JP3063151B2 - Directly bonded floor cushioning material - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION [Industrial Application Field] The present invention relates to a cushioning member for a directly adhered floor having excellent sound insulation and sound insulation.

[Conventional technology]

Resin tiles, tatami mats, carpets, wooden flooring, etc. are used as flooring for apartment houses such as detached houses and condominiums. In recent years, its demand has been increasing not only at the time of new construction but also at the time of renovation, because it is easy to remove and clean.

By the way, when constructing floor materials, it is necessary to take care to prevent noise from being transmitted downstairs. Such floor noise includes a heavy impact sound generated when a child jumps or runs around, and a light impact sound generated by dragging a chair or dropping a spoon. The degree to which a heavy impact sound is transmitted mainly depends on the basic structure of a building, but the degree to which a light impact sound is transmitted largely depends on the material and structure of a floor material.
Therefore, conventionally, various attempts have been made to prevent the transmission of light impact sound by using a cushioning member for the floor material or making the floor a special structure.

For example, in the case of a wooden floor material directly attached floor (thin thickness, a floor directly attached to a concrete slab, etc., total floor thickness of 10 to 30 mm), a rubber foam or felt having a one-layer structure is used as a cushioning member. Have been. In addition, double floor using panels with supporting legs (total floor thickness 150 to 210 mm), foam plastic floor using foam plastic panels (total floor thickness 70 to 160 mm)
Alternatively, floors with a base structure using a cushioning member such as a floating floor (total floor thickness of 70 to 160 mm) using a special glass wool mat have been proposed.

[Problems to be solved by the invention]

However, some floors having a conventional structure with a base have relatively good sound insulation and sound insulation, but have a disadvantage of high cost. In addition, there is also a disadvantage that skill is often required to construct a floor having a substructure. Further, since the floor having such a base structure has a large thickness, there is a disadvantage that the floor of doors and windows rises and the height of the opening is reduced. In particular, at the time of renovation, there has been a problem in that the door has to be replaced because the floor surface rises.

On the other hand, those in which a conventional cushioning member is used for a directly pasted floor are generally low in cost, but have a drawback that their sound insulation and soundproofing effects are not sufficient. On the other hand, the thickness of a cushioning member such as a rubber foam is also increased, but in this case, the cost increases and the floor warps, dents,
There was also a disadvantage that eyes were easily formed.

An object of the present invention is to solve the above-mentioned problems of the prior art, and an object of the present invention is to provide a cushioning member for a directly attached floor that can effectively and inexpensively reduce light impact noise at low cost. And

[Means for solving the problem]

The present inventor uses a specific material as a fiber material and prepares a card web containing a heat-fusible fiber having a specific blending ratio by a needle punching treatment and a heat fusion treatment to obtain a specific range of a basis weight and an apparent density. The inventors have found that the above-mentioned object can be achieved by a nonwoven fabric formed so as to have the present invention, and completed the present invention.

That is, according to the present invention, a card web composed of fibers having a thickness of 30 to 50 deniers, in which the heat-fused fibers are blended at a blending ratio of 10 to 30% by weight, is laminated, and the basis weight is obtained by a needle punching treatment and a heat fusion treatment. 200-500 g / m ^2, apparent density 0.02~0.2g
The present invention provides a cushioning member for a directly bonded floor, which is made of a nonwoven fabric molded to a thickness of / cm ³ .

 Hereinafter, the present invention will be described in detail.

As the fiber material of the nonwoven fabric constituting the cushion member for a directly bonded floor of the present invention, a fiber material having a fiber thickness of 30 to 50 denier is used. By using such a thick fiber, the sound absorption characteristics in the low frequency range of the light impact sound can be improved, and it becomes possible to effectively shield and prevent normal daily sounds.

The use of thin fibers of less than 30 deniers reduces the sound absorption characteristics of light impact sounds. In addition, the flexibility of the nonwoven fabric increases,
It is not preferable because the loadability (subsidence during walking or the like) becomes excessive. Further, the machinability is also reduced, and the so-called "stringing phenomenon" in which the nonwoven fabric becomes fragile when cutting the nonwoven fabric at the construction site of the cushioning member for directly bonded floors is also a problem. Conversely, if the thickness exceeds 50 denier, the uniformity of the web is undesirably reduced.

Further, it is preferable to use a polyamide fiber, a polyester fiber, or a polypropylene fiber as the type of the fiber because it is easily colored and can be obtained at a low cost.

The fibers of the card web are blended with heat fusion fibers. From the viewpoint of adhesive strength, the heat-fused fiber preferably contains a polyester-based fused fiber, a polyamide-based fused fiber, or the like. The mixing ratio depends on the type of fiber used, but is usually 10 to 30% by weight. As a result, the elastic modulus of the non-woven fabric is improved, the sag against the repeated load is reduced, and the non-woven fabric also has a sufficient mechanical strength. On the other hand, if the blending ratio of the heat-fusible fibers is less than 10% by weight, the peel strength between the layers of the laminated card web becomes weak, which is not preferable. On the other hand, when the content is more than 30% by weight, the nonwoven fabric becomes hard, and the sound insulation is deteriorated.

