KR100915949B1 - Shock-absorbing sheet including polyethylene-based mesh, and use thereof - Google Patents

Abstract

A shock-absorbing sheet is provided to minimize an air pollution problem due to an adhesive component, and to offer durability and convenient construction property with low cost by using a relatively inexpensive polyethylene-based mesh. An inter-layered floor buffering material or an inner buffering sheet for a wall includes a polyethylene-based mesh layer(32) and a protective layer(31,33) formed on one or both sides of the polyethylene-based mesh layer. The polyethylene-based mesh layer is formed by intersecting a plurality of polyethylene-based threads. Each thread forms a branch thread. The top or the bottom of the branch threads are arranged to connect the top or the bottom of the other branch thread. The protective layer is made of foamed polyethylene sheet, closed-cell polyethylene foamed resin, a polypropylene sheet, or foamed polystyrene. The thickness of the polyethylene-based mesh layer and the protective layer is respectively 3 ~ 30mm and 2 ~ 20mm.

Description

Shock-absorbing Sheet Including Polyethylene-based Mesh, and Use Thereof}

The present invention relates to a buffer sheet using a polyethylene mesh. More specifically, the present invention relates to a buffer sheet capable of imparting a long-term buffering property by stacking a protective layer such as a foamed polyethylene layer on at least one surface of a polyethylene-based mesh layer, and a heat-insulating buffered laminate sheet comprising the same.

 In general, the impact sound of a multi-family house is divided into light impact sound and heavy impact sound. Lightweight impact sounds are impact sounds that occur when a light object is dropped or when a chair is dragged from the floor, and heavy impact sounds are impact sounds that occur when a heavy object falls, an adult walks on a heel, or a child runs. The impact sound has recently emerged as a social issue, even as a cause of conflict between generations up and down. In general, in the case of a light impact sound, there was a blocking effect as a conventional general shock absorbing material, but in the case of a heavy shock sound, the blocking effect was lower in the structure in which the shock absorbing material was constructed, rather than a bare slab in which the shock absorbing material was not constructed.

Recently, it has been legally mandated that new apartments must be constructed with a shock-absorbing structure in accordance with the recognition and management criteria for the floor-impact sound-blocking structure for multi-unit houses. Many buffers have been developed. Insulation material made of styrofoam material with low price competitiveness has been mostly constructed as a cushioning material. However, the insulation performance is barely satisfied and the performance is significantly reduced in terms of prevention of interlayer noise. In addition, some use petrochemical products such as PE (polyethylene) and EVA (ethylene vinyl acetate), but the existing flat panel products of a certain thickness remain on the slab as it is, so it is limited to the floor impact sound reduction performance of multi-family houses. Have In addition, in the case of the above-described technology, the thermal insulation performance is significantly lowered, exceeding the legal standard, and products having several functional layers laminated in order to secure floor impact sound blocking performance have been developed. It is difficult to commercialize, such as disadvantages in poor workability and durability.

In order to solve the above-mentioned disadvantages of the prior art, the applicant's Korean Patent No. 792101 discloses an integral thermal insulation buffer material in which the surface material layer, the insulation layer, and the air layer-containing buffer layer are sequentially stacked. At this time, the buffer layer is composed of an air layer consisting of an air cap and a protective layer heat-sealed on one side or both sides of the air layer. In the case of the patent, since it is integrally formed, it does not require the intervening of the adhesive, so it is possible to effectively prevent contamination caused by volatile organic materials, and to maintain stable insulation and interlayer impact sound blocking performance. .

In the patent, the air cap included in the cushioning material layer is effective in terms of light and heavy impact sound blocking performance, but when it is repeatedly pressurized downward to the bottom buffer material, air in the air cap is gradually leaked and thus the cushioning property is long-term. Degrading problems can be caused. In particular, since the air cap is relatively expensive, it may have a limit in reducing the cost of the floor buffer.

On the other hand, most of the energy loss of buildings is due to heat loss through the walls, and the noise generated by the sound insulation between floors cannot be completely prevented. In consideration of this, various techniques are known for constructing walls on the inner wall of the building in order to give a function of insulation, moisture proof, soundproofing, and the like. Typically, inner walls of glass fiber and styrofoam materials are known. Glass fiber, as a non-combustible insulation, can effectively suppress the spread of flame in the event of a fire, but it does not have a uniform appearance itself, and it is difficult to expect mechanical properties such as a certain level of compression resistance. It is also disadvantageous in terms of handleability. Styrofoam insulation is used as a wall material as compared to glass fiber, but it is disadvantageous in terms of construction cost and construction time because it requires not only a large volume but also requires a plurality of construction steps.

