JP2002052645A - Method for manufacturing damping exterior material - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a method for manufacturing a damping exterior material keeping good workability which shows not only soundproofing properties brought about by excellent damping but heat insulation and hardly causes dew formation on an inner side of a room due to a temperature difference between the inner and outer sides of the room in winter even when it is used for a roofing material or the like. SOLUTION: A method for manufacturing a damping exterior material comprises a process of laminating a damping sheet (2) having a specific gravity of not less than 1.3 (for example 1.8) composed of a resin composition containing a thermoplastic elastomer and an inorganic filler on one surface of a resin foamed sheet (1) having an expansion ratio of 10 to 50 (for example 30) in such a manner that the surface of the resin foamed sheet is partly covered (20 to 70% of the one surface area thereof) and a process of laminating a metal outer decorative material (4) on the damping sheet (2) laminated on the resin foamed sheet.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for producing a vibration-damping exterior material, which is suitably used, for example, as a folded-plate roof or a horizontal roof.

[0002]

2. Description of the Related Art Conventionally, as a roofing material for buildings such as houses and factories, for example, a folded plate roof having a corrugated shape made of a steel plate has been used. There was a problem that it could not be blocked, the noise inside and outside the room increased, and the sound insulation was poor.

[0003] In order to solve such problems, for example, a method of laminating a vibration damping sheet on the back surface of a folded plate roof has been studied. As such a vibration damping sheet, for example, Japanese Patent Application Laid-Open No. 3-287661 proposes a vibration damping composite material comprising a thermoplastic elastomer and an inorganic powder.
However, the folded-plate roof made of the vibration damping material obtained by laminating the above-mentioned composite material and steel plate has a problem that water condenses on the surface of the vibration-damping composite material inside the room due to the temperature difference between the outside air temperature in winter and the room temperature. Therefore, the following problems due to dew condensation are assumed.

[0004] That is, the dew condensation water falls on the heat insulating material in the attic, and the heat insulating material contains moisture, thereby deteriorating the heat insulation performance, and the dew water generates rust on steel beams such as beams. Was a concern.

[0005]

SUMMARY OF THE INVENTION An object of the present invention is to provide a sound insulation and heat insulating property accompanied by excellent vibration damping properties in view of the above-mentioned problems of the exterior material such as a folded plate roof. Provided is a method of manufacturing a vibration-damping exterior material that can produce a vibration-damping exterior material that hardly causes dew condensation on the indoor side due to a temperature difference between the indoor and outdoor areas in winter, with good workability. It is in.

[0006]

In order to achieve the above object, the present invention according to the first aspect of the present invention provides a resin foam sheet having an expansion ratio of 10 to 50 times so as to partially cover the surface. After adhering a damping sheet having a specific gravity of 1.3 or more made of a resin composition containing a thermoplastic elastomer and an inorganic powder, a metal exterior material is further laminated on the side of the resin foam sheet to which the damping sheet is attached. To provide a method of manufacturing a vibration damping exterior material. The present invention according to claim 2 provides a method for manufacturing a vibration-damping exterior material, which comprises attaching a vibration-damping sheet to one surface of a resin foam sheet in advance and forming the form into a scroll.

According to a third aspect of the present invention, a resin foam sheet made of a polyolefin resin and a vibration damping sheet are laminated by heating via an adhesive. Provided is a method of manufacturing a vibration-damping exterior material.
Hereinafter, the present invention will be described in more detail.

[0008] The vibration damping sheet used in the present invention is formed from a resin composition containing a thermoplastic elastomer and an inorganic powder.

Examples of the thermoplastic elastomer include isoprene-based, olefin-based, and ester-based elastomers. Among these, styrene-
An isoprene block copolymer is preferably used.

The styrene-isoprene block copolymer is a block copolymer of styrene as the first component and isoprene as the second component, butadiene may be used in combination with isoprene.

