-screw or twin-screw extruder and melt-kneaded, a method of melt-kneading using a roll, a method of melt-kneading using a kneader, and the like are exemplified.

If the added amount of the silane graft polymer is too large, crosslinking is excessively performed, and the expansion ratio of the obtained thermoplastic resin foam is lowered. If the added amount is too small, cells are broken and uniform foam cells are formed. Therefore, the amount of the silane graft polymer to be added is preferably 5 to 50% by weight, more preferably 20 to 35%, based on the total thermoplastic resin.

When silane crosslinking is performed using a silane graft polymer, a silane crosslinking catalyst may be used if necessary. The silane crosslinking catalyst is not particularly limited as long as it promotes a crosslinking reaction between the silane graft polymers.For example, dibutyltin diacetate, dibutyltin dilaurate, dioctyltin dilaurate, tin octoate,
Examples include tin oleate, lead octane, zinc 2-ethylhexanoate, cobalt octoate, lead naphthenate, zinc cabrate, and zinc stearate.

When the addition amount of the silane crosslinking catalyst increases, the expansion ratio of the obtained thermoplastic resin foam decreases,
Further, when the amount decreases, the crosslinking reaction rate decreases, and it takes time for water treatment. Therefore, based on 100 parts by weight of the thermoplastic resin, the addition amount of the silane crosslinking catalyst is preferably in the range of 0.001 to 10 parts by weight. , 0.01 to 0.1 part by weight is more preferable.

The thermoplastic resin used for the foamable thermoplastic resin granules is not particularly limited as described above, but may be a foaming agent, a highly crosslinked thermoplastic resin having almost no compatibility with each other, a low crosslinked or noncrosslinked thermoplastic resin. Preferably, it is a mixture with a thermoplastic resin. In this case, the low-crosslinked or non-crosslinked thermoplastic resin easily flows during foaming,
The surface smoothness of the obtained thermoplastic resin foam is enhanced.

As the thermoplastic resin (before crosslinking) used for the two types of resins having little compatibility with each other, two types of the above-mentioned thermoplastic resins [hereinafter referred to as the crosslinking performance of the resin itself, Regardless, the resin that forms a highly crosslinked thermoplastic resin is referred to as a “highly crosslinkable resin”, and the resin that forms a low crosslinked or noncrosslinked thermoplastic resin is referred to as a “low (no) crosslinked resin”
Is appropriately selected and used.

When the difference in the melt index (MI) between the highly crosslinkable resin and the low (non) crosslinkable resin becomes large, the highly crosslinked thermoplastic resin obtained by crosslinking and the low crosslinked or noncrosslinked thermoplastic resin become Is very coarsely dispersed, so that the expansion ratio of the obtained foam is reduced and becomes smaller, and the high crosslinked thermoplastic resin obtained by crosslinking, the compatibility of the low crosslinked or non-crosslinked thermoplastic resin becomes high, and the obtained. Because the surface smoothness of the thermoplastic resin foam may be reduced, the highly crosslinked thermoplastic resin and the low crosslinked or non-crosslinked thermoplastic resin are uniformly and finely dispersed without being compatible with each other,
In order to obtain a thermoplastic resin foam having a high expansion ratio, MI
Is preferably 5 to 13 g / 10 minutes, and 7 to 11 g / 1.
0 minutes is more preferred.

Note that MI in this specification is JIS.
It is a value measured according to K7210. In order to obtain a highly crosslinked thermoplastic resin obtained by crosslinking, a low crosslinked or non-crosslinked thermoplastic resin is uniformly and finely dispersed, and to obtain a thermoplastic resin foam having a high expansion ratio with excellent surface smoothness,
The mixing ratio of the highly crosslinkable resin to the low (non-) crosslinkable resin is preferably from 2: 8 to 8: 2 by weight.

If the degree of cross-linking of the highly cross-linked thermoplastic resin is too high, the cross-linking is excessively performed, and the expansion ratio of the obtained thermoplastic resin foam is lowered. Since a cell may not be obtained, the ultimate gel fraction based on the total amount of the thermoplastic resin is preferably 5 to 60% by weight.

If the degree of cross-linking of the low-crosslinking or non-crosslinking thermoplastic resin is high, the crosslinking is excessive, the fluidity of the obtained thermoplastic resin foam is reduced, and the surface smoothness of the thermoplastic resin foam is lowered. Therefore, the gel fraction as an index of the degree of crosslinking is preferably 5% by weight or less, more preferably 3% by weight or less.

The gel fraction in the present specification refers to the percentage by weight of the residue weight after immersing the crosslinked resin component in xylene at 120 ° C. for 24 hours with respect to the weight of the crosslinked resin component before immersion in xylene.

As a method for preparing a mixture of a highly crosslinked thermoplastic resin having little compatibility with each other and a low crosslinked or non-crosslinked thermoplastic resin, the above two types of thermoplastic resins are mixed, and only the highly crosslinked resin is mixed. Or by cross-linking the highly crosslinkable resin preferentially over the low (no) crosslinkable resin.