Therefore, it is economically advantageous to provide a structure that is commonly applied to building floor interlayers, interior walls, and the like and which can impart the required cushioning function without causing problems with the use of adhesives. In addition, it would be desirable to integrate with the polyurethane layer without requiring the use of an adhesive so as to impart or strengthen the sound insulation and heat insulation functions. As such, there is an urgent need for a method that can be effectively applied to floor buffers, internal walls and the like while overcoming the limitations of the prior art.

The present inventors have continuously studied to overcome the above-mentioned limitations of the prior art and to develop an economical and efficient buffer structure. As a result, one or both sides of a polyethylene-based mesh (or polyethylene in the form of a mesh), which is known as a fruit packaging material, is known. It has been found that a cushioning sheet laminated with a protective layer can be applied to floor buffer or interior wall applications, and is effective in both economical and cushioning performance (blocking light and heavy impact sounds). In addition, the heat insulation buffer lamination sheet in which the foamed polyurethane layer is formed as a heat insulation material layer between the buffer material layer and the surface material layer made of the buffer sheet is not only cushioning performance, but also excellent soundproofing and heat insulating properties, and ease of construction due to the integrated laminated structure. And it is advantageous in terms of cost reduction, and it is recognized that the production and air pollution in the building can be prevented in that it is manufactured in a self-curing continuous method, rather than the interlayer attachment method by the adhesive interposition.

Accordingly, it is an object of the present invention to provide a cushioning sheet that is effectively applied to floor buffer or inner wall applications by using a polyethylene-based mesh layer that has been conventionally limited in scope.

Another object of the present invention is to provide a thermally insulating buffer laminate sheet suitable for use as a floor insulation buffer or an inner wall having a very convenient and durable construction by forming an integrated laminated structure without the use of adhesive buffer sheet.

Another object of the present invention is to operate a self-hardening type continuous method, rather than the interlayer adhesion method by the adhesive intervening to minimize the air pollution problem caused by the adhesive component and to improve the productivity according to the continuous process of the insulation buffer laminate sheet manufacturing method To provide.

According to the first aspect of the invention,

Provided is a cushioning sheet comprising a polyethylene-based mesh layer and a protective layer formed on one or both sides of the polyethylene-based mesh layer.

According to a second aspect of the invention,

An integrated heat insulation buffer lamination sheet in which a surface material layer, a heat insulating material layer, and a buffer material layer are sequentially stacked,

The surface material layer comprises a foamed polyethylene layer, a nonwoven layer or a paper layer;

The insulation layer comprises a foamed polyurethane layer; And

The buffer layer includes a polyethylene-based mesh layer and a protective layer formed on one or both sides of the polyethylene-based mesh layer,

An insulation buffer lamination sheet is provided, wherein an adhesive is not interposed between the surface material layer, the heat insulation material layer, and the buffer material layer.

According to a third aspect of the invention,

As a method of manufacturing an integrated heat-insulating buffer laminate sheet in which a surface material layer, a heat insulating material layer, and a buffer material layer are sequentially stacked,

a) transferring the buffer material layer including the above-mentioned buffer sheet into a double slat conveyor as a lower layer;

b) feeding the reaction raw material of foamed polyurethane onto the buffer layer before the conveyed buffer layer reaches the double slat conveyor;

c) transferring the surface material layer made of foamed polyethylene, nonwoven fabric or paper material as an upper layer with a predetermined vertical distance from the buffer material layer supplied with the reaction raw material in the double slat conveyor; And

d) converting the reaction raw material into a heat insulating material layer made of foamed polyurethane through foaming and resination reaction while the buffer layer and the surface material layer pass through the double slat conveyor, wherein the foamed polyurethane comprises the surface material layer and Forming an integral laminate by self-adhesion while being molded and cured between layers of buffer material;

Including;

The method is characterized in that no adhesive is interposed between the surface material layer, the heat insulating material layer, and the buffer material layer.

The buffer sheet according to the present invention has been conventionally limited to the use as a fruit packaging material, and can be applied as a floor buffer or an inner wall using a relatively inexpensive polyethylene mesh. In addition, the insulation buffer lamination sheet in which the foamed polyurethane layer is integrally formed between the buffer sheet and the surface material layer is very convenient in construction and excellent in durability, and is suitable as a floor insulation buffer or an inner wall. In particular, since the thermal insulation buffer lamination sheet is manufactured in a continuous manner without intervening the adhesive, it is possible to minimize the air pollution problem caused by the adhesive component (formaldehyde, volatile organic substances, etc.), it is possible to improve the productivity by the continuous process have. Therefore, there is a high possibility of commercial use in the future.