When the second component of the styrene-isoprene block copolymer is composed of isoprene alone or a mixture with butadiene, the content of 3.4 and 1.2 bonds of the block portion of the second component is also preferable. Is preferably 40% or more. The content of 3.4 bonds and 1.2 bonds is 40
%, The obtained damping sheet may not exhibit sufficient damping performance in a normal use temperature range.

Further, the molecular weight of the styrene-isoprene block copolymer is preferably 30,000 to 300,000, more preferably 80,000 to 250,000. When the molecular weight is less than 30,000, mechanical properties such as strength at break and elongation of the block copolymer itself may be reduced. On the other hand, when the molecular weight exceeds 300,000, it becomes difficult to mix with an inorganic powder described later. Commercial products of such a styrene-isoprene block copolymer include, for example, "HIBLER" manufactured by Kuraray Co., Ltd.

As the inorganic powder, for example, iron oxide,
Metal oxides such as titanium oxide and magnesium oxide; particulate metals; mineral ground pulverized materials such as clay, talc, mica, and quartz powder, as well as glass fibers, glass powder, calcium carbonate, gypsum and the like. Among them, mica and calcium carbonate are particularly preferable from the viewpoint of vibration damping characteristics and cost.

The particle size of the inorganic powder is not particularly limited, but is preferably from 1 to 500 μm. When the particle diameter is less than 1 μm, the surface area increases and the number of particles per unit weight increases, so that the mixing step takes time. In addition, the particle size is 5
When the thickness exceeds 00 μm, the surface of the vibration damping sheet may be roughened or the sheet may be broken during molding.

[0015] An ethylene-vinyl acetate copolymer may be used in the resin composition. The ethylene-vinyl acetate copolymer preferably has a vinyl acetate content of 2 to 40% by weight. Vinyl acetate content is 2% by weight
If the amount is less than 40%, the obtained vibration damping sheet may have insufficient flexibility. If the amount exceeds 40% by weight, the resin composition has tackiness. It may be.

The resin composition contains 20 to 5,000 parts by weight of an ethylene-vinyl acetate copolymer and 200 to 10,000 parts by weight of an inorganic powder based on 100 parts by weight of a styrene-isoprene block copolymer. Those containing are preferred.

If the compounding amount of the inorganic powder is small, it is necessary to increase the thickness of the obtained vibration damping sheet in order to exhibit a predetermined vibration damping performance. Since the strength may decrease, the amount is preferably 200 to 10,000 parts by weight, more preferably 500 to 3,000 parts by weight, based on 100 parts by weight of the styrene-isoprene block copolymer.

The amount of the ethylene-vinyl acetate copolymer is determined by the amount of the inorganic powder to be described later and the like. If the amount is small, the moldability of the obtained vibration damping sheet may be reduced, and if it is large, the amount may be increased. Since the vibration damping performance of the styrene-isoprene block copolymer may be reduced, it is preferably 20 to 5,000 parts by weight, more preferably 100 to 1,100 parts by weight based on 100 parts by weight of the styrene-isoprene block copolymer. 000 parts by weight.

When the amount of the inorganic powder exceeds 1,000 parts by weight, the styrene-isoprene block copolymer 10 is used to secure the mechanical strength of the vibration damping sheet.
2 parts by weight of ethylene-vinyl acetate copolymer
It is preferable to mix it in an amount of at least 00 parts by weight.

In particular, when the content of the styrene-isoprene block copolymer in the resin composition is 1% by weight or less, the styrene-isoprene block copolymer 1
It is preferable to blend the ethylene-vinyl acetate copolymer in an amount of 1,000 parts by weight or more based on 00 parts by weight.

The above resin composition may contain a heat stabilizer, a weather resistance improver, a lubricant, a processing aid, a pigment, a colorant, and the like, if necessary. In particular, it is preferable to add a petroleum resin (C9 resin) in order to improve the adhesion of the vibration damping sheet to the steel sheet and the fluidity during molding.