The cushioning member for a directly bonded floor of the present invention is obtained by laminating a card web made of a fiber material as described above, performing a heat fusing treatment after a needle punching treatment, and has a basis weight of 200 to 500 g / m ² and an apparent density.
It shall be molded to 0.02 to 0.2 g / cm ³ . Set the apparent density to 0.
If it is larger than 2 g / cm ³ and the nonwoven fabric is hard, the sound absorbing property is undesirably reduced. On the other hand, when the apparent density is smaller than 0.02 g / cm ^{3 and} the flexibility of the nonwoven fabric is increased, the loadability is increased and the nonwoven fabric is not suitable as a cushioning member for a directly attached floor. Furthermore, the stringing phenomenon also becomes a problem at the construction site. Further, when the basis weight is more than 500 g / m ^2, an apparent density of the nonwoven fabric to a suitable range as described above it becomes thicker the thickness of the nonwoven fabric, convenience as direct attachment Floor cushioning member It is not preferable because it lowers. On the other hand, the basis weight is 20
If it is less than 0 g / m ² , the function as a cushioning material is undesirably reduced.

By forming the nonwoven into such a range of the basis weight and density, the thickness is finished to about 1 to 10 mm, the sound absorbing property against light impact noise is enhanced, and the moderate loadability as a cushioning material for directly attached floor It also makes it possible to improve the machinability.

The nonwoven fabric having such a basis weight and density can be obtained by appropriately setting punching conditions and performing a needle punching process on the laminated card web, but in the case of the cushioning member for a directly adhered floor material of the present invention. After the needle punching process, a heat fusion process is further performed to mold. That is, if only the needle punching is used to form the nonwoven fabric, the number of fibers oriented in the longitudinal direction (the direction perpendicular to the cloth surface) in the nonwoven fabric increases. For this reason, the sound easily passes through the nonwoven fabric, and the sound insulation of the nonwoven fabric is reduced. On the other hand, when the nonwoven fabric is formed by performing the heat fusion process after the needle punching process, the needle punching conditions for holding the laminated card web as the nonwoven fabric can be relaxed, so that the longitudinal direction can be reduced. Orienting fibers can be reduced to a minimum. In addition, since sound propagates in the web laminating direction and attenuates, it is possible to further improve sound insulation and sound insulation. Further, it is possible to increase the delamination strength of the laminated card web.

The conditions of the heat fusion treatment depend on the type of fibers constituting the card web, the blending ratio of the heat fusion fibers, the conditions of the needle punching treatment, etc., but usually fusion at a temperature of 150 to 180 ° C. preferable.

The number of layers of the card web to be laminated depends on the denier configuration, fleece weight, and the like, but it is preferable that the card web has a multilayer structure of, for example, 30 to 40 layers, compared to 10 to 20 layers of the conventional product. Thereby, the sound absorbing and sound insulating properties can be improved.

The cushioning member for a directly bonded floor of the present invention is made of the following non-woven fabric, and may be a non-woven fabric further laminated with a water-proof / moisture-proof layer. This allows
Even when a cushioning member for a directly attached floor is provided on a substrate such as concrete, which is likely to be exposed to moisture, a water and moisture barrier layer can be interposed between the substrate and the nonwoven fabric, so that moisture from the substrate can be easily obtained. Can be prevented from entering.

As such a water-blocking / moisture-blocking layer, any thin-sheet-like material having water-blocking / moisture-blocking ability can be used. For example, a water- / water-proof polymer film, a water- / water-proof polymer foam sheet, and the like can be preferably used. As the water-blocking / moisture-blocking polymer film, for example, a hot-melt film such as polyolefin and polyamide can be used. To laminate such a film on a nonwoven fabric, an epoxy-based, chloroprene-based adhesive, or the like can be used.

In the case of laminating a waterproof / moisture proof polymer foam sheet, it becomes possible to prevent the penetration of moisture from the base material as in the case of laminating a waterproof / moisture proof film,
Further, it becomes possible to improve the cushioning property and sound absorbing property of the directly attached floor.

As such a water- and moisture-shielding polymer foam sheet, a closed-cell resin layer can be suitably used, and for example, a resin foam such as foamed polyethylene, foamed polyvinyl chloride, foamed rubber and the like can be used. In laminating such a polymer foam sheet and a nonwoven fabric, a dry lamination method or a frame lamination method may be used, or the foamable resin composition may be coated on the nonwoven fabric and then foamed. .

The thickness of the water and moisture barrier layer depends on the material of the water and moisture barrier layer and the shape of the water and moisture barrier layer, but is generally 30 μm to 5 mm.

[Function] The cushioning member for a directly bonded floor of the present invention has a thickness as a fiber material.
Using a fiber of 30 to 50 denier, and performing a heat fusion process after the needle punching process, a basis weight of 200 to 500 g / m ² ,
Because it uses 0.02~0.2g / cm ³ in the molded nonwoven, superior sound insulation, soundproofing light impact sound, and loading of the direct attachment bed for cushioning material, machinability is improved, even high delamination strength It will be. For this reason, it can be suitably used for a buffer member for a directly attached floor, and it is possible to effectively and inexpensively perform sound insulation and sound insulation at low cost.