Examples of a method of preferentially crosslinking a highly crosslinkable resin alone or a highly crosslinkable resin over a low (non) crosslinkable resin include, for example, only a highly crosslinkable resin or a more highly crosslinkable resin than a low (non) crosslinkable resin. A method of crosslinking using a crosslinking agent that preferentially crosslinks the resin, in the first step, a highly crosslinkable resin having a crosslinkable functional group is mixed and crosslinked with a highly crosslinkable resin of the same type to form a highly crosslinked thermoplastic resin. After the formation, in a second stage, a method of mixing this with a low (non-) crosslinkable resin may be used.

It should be noted that the highly crosslinked thermoplastic resin and the low crosslinked or non-crosslinked thermoplastic resin can be uniformly and finely dispersed, that the highly crosslinked resin can be preferentially crosslinked, and that the thermoplastic resin can be easily prepared. From the above, a crosslinkable resin having the same melt index as the highly crosslinkable resin and having a crosslinkable functional group, and the same type of crosslinkable resin as the high crosslinkable resin and the low (no) crosslinkable resin are mixed, Is most preferred.

The crosslinkable resin of the same type as the highly crosslinkable resin having a crosslinkable functional group having almost the same melt index as the highly crosslinkable resin may be a thermoplastic resin having a reactive functional group and capable of being crosslinked. It is not particularly limited. Examples of such a functional group include the above-described thermoplastic resins having an unsaturated group such as a vinyl group, an allyl group, and a propenyl group, a hydroxyl group, a carboxyl group, an epoxy group, an amino group, a silanol group, and a silanate group. Can be

Specific examples of the highly crosslinkable resin include maleic acid-modified polyethylene, maleic acid-modified polypropylene, silane-modified polyethylene, and silane-modified polypropylene. Silane-modified polyethylene and silane-modified polypropylene are the most preferred because it is easy to crosslink highly crosslinkable resin only or only highly crosslinkable resin over low (no) crosslinkable resin, and easy to crosslink after mixing. preferable.

The method for crosslinking the highly crosslinkable resin having the above-mentioned crosslinkable functional group includes a method of crosslinking using a peroxide, a method of crosslinking with an isocyanate, a method of crosslinking with an amine, and a method of crosslinking with a reactive functional group. And then water crosslinking.

Since the crosslinking after mixing is easy, the method of hydrolyzing the reactive functional groups and then crosslinking with water is most preferable.

Blowing Agent In the present invention, a pyrolytic blowing agent is used as the blowing agent contained in the expandable thermoplastic resin granules and the expandable thermoplastic resin thin film.

The thermal decomposition type foaming agent is not particularly limited as long as it has a decomposition temperature higher than the melting temperature of the thermoplastic resin used. Examples thereof include sodium bicarbonate, ammonium carbonate, ammonium bicarbonate and azide. Compounds, inorganic pyrolytic blowing agents such as sodium borohydride; azodicarbonamide, azobisformamide, azobisisobutyronitrile, barium azodicarboxylate, diazoaminobenzene, N, N'-dinitrosopentamethylenetetramine , P-toluenesulfonylhydrazide, P, P'-oxybisbenzenesulfonylhydrazide, trihydrazinotriazine, and the like. When a polyolefin-based ethylene resin is used as the thermoplastic resin, the decomposition temperature and decomposition rate can be easily adjusted. A large amount of gas is generated, and Zodicarbonamide is preferred.

If the amount of the thermal decomposition type foaming agent is too large, the foam breaks and uniform cells are not formed. On the other hand, if the amount is too small, the foaming may not be sufficiently performed. It is preferable that the content be contained in a proportion of 1 to 25 parts by weight based on 100 parts by weight of the thermoplastic resin.

In order to increase the strength of the foamed thermoplastic resin, the thermoplastic resin used for the foamable thermoplastic resin granules and the foamable thermoplastic resin thin film may be added , if necessary, to the thermoplastic resin. And reinforcing materials such as short glass fibers, short carbon fibers, and short polyester fibers; and fillers such as calcium carbonate, aluminum hydroxide, and glass powder.

When the above-mentioned short fibers are added as a reinforcing material, if the adding ratio of the reinforcing material is too large, the cells are broken at the time of foaming, so that a foam having a high expansion ratio cannot be obtained. 20 parts by weight or less, preferably 10 parts by weight or less, based on 100 parts by weight of the thermoplastic resin.

If the length of the short fibers is too long, the cells are broken during foaming, and a foam having a high expansion ratio cannot be obtained. If the length is too short, the effect of reinforcing the obtained foam is sufficiently obtained. The length of the short fibers may be 1 to 20
mm is preferred, and 3-5 mm is particularly preferred.

When the above-mentioned filler is added, if the amount is large, the cells are broken at the time of foaming, and a foam having a high expansion ratio cannot be obtained. If the amount is small, the obtained foam is reinforced. Effect may not be obtained sufficiently. Therefore, the addition amount of the filler is preferably 100 parts by weight or less, particularly preferably 50 parts by weight or less, based on 100 parts by weight of the thermoplastic resin.

Foamable thermoplastic resin sheet The foamable thermoplastic resin sheet which can suitably obtain the rigid foam according to the second aspect of the present invention has a structure in which foamable thermoplastic resin granules are substantially uniformly arranged in a plane. The foamable thermoplastic resin particles are integrally connected via a foamable thermoplastic resin thin film. The shape of the expandable thermoplastic resin granules is not particularly limited, and includes, for example, a hexagon, a column, and a sphere, but when the expandable thermoplastic resin granules foam, the foaming is uniformly performed. For making this work, a column shape is most preferable.