The above-mentioned resin composition is heated to a temperature higher than the melting softening point (specifically, 100 to 270 ° C.) and molded into a sheet by extrusion molding or calender molding, whereby a vibration-damping sheet is obtained. .

When the specific gravity of the above-mentioned vibration-damping sheet becomes low, the vibration-damping performance decreases, so that the vibration-damping sheet is limited to 1.3 or more, and its thickness is appropriately determined depending on the resin composition, the vibration-damping performance and the like. Preferably, it is 2 mm or less.

As the resin foam sheet used in the present invention, a closed-cell resin foam sheet of polyethylene, polypropylene, ethylene-vinyl acetate copolymer, polystyrene or the like is used. Among these, those made of a polyethylene resin foam are particularly preferable, and those having a closed cell structure and having no water absorbing property or moisture absorbing property are more preferable. Also,
From the viewpoint of improving the adhesiveness, the surface of the resin foam sheet to which the vibration damping sheet is attached is preferably a surface sliced from the skin surface. Commercial products of the above polyethylene resin foam sheet, for example, "Softlon" manufactured by Sekisui Chemical Co., Ltd.
Is mentioned.

When the foaming ratio of the resin foam sheet is small, sufficient dew condensation preventing performance cannot be obtained, and when the foaming ratio is large, the mechanical strength is reduced. Therefore, the foaming ratio is 10 to 50 times, and more preferably 30 to 40 times. It is twice.

Further, when the resin foamed sheet is thin, sufficient dew condensation preventing performance cannot be obtained. When the resin foamed sheet is thick, the press pressure during lamination is not sufficiently transmitted, and poor adhesion to the vibration damping sheet may occur. The thickness is preferably 2 to 10 mm, and more preferably 4 to 10 mm.

In the manufacturing method of the present invention, the above-mentioned vibration damping sheet is attached to one surface of the resin foam sheet so as to partially cover the surface. The degree of partial coating / sticking is not particularly limited, but is usually preferably about 20 to 70% of the surface area of one side of the resin foam sheet.

As a method of attaching the vibration damping sheet to the above-mentioned resin foam sheet, for example, there is a method of bonding using a solvent type rubber adhesive, a hot melt type adhesive, or an emulsion type adhesive. When a solvent-type chloroprene rubber-based adhesive is used as the solvent-based rubber-based adhesive, high adhesive strength can be obtained by drying until the residual solvent amount is in the range of 5 to 30% of the initial solvent content. it can.

Examples of the hot melt type adhesive include natural rubber, isoprene rubber, butadiene rubber, chloroprene rubber, nitrile rubber, butyl rubber, acryl rubber, ethylene-propylene rubber and the like, and ethylene-vinyl acetate. A conventionally known hot-melt adhesive obtained by blending a copolymer, a polyamide, a polyester, a styrene-butadiene-based block copolymer and a hydrogenated product of the block copolymer with a softener such as a tackifier or an oil. Is used.

When a hot-melt type adhesive is used as the adhesive, the coating amount is preferably from 3 to 200 g / m ² . If the coating amount is less than 3 g / m ² , sufficient adhesive strength cannot be obtained, and if it exceeds 200 g / m ² , there is no further improvement in adhesive strength, and the adhesive strength may decrease due to cohesive failure.

The resin foam sheet coated with the hot-melt adhesive has no tackiness at room temperature and can be wound up as a roll without using release paper, thereby improving workability.

Even when the above resin foam sheet is generally made of a polyolefin having poor adhesiveness, it can be laminated by heating with a vibration damping sheet and a hot melt type adhesive and using a solvent type rubber adhesive. Workability is better than when laminating by pressing.

In the production method of the present invention, a metal-sheath material is further laminated on the above-mentioned resin foam sheet on the side where the vibration-damping sheet is attached, to obtain a vibration-damping material.