Further, the cushioning member for a directly attached floor of the present invention, in which a water-proof / moisture-proof film or a water-proof / moisture-proof foam layer is laminated, can easily prevent moisture from entering from a base material such as concrete. Become. Further, in the case of the cushioning member for a directly attached floor of the present invention in which a water-proof / moisture-proof foam layer is laminated, it is possible to improve the cushioning property and the sound absorption of the directly attached floor.

〔Example〕

Hereinafter, the present invention will be specifically described based on examples, but the present invention is not limited thereto.

Example 1 80% by weight of a 40 denier polyester fiber and a thickness of 4
Forty layers of a card web composed of 20% by weight of denier polyester-based fusible fibers are laminated, needle-punched, and heat-fused (processing conditions: 150 ° C.) to give a basis weight of 300 g / m ² ,
A buffer member for a directly bonded floor of the present invention having an apparent density of 0.075 g / cm ³ and a thickness of 4 mm was produced.

Example 2 80% by weight of polyester fiber having a thickness of 40 denier and a thickness of 4
A card web consisting of 20% by weight of a denier polyester fiber was laminated in the same manner as in Example 1 by 40 layers, and was subjected to a needle punch treatment to obtain a basis weight of 250 g / m ² and an apparent density of 0.125 g / cm.
^Three nonwoven fabrics were produced. Furthermore, this non-woven fabric has a thickness of 2.5 mm.
A 30 times expanded polyethylene foam was laminated by a frame lamination method.

The cushioning member for a directly bonded floor of the present invention manufactured in Example 1
The sound insulation level of a light impact sound was measured according to JIS A1418.
As a result, the sound insulation for the octave band center frequencies of 125 Hz, 250 Hz and 500 Hz was L values 45, 44 and 40, respectively.
And showed a sound insulating property of L-45 class. Where L
The sound insulation level of -45 class means, from the point of view of real life, the sound of a dropping floor, the sound of slippers, and the sound of a knife cannot be heard on the floor, but the sound of the larger sandals is finally heard. The level that can be heard (the loudness of the dropping sound of a chopstick <slipper sound <knife sound <sandal sound). As described above, the cushioning member for a directly attached floor of the present invention can achieve a sound insulation level of L-45 grade, there is almost no complaint from the user in a normal use state, and there is no need to worry about noise downstairs. Sound insulation can be achieved.

Note that the cushioning member for a directly bonded floor of the present invention manufactured in Example 2 also exhibited a sound insulation level of L-45 grade.

〔The invention's effect〕

ADVANTAGE OF THE INVENTION According to the buffer member for floors directly adhered of this invention, it becomes possible to sound-insulate and prevent light impact sound effectively at low cost. Further, according to the cushioning member for a directly attached floor of the present invention in which a water-blocking / moisture-blocking film or a water-blocking / moisture-blocking foam layer is laminated, it is possible to easily prevent moisture from entering from a base material such as concrete. It becomes possible. Further, in the case of the cushioning member for a directly attached floor of the present invention in which a water-proof / moisture-proof foam layer is laminated, it is possible to improve the cushioning property and the sound absorption of the directly attached floor.

──────────────────────────────────────────────────続 き Continuing on the front page (72) Takashi Hirao 2-6-10 Komyobashi, Chuo-ku, Osaka-shi, Osaka Dynic Co., Ltd. Osaka Branch Office (72) Inventor Yutaka Hiroshi 3-3-1 Higashiikebukuro, Toshima-ku, Tokyo 1 Dynick Co., Ltd. Tokyo Head Office (56) References JP-A-1-148860 (JP, A) JP-A-58-23999 (JP, A) Fully open 50-56777 (JP, U) Really open 62-160046 (JP, U) (58) Fields investigated (Int. Cl. ⁷ , DB name) D04H 1/00-5/08

Claims (6)

(57) [Claims] 1. A card web made of fibers having a thickness of 30 to 50 deniers in which heat-fused fibers are blended at a blending ratio of 10 to 30% by weight, and a basis weight of 200 to 50% is obtained by a needle punching treatment and a heat fusion treatment. A buffer member for a directly adhered floor, comprising a nonwoven fabric formed to a thickness of up to 500 g / m ² and an apparent density of 0.02 to 0.2 g / cm ³ . 2. The cushioning member for a directly attached floor according to claim 1, wherein the fibers are made of polyamide fibers, polyester fibers or polypropylene fibers. 3. The cushioning member for a directly bonded floor according to claim 1, wherein a polyester-based fusible fiber is blended as the heat fusible fiber. 4. The cushioning member for a directly adhered floor according to claim 1, further comprising a water-blocking / moisture-blocking layer. 5. The cushioning member for a directly adhered floor according to claim 4, wherein a water-blocking / moisture-proof polymer film or a water-blocking / moisture-blocking polymer foam sheet is laminated as the water-blocking / moisture-blocking layer. 6. The card web according to claim 1, wherein 30 to 40 layers of card web are laminated.
A cushioning member for a directly attached floor according to any one of claims 1 to 5.