Hereinafter, the present invention can be achieved by the following description with reference to the accompanying drawings. The following description is to be understood as describing preferred embodiments of the invention, but the invention is not necessarily limited thereto.

1 is a perspective view schematically showing a laminated structure of a buffer sheet according to an embodiment of the present invention.

2 is a photograph showing a cross-sectional structure of a buffer sheet according to an embodiment of the present invention.

In the buffer sheet according to the above embodiment, protective layers 31 and 33 are formed on both sides of the polyethylene-based mesh layer or the mesh-type polyethylene layer 32. At this time, the polyethylene-based mesh layer and the protective layer is preferably attached by heat bonding or heat fusion. Thus, there is no need to use an adhesive for interlayer attachment. In the above embodiment, the protective layers are formed on both sides of the mesh layer, but when the construction is performed separately in the field together with the heat insulating material and the existing interlayer insulating buffer material, the protective layer on one side of the mesh layer may be omitted.

Figure 3 is a photograph showing the structure of a polyethylene-based mesh included in the buffer sheet according to an embodiment of the present invention.

The basic configuration of the polyethylene-based mesh layer illustrated in the figure is known in the field of fruit packaging and is available at a relatively low cost. Representatively, a plurality of threads are connected while crossing each other. The example illustrated in the figure consists of a plurality of threads 34 arranged at regular intervals, each thread being divided and branched in two directions, for example at an angle of 90 ° or less. 36, 35 'and 36'). The bottom or top of each branched thread is connected with the top or bottom of an adjacent branched thread. For example, the bottom of the left thread 35 'of the branched threads is arranged and connected on top of the adjacent branched thread 36, while the top of the right thread 36' is the adjacent branched thread 35 '. ') Are arranged and connected on the lower part.

Although the present invention is not necessarily limited to a mesh having such a specific shape and arrangement, the three-dimensional mesh shown in the drawings may be advantageous in terms of cushioning properties because it may contain more air in the cushioning sheet than the planar mesh. .

In the illustrated example the thickness of the polyethylene threads 34, 34 ′, 34 ″ is preferably about 3 to 20 mm, more preferably about 5 to 15 mm. The thickness of the branched threads is preferably about 2 to 10 mm, more preferably about 3 to 8 mm.

In the cushioning sheet according to the present invention, the diameter of the void space in the mesh structure is preferably in the range of about 5 to 50 mm, more preferably about 5 to 30 mm, and the thickness of the mesh layer is about 3 to 30 mm in total, More preferably about 5 to 20 mm. If the thickness of the mesh layer is too small, the cushioning performance by air cannot reach the intended level, while if the mesh layer is too large, problems such as cracking and sinking when applied to the ondol component layer due to insufficient strength of the buffer material Since there may be, it is preferable to adjust the above range, but the present invention is not necessarily limited thereto.

In addition, polyethylene (particularly, foamed polyethylene) is preferable as a material of the methamphetamine layer, and exemplary reference physical property values thereof are shown in Table 1 below.

TABLE 1

Item Reference property value density 0.020 g / cm 3 or more The tensile strength 20 N / ㎠ or more Elongation 50% or more Water absorption 4 v / v% or less

According to one embodiment of the present invention, the polyethylene-based mesh may be preferably manufactured as follows, but the present invention is not limited thereto.

First, about 60 to 87 weight percent low density polyethylene, about 5 to 30 weight percent blowing agent, about 0.5 to 2 weight percent crosslinking agent and about 3 to 8 weight percent other additives (e.g. colorants, co-foaming agents, elvan And a raw material consisting of a single or a combination of polysilica and the like) were introduced into an extruder foamer, preheated under a temperature condition of about 140 to 180 ° C., foamed under a temperature condition of 180 to 230 ° C., and rotated in opposite directions. It is extruded through a double die which is formed to have a mesh structure. At this time, the thickness of the thread (and / or branched thread) can be adjusted through the size of the discharge hole in the double die, and the faster the speed of the double die, the denser the mesh, and the slower the wider the mesh, the more suitable for the purpose. It can be adjusted appropriately.