When the expandable thermoplastic resin particles are cylindrical, the diameter thereof is not particularly limited because it varies depending on the expansion ratio and thickness of the target foam. If it is too low, the column is melted by heating during foaming, easily deformed and one-dimensional foamability cannot be exhibited, and the thickness accuracy and weight accuracy vary greatly.
Also, the surface smoothness is reduced. Therefore, when the expandable thermoplastic resin particles are cylindrical, the diameter thereof is preferably 1 mm to 30 mm, and particularly preferably 2 mm to 20 mm.

When the expandable thermoplastic resin particles are columnar, the height thereof is not particularly limited because it varies depending on the expansion ratio and thickness of the target foam. If it is too low, it will be foamed simultaneously with the foamable thermoplastic resin thin film, so that it will expand significantly in the width and longitudinal directions. Therefore, the height of the columnar foamable thermoplastic resin granules is preferably 1 mm to 30 mm, particularly preferably 2 mm to 20 mm.

The distance between the foamable thermoplastic resin granules is not particularly limited because it varies depending on the expansion ratio, thickness, etc. of the target foam. Insufficient filling may occur when the plastic resin particles are foamed. If the length is too short, the area that can be expanded during foaming is insufficient, and the particles tend to expand significantly in the width direction and the longitudinal direction. Therefore, the center-to-center distance between the foamable thermoplastic resin granules is preferably 2 mm to 50 mm, and 3 mm to
30 mm is particularly preferred.

In order to improve the thickness accuracy and weight accuracy of the finally obtained foam, to provide high surface smoothness and to make the expansion ratio uniform, the foamable thermoplastic resin granules are formed by foaming heat. It is necessary that the plastic resin sheet is arranged almost uniformly in a plane. The mode of arranging the thermoplastic resin particles substantially uniformly in a plane is not particularly limited, and the thermoplastic resin particles may be arranged in a lattice shape. Since the high foam obtained by foaming the thermoplastic resin granules has a hexagonal column shape, a pseudo honeycomb structure is formed. Therefore, the surface smoothness of the obtained foam is enhanced, and the compressive strength is improved. Therefore, preferably, the foamable thermoplastic resin particles are arranged in a staggered manner.

The thickness of the foamable thermoplastic resin thin film is not particularly limited because it varies depending on the foaming ratio, thickness, and the like of the intended foam. When the resin granules are moved, the expansion in the width direction and the longitudinal direction increases, and when the resin granules are too thin, the foamable thermoplastic resin granules cannot be held. Therefore, the thickness of the foamable thermoplastic resin thin film is 0.05 to 3 m.
m is preferable, and 0.1 to 2 mm is particularly preferable.

Method for Producing a Foamable Thermoplastic Resin Sheet The method for producing the above-mentioned foamable thermoplastic resin sheet is not particularly limited. For example, 1) constituting a foamable thermoplastic resin sheet The thermoplastic resin and the foaming agent are supplied to the injection molding machine, melt-kneaded at a temperature lower than the decomposition temperature of the pyrolytic foaming agent, and injected into a mold having a concave portion corresponding to the shape of the foamable thermoplastic resin granules. 2) The thermoplastic resin and the foaming agent constituting the foamable thermoplastic resin sheet are supplied to an extruder and cooled at a temperature lower than the decomposition temperature of the pyrolytic foaming agent. After melt-kneading, the sheet-like foamable thermoplastic resin in a softened state has a clearance smaller than the thickness of the sheet-like foamable thermoplastic resin, and a large number of recesses are uniformly arranged on at least one outer peripheral surface. Different Introduced to a pair of forming roll that rotates in direction, after the press-fitted portion of the sheet-shaped foamable thermoplastic resin softened state into the recess, cooling method for releasing being most preferred.

The method 2) will be described in more detail.
First, in order to obtain a sheet-shaped foamable thermoplastic resin in a softened state, a method of melt-kneading and extruding the foamable thermoplastic resin with an extruder or a method of melting using a calender roll is usually used. The melting used is most preferable from the viewpoint of continuous weight accuracy and quantitativeness.

The foamed thermoplastic resin in the softened state has the form
The form is not particularly limited as long as it can be continuously formed, and includes a sheet form, a large number of strand forms, and the like. The sheet form is most preferable from the viewpoint of quantitativeness in the direction perpendicular to the flow (width direction).

The recesses on the outer peripheral surface of the shaping roll are preferably arranged substantially uniformly in order to improve the weight accuracy and the thickness accuracy of the foamable thermoplastic resin sheet obtained.
The arrangement of the concave portions on the outer peripheral surface of the shaping roll is not particularly limited as long as it is substantially uniform over the entire outer peripheral surface of the shaping roll, but since it is more uniform, it is most preferably arranged in a lattice or staggered manner. .

The shape of the concave portion on the outer peripheral surface of the shaping roll is not particularly limited, and examples thereof include a hexagonal shape, a columnar shape, a spherical shape, and the like. The column shape is most preferable because the body can be easily molded uniformly and the mold can be easily released after cooling.