As a specific method of laminating the exterior material on the side of the resin foam sheet to which the vibration damping sheet is attached, there is a method of bonding using an adhesive. As the adhesive used for lamination, a solvent-type rubber-based adhesive, a two-part type epoxy adhesive, a urethane-based adhesive, or the like can be used, and among these, a solvent-type chloroprene-based rubber adhesive is preferable. .
The bonding surface of the vibration damping sheet may be subjected to a primer treatment (adhesive application) in advance.

Examples of the metal exterior material include a steel plate,
Metal plates, such as a zinc steel plate, a copper plate, and a PVC steel plate, are mentioned. When using the exterior material, a material processed in a predetermined shape (for example, a roof with a roof) may be used. After a resin foam sheet and a vibration damping sheet are laminated with a metal plate, a predetermined process is performed by forming. (For example, folded plate roof shape).

As described above, the vibration-damping exterior material of the present invention is suitably used as a roof material such as a folded-plate roof or a horizontal roof, but is not limited thereto, and may be used as an outer wall. , Does not necessarily require a three-dimensional shape,
In some cases, a laminated structure of a resin foam sheet, a vibration damping sheet, and a planar metal exterior material may be used.

[0037]

Embodiments of the present invention will be described in more detail with reference to the following examples.

(Example 1) [Production of damping sheet] Styrene-isoprene block copolymer ("HIBLER" manufactured by Kuraray Co., Ltd., molecular weight: about 140,000)
100 parts by weight, 100 parts by weight of an ethylene-vinyl acetate copolymer (vinyl acetate content: 30% by weight), 200 parts by weight of calcium carbonate (average particle size: 2 μm) and mica (100 mesh pass) as inorganic powder A resin composition consisting of parts by weight was supplied to an extruder and heated and kneaded to extrude a vibration damping sheet having a specific gravity of 1.8, a thickness of 1 mm and a width of 100 mm.

[Production of Resin Foam Sheet Attached with Damping Sheet] Next, as shown in FIG. 1 schematically showing the arrangement state, the thickness of the styrene-butadiene hot-melt type adhesive (primer) previously applied is applied. A 4 mm, 500 mm wide polyethylene resin foam sheet ("Taika Softlon" manufactured by Sekisui Chemical Co., Ltd., foaming ratio: 30 times) (1)
m, two or more vibration-damping sheets (2)
It was stuck along the flow direction (extrusion direction) and wound up in a roll (as a roll). Specifically, using an infrared lamp, the surface temperature of the vibration damping sheet (2) on the sticking side is set to 100 to
The polyethylene resin foam sheet (1) is heated to 140 ° C. so that the surface (primer coated surface) temperature of the polyethylene resin foam sheet (80) is 80 to 120 ° C., and then both are superposed and adhered, and the polyethylene resin foam sheet ( 3) A roll (not shown) was obtained. In the polyethylene resin foam sheet (3), the affixing area of the vibration damping sheet (2) was 25% of the surface area of the polyethylene resin foam sheet (1).

[Manufacture of Composite Folded Roof] The above resin foam sheet (3) was rewound, and the vibration damping sheet (2) was placed in contact with a metal plate (steel plate, thickness 0.6 mm). After laminating with a chloroprene rubber-based adhesive, the laminate including the metal plate is subjected to forming processing to form a vibration damping sheet (2) inside the metal plate (4) and a polyethylene resin inside the metal plate (4) as shown in FIG. A composite folded plate roof (5) having a layer configuration in which the foam sheet (1) was laminated was obtained. The vibration damping sheet (2) of the composite folded plate roof (5) had a configuration in which the surfaces of the polyethylene resin foam sheet (1) and the metal plate (4) were partially covered.

(Example 2) In the polyethylene resin foam sheet (3) to which the vibration damping sheet was stuck, the area of the vibration damping sheet (2) to be stuck was changed to the polyethylene resin foam sheet (1).
A composite folded plate roof (5) was obtained in the same manner as in Example 1 except that the surface area was set to 50% of the surface area.

(Comparative Example 1) A vibration-damping sheet (2) was attached to the entire surface area of the polyethylene resin foam sheet (1) in the same manner as in Example 1 except that the attachment area was 100% of the total surface area. To obtain a composite folded plate roof (5).