On the other hand, as a representative example of the protective layer adhered to one or both sides of the polyethylene-based mesh layer, polyethylene sheet (preferably foamed polyethylene sheet), free-foam polyethylene foamed resin, polyester nonwoven fabric, polypropylene sheet, bead method styrofoam And extrusion method styrofoam, fabric fabric and the like. In addition, when the protective layers are attached to both sides of the polyethylene-based mesh layer, each of the protective layers may be made of the same material, but in some cases may be made of a different material.

The thickness of the protective layer is preferably about 2 to 20 mm, more preferably 5 to 15 mm. When the thickness of the protective layer is too small, not only the production of the sheet itself is difficult, but also the function as the protective layer cannot be effectively exhibited, while when the protective layer is too large, it may not be preferable in terms of space economy. Therefore, it would be desirable to adjust to the aforementioned range.

As mentioned above, the mesh layer and the protective layer are attached to each other by a heat bonding or heat fusion method, details of which are commonly known in the art. For example, continuously passing through a hot air fan at about 150 to 400 ℃, or if one side of the protective layer is slightly melted by using a gas flame immediately laminated with the mesh layer and passed through the compression roller to harden the molten portion of one side It may be thermally bonded or heat-sealed by making it. At this time, the overall thickness of the cushioning sheet may be slightly smaller than the sum of the thicknesses of the mesh and the protective layer, depending on the press melting conditions during thermal bonding (heat fusion).

The buffer sheet according to the present invention has a structure including a mesh layer therein, and is easy to handle regardless of a roll form or a sheet form. In particular, the empty space of the inner mesh layer serves as an air layer. In the case of the fruit-based polyethylene mesh, tensile strength and tearing performance alone are not suitable for building materials, but in the present invention, one side of the mesh layer Or by forming a protective layer on both sides to form an air layer of a multi-layer structure, to withstand heavy loads. In addition, the air present in the empty space of the mesh layer may provide not only a cushioning effect but also an effect of suppressing transmission of interlayer impact sounds (light weight and / or weight) or wall noise. Therefore, it should be noted that in some cases, the cushioning sheet of the above-described structure alone may be applied as an interlayer floor or an interwall inner wall.

According to the present invention, since the buffer sheet has good adhesion and compatibility with other materials, for example, when the polyurethane is directly coated and foamed, it is possible to add or reinforce effects such as heat insulation and sound insulation.

4 is a view schematically showing an integrated heat insulating buffer laminate sheet according to another embodiment of the present invention.

5 is a photograph showing a cross-sectional structure of an integrated heat-insulating buffer laminate sheet according to another embodiment of the present invention.

In the figure, the surface material layer 10, the heat insulating material layer 20 and the buffer material layer 30 are sequentially stacked. The buffer layer is made of the above-described buffer sheet, the protective layer is formed on both sides of the polyethylene-based mesh layer. In particular, since the adhesive is not interposed between the surface material layer, the heat insulating material layer and the buffer material layer, the interlayer adhesion process is omitted, and the construction is simple, and is usually caused by formaldehyde, volatile organic compounds, etc. contained in the adhesive. It can also prevent air pollution.

According to another embodiment of the present invention, the above-described polyethylene-based mesh layer (not shown) may be additionally included below the heat insulating material layer 20 on the buffer material layer 30. For example, it may be included in the form embedded in the lower side of the heat insulating material layer (embedded), it is more preferable that the foamed state. This will be described in more detail in the manufacturing process described later.

The surface material 10 may be made of polyethylene (for example, foamed polyethylene), nonwoven fabric, or paper, and may be made of the same material as foamed polystyrene, which may be used as a protective layer of the cushioning sheet. Such a surface material layer can protect the lower insulation layer from external impact, and in particular, a foamed polyethylene resin material is preferred, which is chemically inert and has no fear of deterioration due to material properties, and has excellent moisture resistance and chemical resistance. For example, because it is particularly suitable as the material of the floor constituting the ondol floor insulation of the multi-family house. However, when used as an internal wall of the building may be composed of a surface layer of non-woven or paper material. In addition, the foamed polyethylene has a very low dynamic modulus of elasticity (for example, in the range of about 3 to 40 MN / m 3 according to KS F 2868), which is effective for preventing interlayer or interwall noise and vibration. The method for producing such expanded polyethylene can be exemplified as follows, but the present invention is not limited thereto.