When the shape of the concave portion on the outer peripheral surface of the forming roll is cylindrical, the diameter of the cylindrical column is not particularly limited because it varies depending on the shape of the target foamable thermoplastic resin sheet, but is too large. And the mold release after cooling is difficult to perform, the foamable thermoplastic resin thin film is broken, and if it is too small, the foamable thermoplastic resin granules are broken at the time of mold release after cooling.
30 mm is preferable, and 2 mm to 20 mm is particularly preferable.

When the shape of the concave portion on the outer peripheral surface of the shaping roll is cylindrical, the height of the cylinder is not particularly limited because it varies depending on the shape of the target foamable thermoplastic resin sheet. If too low, the mold release after cooling is difficult to perform, the foamable thermoplastic resin thin film is broken, and if it is too low, a foamable thermoplastic resin sheet that can perform one-dimensional foaming cannot be formed,
1 mm to 30 mm is preferable, and 2 mm to 20 mm is particularly preferable.

The clearance of the shaping roll needs to be smaller than the thickness of the softened sheet-like foamable thermoplastic resin. Therefore, if it is in this range, it is not particularly limited because it changes depending on the shape of the target foamable thermoplastic resin sheet, but if it is too thick, a foamable thermoplastic resin sheet that can perform one-dimensional foaming is formed. If it is too thin, the foamable thermoplastic resin thin film is easily broken at the time of release after cooling.
m to 2 mm are particularly preferred.

The method of press-fitting a part of the softened sheet-like foamable thermoplastic resin into the concave portion is performed by changing the clearance of the pair of shaping rolls into the softened sheet-like foamable thermoplastic resin. This is achieved by applying pressure from a shaping roll.

The method of cooling the soft foamed sheet-like thermoplastic resin which has been partially press-fitted and shaped is not particularly limited as long as it can be lowered to the melting point of the foamable thermoplastic resin or lower. There is a method such as flowing cooling water inside.

Thermoplastic Resin Foam The thermoplastic resin foam is preferably foamed by heating the foamable thermoplastic resin sheet above the decomposition temperature of the foaming agent and cooling the foam obtained. By doing
Can be manufactured.

That is, when the foamable thermoplastic resin sheet is foamed, the portion of the foamable thermoplastic resin granule foams. At this time, the outer surface of the foamable granule holds bubbles generated by foaming. Since the foaming ratio is low, the foaming ratio is lower than that of the inside, and a low foamed thin film is obtained. Such a low-foamed thin film comes into close proximity to the low-foamed thin film of an adjacent granular material and thermally fuses due to foaming inside the granular material. As a result, the outer surface of the high foam having a high expansion ratio inside the expandable granular material is covered with the low foam thin film, and the plurality of high foams are thermally fused to each other via the low foam thin film. State.

Further, the expandable thermoplastic resin thin film connecting the expandable granules of the expandable thermoplastic resin sheet becomes a continuous foam layer, and a plurality of high foams are arranged on the continuous foam layer. State. The continuous foamed layer also has a small thickness and is difficult to hold air bubbles, and thus has low foaming. However, the thermoplastic resin foam is not limited to a thermoplastic resin foam produced by foaming the foamable thermoplastic resin sheet.

Therefore, a continuous foam layer made of a thermoplastic resin, a high foam body made of a thermoplastic resin disposed on at least one surface of the continuous foam layer, and a thermoplastic resin covering the outer surface of the high foam body With a low-foaming thin film made of resin,
A thermoplastic resin foam in which the plurality of high foams are thermally fused to each other via the low foam thin film can be obtained.

The high-foamed body is disposed on at least one surface of the continuous foam layer, and is disposed as a single layer so as not to overlap in the thickness direction (one-dimensional). In (2), those which are heat-sealed to each other via the low-foaming thin film are preferable.

When the high-foamed material is arranged as described above, it becomes uniform in the thickness direction of the thermoplastic resin foam, and the low-foamed thermoplastic resin thin film is continuous in the thickness direction of the thermoplastic resin foam. Because of the pseudo truss structure, the compressive strength of the thermoplastic resin foam is further improved, and the variation in compressive strength is reduced.

The form of the thermoplastic resin foam is usually a sheet or a plate. If the expansion ratio of the low-foamed thin film is too low, the flexibility of the thermoplastic resin foam is reduced, and the thermal conductivity is increased, and the heat insulating property is impaired.
Since a thermoplastic resin foam having high compressive strength cannot be obtained, the ratio is preferably 1.1 to 10 times, more preferably 1.2 to 7 times, and still more preferably 1.2 to 5 times.

If the thickness of the low-foaming thin film is too large, the weight of the thermoplastic resin foam cannot be reduced. If the thickness is too small, a thermoplastic resin foam having high compressive strength cannot be obtained. Is more preferably 40 μm to 400 μm, more preferably 50 μm to 400 μm.
μm to 400 μm.

The thickness of the low-foaming thin film does not need to be uniform, but may be non-uniform. Here, the thickness of the low-foaming thin film refers to the average thickness of the low-foaming thin film in the cross-sectional direction of the thermoplastic resin foam.

In the present invention 2, when the foaming ratio of the low foamed thin film is 1.1 to 10 times and the thickness is 30 μm to 500 μm, both the compressive strength and the weight reduction of the thermoplastic resin foam are compatible. Magnification and thickness are preferred. More preferably, the expansion ratio is 1.2 to 7 times, and the thickness is 40 μm to 40.
0 μm, more preferably 1.2 to 5
Twice as thick as 50 μm to 400 μm.