(Comparative Example 2) The foamed polyethylene resin sheet (1) was directly adhered to the metal plate (5) without adhering the vibration damping sheet to the foamed polyethylene resin sheet (1) at all. ), And a composite folded plate roof (5) was obtained in the same manner as in Example 1.

(Example 3) [Production of composite horizontal roof] A polyethylene resin foam sheet to which the vibration damping sheet obtained in Example 1 was adhered (attachment area 25
%) Is rewound and a metal plate (steel plate, thickness 0.6 mm) previously formed into a shape as shown in FIG.
(14), the damping sheet (12) is arranged so as to be in contact therewith, and bonded with a solvent-type chloroprene rubber-based adhesive, so that the damping sheet (12) and the lower part thereof are placed below the metal plate (14). A composite horizontal roof (15) having a layer configuration in which a polyethylene resin foam sheet (11) was laminated on the side was obtained. The vibration damping sheet (12) of this composite roof (15) had a configuration in which the surfaces of the polyethylene resin foam sheet (11) and the metal plate (14) were partially covered. FIG.
(A) is a plan view of the composite thatched roof (15), FIG. 3 (b) is a bottom view thereof, and FIG. 4 is a perspective view of the composite thatched roof (15). Are used by being connected to each other in the approximate left-right direction.

(Example 4) The affixing area of the vibration damping sheet (12) was set at 50% of the surface area of the polyethylene resin foam sheet (11).
%, And a composite horizontal roof (15) was obtained in the same manner as in Example 3.

(Comparative Example 3) The same procedure as in Example 3 was carried out except that the affixed portion of the vibration damping sheet (12) was the entire surface of the polyethylene resin foam sheet (11) (the affixed area was 100% of the total surface area). Similarly, a composite horizontal roof (15) was obtained.

Comparative Example 4 A foamed polyethylene resin sheet (11) was directly adhered to a metal plate without adhering the vibration damping sheet (12) to the foamed polyethylene resin sheet (1) at all. 0% of the
A composite roof (15) was obtained in the same manner as in Example 3.

Vibration Suppression (Soundproofing) of Roof Material The composite folded-plate roof or composite roofing roof obtained in the above Examples 1 to 4 and Comparative Examples 1 to 4 (however, the affixing area is described in Tables 1 and 2) 5 was laid on a predetermined portion of a roof (7) of a one-sided test chamber made of plywood having a thickness of 12 mm as shown in FIG. An artificial rain with a rainfall of 100 mm / hour (raindrops with a diameter of 3 mm were dropped at intervals of 5 cm) was dropped from a position of 7 m. Then, the indoor noise at a position about 30 cm below the center of the roof is measured with a normal sound level meter (NA-
29).

In the above Examples and Comparative Examples, the sound pressure level (dB) (5
(Average for 2 seconds), 500Hz, 1
It was measured at 1/1 octave band frequency at 000 Hz, 2000 Hz, and 4000 Hz. The results are shown in Table 1 (composite folded plate roof) and Table 2 (composite horizontal roof).

[0050] 25% or 50% of the area where the damping sheet is attached
The sound pressure levels in Examples 1 and 2 were sufficiently lower than those in Comparative Example 2 in which the vibration damping sheet was not affixed, and soundproofing was observed. The relationship between Examples 3 and 4 and Comparative Example 4 was the same. In Comparative Example 1 in which the vibration damping sheet was attached to the entire surface of the resin foam sheet, the sound pressure level was lower than in Examples 1 and 2, but the vibration damping sheet having a specific gravity of 1.8 was attached to the entire surface of the resin foam sheet. , This resin foam sheet is heavy,
Workability of the lamination work was poor. Also, the production cost of the composite folded plate roof in consideration of the material cost and low workability has become expensive. Similarly, in Comparative Example 3, although the sound pressure level was lower than Examples 3 and 4, the resin foam sheet to which the vibration damping sheet was attached was heavy, and the workability of the steel sheet laminating operation was poor. Therefore, the manufacturing cost of the composite folded roof that takes into account the material cost and low workability is high.