First, polyethylene, which is the main raw material, preferably about 60 to 87% by weight of low density polyethylene (LDPE) having a melt index of about 0.6 to 1 g / 10 min, preferably about 0.7 to 0.9 g / min, and a decomposition temperature of about About 5 to 10 wt% of blowing agent at 180 to 185 ° C., about 5 to 10 wt% of blowing agent having decomposition temperature of about 197 to 203 ° C., about 0.5 to 2 wt% of foam stabilizer (crosslinking agent), and catalyst (eg, KCN And other additives, including about 3-8 wt%, preheated to about 160-240 [deg.] C. and then foam molded at about 180-260 [deg.] C. FIG.

In consideration of sound insulation performance and surface strength, the thickness of the surface material layer is preferably in the range of about 2 to 20 mm, more preferably about 5 to 15 mm. When the thickness of the surface material layer is too small, it is not only vulnerable to external impact, but also has a high elastic modulus, thereby lowering the impact sound reduction performance. However, when the surface material layer is too large, the surface material layer is disadvantageous in terms of space utilization.

On the other hand, in the embodiment of the present invention, the heat insulator 20 is made of polyurethane, in particular foamed polyurethane. Polyurethane is a polymer containing a urethane bond formed by the reaction of a polyol and an isocyanate (-NCO) containing a hydroxyl group and the reaction of a blowing agent and an isocyanate (-NCO). It has a low thermal conductivity and shows very good heat insulating properties.

6 is a view schematically showing an embodiment of a process for producing an integral heat-insulating buffered laminate sheet according to the present invention.

According to the drawing, the raw material for producing a heat insulating material is composed of a two-component type. That is, the raw material tank of a polyol type compound and the raw material tank of an isocyanate type compound are arrange | positioned separately. In addition, a detergent, for example, methylene chloride (Methylene Chloride (MC)) is stored in a separate tank. The cleaning agent is intended to remove the urethane reactant remaining in the raw material input line and the mixing head after the end of the operation. The reason for configuring the cleaning agent as a separate cleaning line is to mix the cleaning agent with the polyol compound and / or the isocyanate compound. In this case, since it does not act as a cleaning agent and acts as an auxiliary blowing agent, it is considered that it may cause problems such as delayed curing, post-foaming and shrinkage after curing.

On the other hand, a representative example of the polyol-based compound is a polyether-based polyol having an ether group is repeatedly bonded, such as polypropylene glycol (PPG) and a polyester-based polyol to which an ester group is repeatedly bonded. The said polyol type compound can be used individually or in combination. Preferably, the molecular weight of the polyol-based compound is about 300 to 20,000, the hydroxyl content is about 30 to 500 KOH level.

As the isocyanate compound, diphenylmethane diisocyanate (4,4'-Diphenylmethane diisocyanate; MDI) may be used. MDI is a substance obtained by treating phosgene with diphenylmethanediamine (MDA), which is usually produced by condensation of aniline and formaldehyde, and is purified and separated into Crude MDI. Since monomeric MDI is a white solid at room temperature, it is preferable to use it by modifying it to liquid phase, such as carbodiimide modified MDI or uretonimine modified MDI. In particular, it is preferable to use a liquid polymer MDI, Crude MDI and the like at room temperature, in particular, the molecular weight is about 3,000 to 5,000, the average number of functional groups is about 2 to 3, the viscosity (25 ℃) is about 150 to 300 cps, and It is preferred that the NCO% content is about 20-40.

According to a preferred embodiment of the present invention, a urethane catalyst (e.g., an amine and / or metal catalyst), chemical and physical blowing agents (and auxiliary blowing agents), surfactants, and other additives (flame retardants) in a polyol compound tank , Chain transfer agent, etc.), and the like are mixed and stored.

The urethane catalyst is not particularly limited, and conventional kinds such as secondary or tertiary amine compounds (for example, DMEA, TEDA, DMCHA, TMCHA, etc.), organometallic catalysts, and the like can be used. In particular, two or more catalysts may be used in combination according to the required properties.

The blowing agent is a component that generates bubbles during the resin reaction. Water (chemical reaction agent that generates carbon dioxide by reacting with isocyanate) can be used as the main blowing agent. As the auxiliary blowing agent, the blowing agent does not participate in the resin reaction and is vaporized by the heat of reaction. Components to be formed, for example, chlorofluorocarbons CFC-11, HCFC-141b, C-Pentane, HFCs, etc. may be selectively used, preferably HCFC-141b, C-Pentane, HFCs that are more environmentally friendly And the like can be used.

The foam stabilizer may be appropriately selected in consideration of the cell structure in the foamed polyurethane as a surfactant, and specific examples thereof include silicone foam stabilizers (for example, product names L-5420 and L-6900 manufactured by OSI).