If the expansion ratio of the high-foamed product is too low, it is difficult to reduce the weight, and the thermal conductivity of the thermoplastic resin foam is increased, and the heat-insulating properties of the obtained foamed molded product are reduced and are too high. And 2 to 100 times, more preferably 5 to 50 times, more preferably 10 to 35 times, since a thermoplastic resin foam having high bending strength cannot be obtained.
It is twice.

If the size of the high foam is too large, the flexural strength of the thermoplastic resin foam obtained is reduced, and if it is too small, it becomes difficult to reduce the weight. Therefore, the size is preferably 3 to 50 mm, more preferably. Is 5 to 30 mm.

The size of the highly foamed material does not need to be uniform, and may be non-uniform. Here, the size of the high foam refers to the maximum value of the size in the cross-sectional direction. The expansion ratio of a low-foam thin film is generally １ ／ of the expansion ratio of a high-foamed product.
It is as follows.

If the expansion ratio of the continuous foam layer is too low, it is difficult to reduce the weight. If the expansion ratio is too high, a thermoplastic resin foam having high bending strength cannot be obtained.
0 times is preferable, and more preferably 2 to 15 times,
More preferably, it is 5 to 12 times.

If the thickness of the continuous foam layer is too large, it is not possible to reduce the weight of the thermoplastic resin foam, and if it is too thin, a thermoplastic resin foam having high bending strength cannot be obtained. Is preferably 300 μm to 3 mm, more preferably 500 μm.
m to 2 mm.

The thickness of the continuous foam layer does not need to be uniform, and may be non-uniform. Here, the thickness of the continuous foam layer refers to the average thickness of the continuous foam layer in the longitudinal section direction of the thermoplastic resin foam.

The thermoplastic resin foam produced by foaming the expandable thermoplastic resin sheet in which the expandable thermoplastic resin granules are arranged in a staggered manner includes a plurality of high foams in a staggered manner. Be placed. When a plurality of high foams are arranged in a staggered manner, the plurality of high foams have a hexagonal column shape, and each high foam has a structure which is thermally fused via a low foam thin film. A honeycomb-like thermoplastic resin foam is obtained. Such a honeycomb-shaped thermoplastic resin foam becomes a thermoplastic resin foam having excellent surface smoothness and particularly excellent compressive strength and bending strength.

When a polyolefin-based foam is used for the continuous foam layer, the low-foam thin film and the high-foam, the expansion ratio of the foam as a whole is preferably 2 to 20 times, more preferably 5 to 15 times. And more preferably 7 to 12 times.

Method for Producing Thermoplastic Resin Foam The thermoplastic resin foam is obtained by heating the foamable thermoplastic resin sheet to a temperature equal to or higher than the decomposition temperature of a foaming agent and foaming the foamed thermoplastic resin. It can be produced by cooling a foam obtained by foaming, but is not limited to this.

For example, a foaming thermoplastic resin pellet containing a foaming agent is foamed to form a high-foamed body which is heat-sealed through a low-foaming thin film other than the continuous foaming layer, and is molded in a separate step. It may be manufactured by heat-sealing a continuous foam layer made of a thermoplastic resin.

The rigid foam used in the present invention 2 is obtained by laminating the above-mentioned hard plate and the soft foam described later from the thermoplastic resin foam obtained as described above. What satisfies the conditions of Invention 1 may be appropriately selected.

The thickness of the hard foam is preferably 3 mm or more in order to obtain a good walking sensation even if the thickness of the hard plate is reduced in order to improve soundproofing performance.

The soft foam used in the present invention 2 is not particularly limited as long as it has a relatively low compression modulus relative to the above-mentioned hard foam. For example, a polyethylene foam having an expansion ratio of 10 to 30 times, Polyurethane foams having an expansion ratio of 20 to 40 times are exemplified.

The compression elastic modulus of the soft foam is not particularly limited, but if it is too small, walking feeling is reduced (the above-mentioned "fluffy" state), and if it is too large, soundproofing performance is reduced. / Cm ² is preferred.

The thickness of the soft foam is not particularly limited. If the thickness is too small, the soundproofing performance is reduced. If the thickness is too large, walking feeling is reduced (the above-mentioned "fluffy" state).
m or less, more preferably 1-2 mm.

The hard foam and the soft foam are provided with a soundproofing property as required, or in order to cope with unevenness of the adherend (generally, concrete).
Groove processing or uneven processing may be performed.

Laminate Structure The floor material of the present invention 2 is the floor material of the present invention 1, wherein the hard plate-like body (A) has a surface layer, and the hard foam (B) and the soft foam (C) are different from each other. They are stacked. The lamination order is preferably (A) / (B) / (C) in order to obtain a good walking feeling, but when the flexible foam (C) is thin, (A) / (C) / (B) ) May be stacked in this order. Further, if necessary, to enhance the soundproofing performance, (A) / (C) /
(B) / (C ′) may be laminated in the order [(C) and (C ′) may be the same material or may be different), increase rigidity, and increase walking sensation. To improve
The layers may be laminated in the order of (A) / (B) / (A ′) / (C) ((A) and (A ′) may be the same material or may be different). .