[0051]

[Table 1]

[0052]

[Table 2]

[0053]

The method for producing a vibration-damping exterior material of the present invention is configured as described above, and the obtained vibration-damping exterior material exhibits excellent sound-damping performance accompanying excellent vibration-damping properties, and can be used during rainfall. Due to the heat insulation effect of the resin foam sheet, even if it is used for building materials such as folded-plate roofs and side-roofed roofs, dew condensation on the indoor side due to temperature differences between indoor and outdoor areas in winter Is unlikely to occur.

Further, in the present invention, after the vibration damping sheet is pasted on the resin foam sheet in advance, the metal cladding material is laminated on the side where the vibration damping sheet is adhered. In addition, the workability is good because there is no need to apply twice, and in addition, a vibration damping sheet is laminated on one surface of the resin foam sheet so as to partially cover the surface, so that the resin foam sheet is Compared to the case where the damping sheets are laminated so as to cover the entire surface of one side, together with the light weight, workability is very good, and at the same time, the partial use of the damping sheets As a result, the cost can be reduced, and a great effect can be obtained practically.

According to the second aspect of the present invention, since the form of the resin foam sheet to which the vibration damping sheet is affixed is in the form of a scroll, a large space is not required in a storage place or the like, and the handling is convenient. is there. According to the third aspect of the present invention, since the resin foam sheet and the vibration damping sheet made of a polyolefin resin are laminated by heating with an adhesive, the laminate is formed by pressing with a solvent type rubber adhesive. Workability is better than that of

[Brief description of the drawings]

FIG. 1 is a plan view showing one embodiment of a resin foam sheet to which a vibration damping sheet according to the present invention is attached.

FIG. 2 is a sectional view showing a composite folded plate roof obtained using a resin foam sheet to which the vibration damping sheet shown in FIG. 1 is attached.

3A and 3B are views showing a composite horizontal roofing roof obtained by using another metal exterior material, wherein FIG. 3A is a plan view and FIG. 3B is a bottom view.

FIG. 4 is a perspective view showing the composite horizontal roof shown in FIG. 3;

FIG. 5 is a view schematically showing a roof surface of the artificial rainfall device and a mounting position of a composite roof and the like.

[Explanation of symbols]

 1, 11: Resin foam sheet 2, 12: Damping sheet 3, 13: Resin foam sheet with damping sheet attached 4, 14: Metal exterior material 5: Composite folded plate Roof 15 ・ ・ ・ Composite horizontal roof

 ──────────────────────────────────────────────────続 き Continuing on the front page F term (reference) 2E108 BN06 CC02 CC04 CV03 CV06 CV09 CV10 GG01 GG03 GG04 GG08 4F100 AA01B AA08 AB01C AB03 AC05 AK01A AK01B AK04 AK12 AK28 AK68 AL01 AL09B AN02 BA03 DC01 EC01 DD10 EC182 EH17 EJ26 EJ422 GB07 JA13B JB16B JH01 JH02 JH02B JJ02

Claims (3)

[Claims] 1. A specific gravity of at least 1.3 comprising a resin composition containing a thermoplastic elastomer and inorganic powder so as to partially cover one surface of a resin foam sheet having an expansion ratio of 10 to 50 times. A method for producing a vibration-damping exterior material, comprising laminating a metal exterior material on the side of the resin foam sheet to which the vibration-damping sheet is pasted after adhering the vibration-damping sheet. 2. The method for producing a vibration-damping exterior material according to claim 1, wherein a vibration-damping sheet is attached to one surface of the resin foam sheet in advance, and the form is a scroll. 3. The method for producing a vibration damping exterior material according to claim 1, wherein a resin foam sheet made of a polyolefin resin and a vibration damping sheet are laminated by heating with an adhesive therebetween.