In addition, the flame retardant may be used in an appropriate amount in consideration of the required level, and mainly phosphorus-based flame retardants (eg, TCPP, TCEP, Phosphorus ester, etc.) may be used.

In the above embodiment, the raw material in the polyol compound tank may be, for example, about 0.1 to 2 parts by weight of the urethane catalyst, about 15 to 40 parts by weight of the blowing agent (including the auxiliary blowing agent), and about 1.0% of the foaming agent based on 100 parts by weight of the polyol compound. To 2 parts by weight and about 8 to 15 parts by weight of a flame retardant, and in addition, a bifunctional chain transfer agent such as diol or diamine may be further used in an appropriate amount. In addition, each feed tank is preferably maintained at about 15 to 30 ° C, more preferably at about 20 to 25 ° C.

According to this embodiment, the double slat conveyor is provided with a conveyor installed over the top and bottom as shown, so that the surface material layer 10 as the upper layer and the buffer layer 30 as the lower layer are fed at a constant speed and the same, respectively, supplied from the two rolls. It is driven to feed at speed. At this time, during the process of continuously transferring the buffer layer 30 from the roll to the double slat conveyor, the reaction raw material of polyurethane is first discharged onto the buffer layer from the raw material stirring ejector, and the surface material layer 10 is discharged in the double slat conveyor. It is conveyed while maintaining a constant gap with the buffer layer 30 which is conveyed with the reaction raw material.

On the other hand, the polyol compound and the isocyanate compound from each raw material tank are mixed in the raw material stirring ejector, preferably by a desired amount independently using a metering pump (not shown) provided in each tank to the raw material stirring ejector. Supply. At this time, the ratio (weight ratio) of the usage-amount of a polyol type compound and an isocyanate type compound becomes like this. Preferably it is adjusted to about 1: 1-1: 3, More preferably, it is about 1: 1: 1: 1.5. The ratio of the above-mentioned usage amount is appropriately selected in consideration of the characteristics of the polyol, the difference in seasons, the difference in product hardness required, and the like. A mixer is provided inside the raw material stirring ejector, so that the reactant components are mixed with each other while passing through a stirrer head rotating at a speed of about 750 to 4000 rpm, more preferably about 1500 to 3500 rpm. do.

Through the above-described process, the raw material mixture of the polyurethane for the insulation layer is positioned between the surface material layer 10 and the buffer layer 30 to be transferred at regular intervals in the double slat conveyor.

The amount of reactant material discharged may be determined in consideration of the volume occupied by the space between the two layers, the surface finishing material layer or the transfer speed of the surface material layer, etc., but once the discharge amount is determined, It is preferred to be supplied. In addition, the surface material layer 10 and the buffer material layer 30, especially the surface material layer, which are respectively supplied from the two rolls, preferably maintain sufficient tension to prevent wrinkles on the surface during movement.

The reaction mixture, located between the upper and lower layers, moving at regular intervals, passes through the double slat conveyor while blowing reactions (carbon dioxide and heat are generated by the reaction of water and isocyanate compounds, and assisted by the heat generated). Blowing agent is evaporated and foamed on a continuous line) and swelled through a resination reaction to form a constant thickness (ie, the space between the two layers) between the upper surface material layer 10 and the lower buffer layer 30. Cures. The total time of the reaction is preferably maintained at about 1 to 3 minutes and the reaction temperature is maintained at about 20 to 120 ° C.

Carbon dioxide and heat are generated by the reaction of the isocyanate compound with water, and the auxiliary blowing agent is vaporized by the generated heat to foam on the continuous line. Since the foamed polyurethane is attached to and integrated with the surface material layer 10 and the buffer material layer 30 by the self-adhesive force generated while curing, there is no need to use a separate adhesive.

The thickness of the insulation layer is adjusted in consideration of the application (for example, floor insulation buffer sheet or insulation buffer inner wall), required insulation and sound insulation performance, space utilization, etc., typically about 5 to 100 Mm, more typically in the range of about 10 to 40 mm.

After passing through the double slat conveyor in a state in which the buffer layer 30, the polyurethane insulation layer 20, and the surface layer 10, including the mesh layer, are sequentially laminated and cured as described above, typically, an automatic self-cutting machine By cutting the side and cross section to a certain standard can form a finished product.