[0120] In the flooring material of the second aspect of the present invention,
A soundproofing sheet having excellent soundproofing properties, such as a rubber, a soft elastomer layer, a nonwoven fabric, or a foamed resin sheet, may be interposed between the respective layers.

To laminate the layers of the flooring material, an adhesive or a pressure-sensitive adhesive is applied to both sides of the hard foam (B), and the hard plate (A) and the soft foam (C) are applied to both sides. May be integrated by lamination, or a double-sided tape may be attached to both sides of the rigid foam (B) to laminate the rigid plate (A) and the flexible foam (C). Examples of the adhesive and pressure-sensitive adhesive include a vinyl acetate emulsion (for example, manufactured by Sekisui Chemical Co., Ltd., trade name: Esdine # 6354) and an acrylic pressure-sensitive adhesive (for example, manufactured by Sekisui Chemical Co., Ltd., trade name: Esdine #)
7850) and a chloroprene-based adhesive (for example, trade name: Esdine # 280L, manufactured by Sekisui Chemical Co., Ltd.).

When the rigid foam (B) has poor adhesion to a polyolefin resin or the like, the rigid foam (B) is preliminarily subjected to auxiliary means such as corona treatment in order to improve the adhesion to other layers. You may. When a nonwoven fabric made of synthetic fibers is integrally laminated on the surface during foaming, the adhesion can be improved by an anchor effect when other layers are laminated.
Further, when the rigid foam (B) is made of rigid polyurethane, it is preferable to laminate the paper integrally at the time of foaming, since the adhesion to the rigid plate-like body (A) is good.

The thickness of the flooring material of the present invention 2 is not particularly limited, but is preferably 60 mm or less in order to eliminate a step with a tatami room (usually 10 to 55 mm thick).

In the flooring material according to the second aspect of the present invention, the thickness of the hard plate (A), the hard foam (B) and the soft foam (C) is 1: (1-5) :( 0.2 To 2).

When the thickness ratio of the rigid foams (B) and (C) is too small as compared with (A), the soundproofing performance is deteriorated, and when the overall thickness is constant, walking feeling is too large. Falls and cracks when walking on the floor,
1: (1 to 5): (0.2 to 2) is preferable.

The floor materials of the present invention 1 and the present invention 2 may be directly adhered to a floor base material such as concrete, or may be laid through joists or the like if space is required under the floor. It may be further laid via a particle board as needed. Further, a layer such as a peel-up material may be provided between the floor base material and the floor material to facilitate replacement.

The condominium of the present invention 3 is the same as that of the present invention 1 or 2
Is directly attached to a floor base material. Generally, the thickness of the floor material is suitably 5 to 20 mm, and 12 mm and 15 mm are often used as standard sizes.

(Function) The flooring material of the present invention 1 is JIS A1
When a floor impact sound level is measured by a floor impact sound generator conforming to 418, a peak value obtained by measuring a time change of acceleration when a hammer used for the measurement collides with a floor surface is 15 G or less. Since the half width is set to 2 ms or more, the floor vibration is minimized when an impact sound is generated, and the sound transmitted to the outside of the system can be reduced. Becomes

Further, the floor material of the present invention 1 has a weight of 4 kg / cm ²
Since the amount of distortion when applying a compressive stress of 3 mm or less is 3 mm or less, the flooring material has a good walking feeling.

[0130] The flooring material of the second aspect of the present invention is the flooring material of the first aspect of the present invention, in which a hard plate-like body is used as a surface layer and a hard foam and a soft foam are laminated. The flexural modulus is reduced while securing the necessary compressive modulus, so the thickness of the soft foam layer can be reduced, so it is possible to eliminate the `` sickness phenomenon '' when walking while having high soundproofing performance. It can be used as a floor material with a good walking feeling.

Since the condominium of the present invention 3 has the floor material of the present invention 1 or 2 directly adhered thereto, not only can the unevenness of the floor material such as concrete be easily adjusted, but also the sound insulation is high. It has performance and is excellent in comfort.

[0132]

Embodiments of the present invention will be described in detail with reference to the drawings. FIG. 1 is a partially cutaway sectional view illustrating an example of a foamable thermoplastic resin sheet that can be used in the present invention. This foamable thermoplastic resin sheet will be described below as an example. The foamable thermoplastic resin sheet 1 has a columnar foamable thermoplastic resin granule 2.
Are integrally connected by a foamable thermoplastic resin thin film 3. In other words, the foamable thermoplastic resin sheet 1 is formed such that the columnar protrusions composed of the foamable thermoplastic resin granules 2 project from one surface of the foamable thermoplastic resin thin film 3. Has the shape that is

FIG. 2 is a plan view for explaining a form in which foamable thermoplastic resin particles are arranged in a foamable thermoplastic resin sheet that can be used in the present invention.
In the foamable thermoplastic resin sheet 1, the foamable thermoplastic resin granules 2 are arranged in a zigzag as shown in FIG.