On the other hand, according to another embodiment of the present invention, as described above,

In the manufacture of the insulation buffer lamination sheet, the above-described polyethylene-based mesh layer (not shown) may be additionally included below the insulation layer 20 on the buffer layer 30. That is, in the above-mentioned foaming process, the polyethylene-based mesh is supplied onto the buffer layer to be transported. In this case, the urethane raw material fills the space of the polyethylene-based mesh and the foaming reaction occurs. In this case, foaming may occur in the material of the polyethylene-based mesh, which is a thermoplastic resin, by heat generated during the foaming reaction of the urethane, and thus pores may be additionally formed. Thus, additional sound insulation properties can be imparted.

As such, the heat insulation buffer lamination sheet according to the present invention can be applied as an interlayer floor insulation buffer or a wall insulation buffer inner wall. In particular, the polyurethane insulation layer formed by the foaming reaction is molded and cured according to the fine shape of the mesh layer included in the lower buffer layer, so that the load transmitted from the top can be very effectively dispersed to maintain the mesh layer stably. do. In the case of the actual construction of the floor construction site for the subsequent process, the builders step on the floor insulation buffer, the insulation buffer lamination sheet of the present invention can be protected even in this case the mesh layer. In other words, the integrated heat-insulating buffered laminate sheet according to the manufacturing method of the present invention can prevent performance degradation due to external factors. In addition, it is possible to produce the thickness of the conventional floor buffer material (for example, about 20 to 120mm), and compared to the commercially available products, the wall noise or interlayer floor impact sound reduction performance and insulation performance is excellent, while mass production is It has an easy advantage.

In addition, the conventional floor buffer or the inner wall has to use an adhesive at the time of construction in order to integrate the laminated structure, so that in order to prevent the occurrence of formaldehyde, volatile organic compounds, etc., each layer of the laminated structure must be constructed separately. Difficulties existed. However, the cushioning sheet, or the insulation buffer lamination sheet of the present invention is manufactured integrally without intervening an adhesive, so that it can be easily constructed and easily cut with a general portable knife, so it is easily cut in the field regardless of the internal structure of the apartment house. Can be installed.

The present invention can be more clearly understood by the following examples, which are only intended to illustrate the present invention and are not intended to limit the scope of the invention.

Example 1

Manufacture of buffer sheet

The foamed polyethylene layer was prepared as follows:

80 parts by weight of colorless transparent low density polyethylene (product name: FB0800) with a melt index of about 0.8 g / 10 min, 9 parts by weight of blowing agent (UNICELL D1500PE), 9 parts by weight of blowing agent (UNICELL D1500TSK), 1 part by weight of crosslinking agent (DCP) and catalyst 1 part by weight of (KCN) was added, followed by preheating at 200 ° C., followed by foaming at 220 ° C. to prepare a foamed polyethylene layer. It was evaluated whether the foamed polyethylene layer met the actual process specifications described in Table 1 below.

The foamed polyethylene layer was thermally bonded to both sides of a commercially available polyethylene-based mesh for fruit packaging under a gas flame at 700 ° C. to produce a buffer sheet having a three-layer structure, and it was confirmed whether the process specifications set forth in Table 2 were satisfied.

TABLE 2

Foamed polyethylene layer Buffer Sheet Thickness (mm) 5 ± 1 (5) 12 ± 3 (12.2) Density (g / cm 3) 0.020 (0.031.) 0.015 (0.031) minimum Tensile Strength (N / ㎠) 20 (40) minimum 20 (40) minimum Elongation (%) 50 (100) minimum 50 (100) minimum Absorption amount (g / 100㎠) 4 (0.1) max 4 (0.1) max

In the table above, the actual measurements are shown in parentheses. As a result of the measurement, it was confirmed that the foamed polyethylene layer and the buffer sheet satisfied all of the set standards.

Example 2

Preparation of Insulation Buffer Laminated Sheet

Using the foamed polyethylene layer and the buffer sheet prepared in Example 1 as a surface material layer and a buffer material layer, respectively, a heat insulating buffer laminate sheet was prepared according to the process shown in FIG. 6. In this embodiment, the raw material composition for each tank for the production of the insulation layer, and the process conditions are as follows.