FIG. 3 is a schematic side view for explaining a process for producing a foamable thermoplastic resin sheet which can be used in the present invention. The thermoplastic resin and the thermal decomposition type foaming agent constituting the foamable thermoplastic resin sheet are supplied to the extruder 11 and melt-kneaded at a temperature lower than the decomposition temperature of the thermal decomposition type foaming agent. The extruded and softened sheet-like foamable thermoplastic resin is shaped by a shaping roll 13 and a shaping roll 14 having a concave portion 13a corresponding to the shape of the foamable thermoplastic granular material and maintaining a clearance. While being cooled, the foamable thermoplastic resin sheet has a shape in which the columnar protrusions formed of the foamable thermoplastic resin granules 2 are formed to protrude from one surface of the foamable thermoplastic resin thin film 3. A shape is obtained.

To obtain a thermoplastic resin foam from the foamable thermoplastic resin sheet obtained as described above, the foamable thermoplastic resin sheet is heated to a temperature not lower than the decomposition temperature of the blowing agent. Foam and cool the resulting foam.

FIG. 4 is a schematic sectional view showing an example of a thermoplastic resin foam which can be used for the flooring of the present invention. As shown in FIG. 4, the thermoplastic resin foam 4 has a plurality of high foams 4a made of a thermoplastic resin having a high expansion ratio arranged on at least one surface of a continuous foam layer 4c made of a thermoplastic resin. The outer surface of the high foam 4a is covered with a low foam thin film 4b made of a thermoplastic resin having a low expansion ratio. Adjacent high foam 4a is heat-sealed via low foam thin film 4b.

As described above, the expandable thermoplastic resin thin film (FIG. 1) for integrally connecting the expandable thermoplastic resin particles.
3) becomes the continuous foam layer 4c, the foamable thermoplastic resin granules foam, the outer surface thereof becomes the low foam thin film 4b, and the inside thereof becomes the high foam body 4a. Adjacent low-foaming thin films 4b are heat-sealed and integrated. Therefore, the outer surface of the high foam 4a is covered with the low foam thin films 4b and 4c and integrated.

When the foamable thermoplastic resin particles 2 are arranged in a zigzag pattern as shown in FIG. 2, the plurality of high foams 4a are formed as shown in FIG. It has a hexagonal column shape, and each high foam 4a has a structure in which it is thermally fused via the low foam thin film 4b, so that a honeycomb-like thermoplastic resin foam as a whole is obtained. Such a honeycomb-shaped thermoplastic resin foam becomes a thermoplastic resin foam having excellent surface smoothness and particularly excellent compressive strength and bending strength.

The flooring materials of the present inventions 1 and 2 are obtained, for example, by laminating a hard plate-shaped body on one surface of a hard foam made of a thermoplastic resin foam obtained as described above, and It is obtained by laminating a soft foam having a lower compression modulus and a lower flexural modulus than a hard foam.

FIG. 6 is a sectional view showing an example of the flooring material of the present invention 1 or 2. The floor material according to the second aspect of the present invention includes the rigid foam B
The hard plate-shaped body A is laminated as a surface layer on one side, and the soft foam C is laminated on the opposite side.

To laminate the layers of the flooring, for example,
It is advisable to apply a double-sided tape to the hard foam B and to laminate the hard plate A and the soft foam C on both sides thereof.

[0142]

EXAMPLES The present invention will be described in more detail with reference to Examples. Example 1 Rigid foam B high-density polyethylene (trade name “HY34” manufactured by Mitsubishi Chemical Corporation)
0 ", MI = 1.5 g / 10 min) 50% by weight, silane-grafted polypropylene (manufactured by Mitsubishi Chemical Corporation, trade name" XPM ")
800H ", MI = 11 g / 10 min, gel fraction after crosslinking 80% by weight) 20% by weight, polypropylene (manufactured by Mitsubishi Chemical Corporation, trade name" MA3 ", melt index (MI) =
11 g / 10 min) Thermoplastic resin 10 consisting of 30% by weight
0 parts by weight (gel fraction 16% by weight based on the total amount of thermoplastic resin), azodicarbonamide (manufactured by Otsuka Chemical Co., Ltd., trade name:
A composition containing 5 parts by weight of SO-20 and a decomposition temperature of 210 ° C.) and 0.1 part by weight of dibutyltin dilaurate as a silane crosslinking catalyst was supplied to the twin-screw extruder 11 shown in FIG. As the twin screw extruder 11, one having a diameter of 44 mm was used. In the twin-screw extruder 11, the composition was heated at 180 ° C.
Melt and knead with a T of 300 mm in surface length and 1.5 mm in lip
The sheet-like foamable thermoplastic resin in a softened state was extruded by the die 12.

Further, the foamable thermoplastic resin sheet material was placed between rolls 13 and 14 having a diameter of 250 mm and a surface length of 300 mm in which cylindrical concave portions 13 a having a depth of 5 mm and a diameter of 4 mm were arranged in a zigzag pattern at intervals of 10 mm. The foamed thermoplastic sheet is immersed in water at 98 ° C. for 2 hours and then dried to obtain a height of 5 mm and a diameter of 4 m.
Thus, a foamable thermoplastic resin sheet 1 in which m cylindrical foamable thermoplastic resin granules 2 are arranged in a zigzag at 10 mm intervals was obtained.

In the foamable thermoplastic resin sheet 1 obtained as described above, the foamable thermoplastic resin granules 2 are connected by the foamable thermoplastic resin thin film 3, and as a whole, the foamable thermoplastic resin sheet is formed. Form 1 was constituted.