-Raw material composition in the polyol compound tank (maintenance temperature: 22 ℃)

90 parts by weight of polyether polyol (hydroxyl group: 200 to 500 KOH)

10 parts by weight of polyester polyol (hydroxyl group: 150-300 KOH)

1.1 parts by weight of amine catalyst (DMEA)

0.7 parts by weight of metal catalyst (T-45)

1 part by weight of water as blowing agent

Co-foaming agent (HCFD-141b) 30 parts by weight

Foam Detergent (L-6900) 1.8 parts by weight

Flame retardant (TCPP) 12 parts by weight

-Raw material composition in isocyanate compound tank (maintenance temperature: 22 ℃)

MDI (NCO% content: 31.5, viscosity (25 ° C) 170-250 cps) 200 parts by weight

A metering pump was used to feed the raw material stirring ejector while adjusting the weight ratio of polypropylene glycol: MDI to 1: 1.5. The raw material stirring ejector was a mixer of Sungwon ENG (discharge pressure about 2kgf / ㎠) to discharge the reaction raw material mixture at a speed of 1500g per minute while stirring at about 3500rpm in a mixer provided therein. Using a two SUS roller (diameter: 15 cm) conveyor, a buffer layer (thickness: 12 mm), which is a lower layer, is supplied, and a surface material layer (thickness :), which is an upper layer, using a SUS roll (diameter: 15 cm). 5 mm). In this case, in the double slat conveyor, the surface material layer and the buffer material layer were respectively transferred at a constant speed of 5 m / min, and the distance between the surface material layer and the buffer material layer was about 30 mm. The temperature between the top and bottom of the double slat conveyor was adjusted to 40 ℃, the total time of the foaming and curing reaction was adjusted to be about 2 minutes. The laminated sheets of the three surface material layer-insulation layer-buffer layer obtained as a result of the reaction were cut using an automatic cutting machine (manufactured by Sungwon ENG Co., Ltd.).

The physical properties of the cut insulation buffer lamination sheet was measured, and compared with the prior art that has been attempted by the present applicant to measure the physical properties of the insulation buffer lamination sheet using an air cap instead of a polyethylene-based mesh It is shown in Table 3 below.

TABLE 3

Item The present invention Prior art Floor impact sound (light weight) 1st grade 1st grade Floor impact sound (weight) 2nd class Level 3 Dynamic modulus 8 10 Compression Deformation (2ton / 1㎥) 2 mm 3 mm

As can be seen from the table, the heat insulating buffer laminate sheet according to the present invention showed an excellent buffering performance compared to the prior art. In particular, unlike currently commonly used techniques, no separate adhesive or adhesive mortar is required for the formation of an integral laminate structure. Therefore, it is considered that it can be widely applied as a conventional floor insulation buffer or inner wall.

Simple modifications and variations of the present invention can be readily used by those skilled in the art, and all such variations or modifications can be considered to be included within the scope of the present invention.

1 is a perspective view schematically showing a laminated structure of a buffer sheet according to an embodiment of the present invention,

2 is a photograph showing a cross-sectional structure of a buffer sheet according to an embodiment of the present invention,

Figure 3 is a photograph showing the structure of a polyethylene-based mesh included in the buffer sheet according to an embodiment of the present invention,

4 is a view schematically showing an integrated heat insulating buffer laminate sheet according to another embodiment of the present invention,

5 is a photograph showing a cross-sectional structure of an integrated heat-insulating buffered laminate sheet according to another embodiment of the present invention, and

6 is a view schematically showing an embodiment of a process for producing an integral heat-insulating buffered laminate sheet according to the present invention.

<Description of Drawing>

10: surface material layer 20: insulation material layer

30: buffer layer 31, 33: protective layer

32: mesh layer 34, 34 ', 34' ': thread

35, 35 ', 35' ': branched thread 36, 36', 36 '': branched thread

Claims (11)

In the interlayer bottom buffer material or the inner wall of the buffer sheet comprising a polyethylene-based mesh layer and a protective layer formed on one or both sides of the polyethylene-based mesh layer, The polyethylene-based mesh layer is a form in which a plurality of polyethylene-based threads are connected while crossing each other, wherein each thread is divided in two directions to form a branching thread, but the lower surface (or upper surface) of the branching thread is an adjacent branch divided from another thread Arranged to connect with the top (or bottom) of the thread, The polyethylene mesh layer is a foamed polyethylene material, The protective layer is a foamed polyethylene sheet, independent foamed polyethylene foamed resin, polypropylene sheet, bead method styrofoam or extrusion method styrofoam material, The polyethylene-based mesh layer and the protective layer are attached to each other by heat bonding or heat fusion, and The polyethylene-based mesh layer and the protective layer has a thickness of 3 to 30 mm and 2 to 20 mm, respectively. delete delete delete delete delete delete delete delete delete delete

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