The foamable thermoplastic resin sheet 1 thus obtained
Is placed on a polyfluorinated ethylene sheet, the above-mentioned polyfluoroethylene sheet is placed on the upper surface thereof, and the thickness is adjusted to 7.3 mm by a hand press.
After foaming by heating at 10 ° C. for 10 minutes, the mixture was cooled by a cooling press at 30 ° C. for 10 minutes to obtain a rigid foam B having an expansion ratio of 10 (see FIG. 6).

The expansion ratio of the obtained rigid foam B was
The thickness of the foam was measured by the following method.

(Expansion Ratio) The expansion ratio was measured in accordance with JIS K6767. (Thickness of foam) Using a caliper, the thickness of the obtained foam was measured.

Hard plate A A 0.2 mm-thick veneer (manufactured by Kitasansha) was bonded to a plywood adjusted to the thickness shown in Table 1 (partially cut with a plane to a predetermined thickness), and an epoxy resin was used. Paint the resin and cure it with ultraviolet light,
A hard plate A was obtained.

Soft foam C A 30-fold soft urethane foam (compressive modulus: 0.5 kg / cm ² , flexural modulus: 21 kg / cm ² ) manufactured by Bridgestone and having a predetermined thickness shown in Table 2 was used.

On both sides of the obtained rigid foam B, double-sided tape [double tack tape (400 mm, manufactured by Sekisui Chemical Co., Ltd.)
Width)], and each of them has a hard plate-like body A and a soft foam C
Are adhered and laminated, and the floor material (300 × 900 m
m). The rigid foam B was shaved by an electric plane to a predetermined thickness.

Example 2 and Comparative Examples 1 to 3 Except that the thicknesses of the hard plate A, the hard foam B and the soft foam C were as shown in Table 1, the floor material was the same as in Example 1. I got

The floor material thus obtained was measured for floor impact sound level in accordance with JIS A1418. However, the number of hammers is 1, and at that time, the upper part of the hammer (cylindrical type having a diameter of 3 cm, steel, weight 500 g, impact surface against the floor of the head is a convex spherical surface with a radius of curvature of 50 cm) used for the measurement. To an accelerometer (Rion, product name "Acceleration Pickup PV
-95 ") is attached with a double-sided tape, and the curve obtained by measuring the time change of the acceleration when the hammer collides with the floor surface by free fall from the position of 4 cm in height is smoothed. The peak value and the half width were obtained, and are shown in Table 1 as the peak value and the half width.

When the obtained floor material is pressed with an indenter (a steel cylinder having a diameter of 50 mm) against the surface of the floor material (the hard plate (A) side) with a force of 80 kgf in accordance with JIS K7220. The amount of strain (compression stress 4 kg / cm ² ) was measured with a universal material testing machine (trade name “Autograph” manufactured by Shimadzu Corporation). At this time, the steepest linear portion of the compressive stress / strain curve was extended to the zero pressure stress line using a straight line ruler, and the zero deformation point was plotted. Table 1 shows the amount of strain from this zero deformation point. Indicated.

Performance Evaluation Floor Impact Sound Level The obtained floor material was measured for lightweight floor impact sound level in accordance with JIS A1418.

Walking Feeling The feeling when a human walks on the obtained flooring is shown based on the following criteria. ○ There is no feeling of sinking. △ There is a fluffy feel. × Feels sinking when walking. The above results are summarized in Table 1.

[0156]

[Table 1]

[0157]

As described above, the flooring material according to the first aspect of the present invention is excellent in soundproofing performance and has a good walking sensation.

The flooring material of the second aspect of the present invention has the above-mentioned laminated structure of the flooring material of the first aspect of the invention. Can be

The condominium of the present invention 3 is different from the condominium of the present invention 1 or 2
Since the floor material is directly attached, not only the unevenness of the floor base material such as concrete can be easily adjusted, but also the feeling of living is excellent.

[Brief description of the drawings]

FIG. 1 is a partially cutaway sectional view for explaining an example of a foamable thermoplastic resin sheet that can be used in the present invention.

FIG. 2 is a plan view for explaining a form in which foamable thermoplastic resin particles are arranged in a foamable thermoplastic resin sheet that can be used in the present invention.

FIG. 3 is a schematic side view for explaining a step of producing a foamable thermoplastic resin sheet that can be used in the present invention.

FIG. 4 is a schematic longitudinal sectional view showing an example of a thermoplastic resin foam that can be used for the flooring of the present invention.

FIG. 5 is a schematic cross-sectional view showing an example of a thermoplastic resin foam that can be used for the flooring of the present invention.

FIG. 6 is a cross-sectional view showing an example of the flooring material of the first invention.

[Explanation of symbols]

 A Hard plate-shaped body B Hard foam C Soft foam

Claims (3)

[Claims] When a floor impact sound level is measured by a floor impact sound generator conforming to JIS A1418, a time change of acceleration when a hammer used for the measurement collides with a floor surface is measured. The peak value is 15 G or less, the half width is 2 ms or more, and the amount of strain when applying a compressive stress of 4 kg / cm ² is 3 m
m or less. 2. The flooring material according to claim 1, wherein a hard plate-like body is used as a surface layer, and a hard foam and a soft foam are laminated. 3. An apartment to which the floor material according to claim 1 is directly attached.