JP2009001969A - Ceiling laying material and roof structure - Google Patents

Abstract

A member for ensuring good air permeability in a ceiling is provided.
A plurality of continuous filaments having a thickness of 0.1 to 10 mm are spun onto a carrier having a protruding portion that is moving at a constant speed, thereby at least one of the intersections of the continuous filaments. A mesh body in which filaments are bonded to each other at the intersection of the sections, and has a plurality of protrusions made of continuous filaments that meander irregularly, and the protrusion height is 5 mm or more. Then, if necessary, a sheet (for example, a non-woven fabric sheet) is overlaid and integrated by thermal bonding of filaments to constitute a ceiling laying material.
[Selection] Figure 1

Description

  The present invention relates to a laying material and a roof structure using the same, which are used when a ceiling and a roof are constructed in a house or a building in general.

  When constructing a building such as a residence, various construction methods or materials are used so as to ensure sufficient ventilation and ventilation. For example, Patent Document 1 proposes a building sheet that includes a core member that is entangled with a fibrous synthetic resin and has a hollow structure with a three-dimensional arrangement with high pressure resistance. The building sheet is disposed between a roof base plate and a tile, a decorative slate plate, a metal plate, and the like to form a ventilation layer, thereby obtaining moisture and ventilation effects.

  In addition, Patent Document 2 is provided with a ventilation plate formed by molding a number of hollow cones on a plastic plate such as polypropylene for the purpose of ensuring heat insulation and heat insulation ventilation on a roof, a wall, and the like. A heat-insulating ventilation member provided with a heat shield cover on the front side of the bottom opening side of the group, and a plate formed by laminating a large number of hard plastic monofilaments in a random loop shape, and having a plurality of thickness portions Proposed a heat-insulating and heat-insulating air-permeable material that is provided with a ventilation plate consisting of cylindrical cavities arranged in a row and a loop crushing layer covering the front and back, and a heat-insulating cover is attached to at least one surface of the ventilation plate ing. In the heat insulating and heat insulating ventilation material described in Patent Document 2, the space between the hollow cones or the cylindrical cavity serves as a ventilation space to ensure air permeability.

JP 2003-278285 A JP 2006-169951 A

  However, the building sheet described in Patent Document 1 requires a three-dimensional arrangement of a single sheet that is entangled in a fibrous form in order to increase the pressure resistance, and is preferably a three-dimensional arrangement. As an example, a V-shaped undulation is shown. A core member having such a V-shaped undulation is difficult to bend in the vertical direction (the direction in which the vertex of the V-shape extends), but bends relatively easily in the horizontal direction. Therefore, for example, when constructing this building sheet according to a construction surface having a curve, the bending direction of the sheet is restricted (that is, it cannot be bent in the vertical direction), that is, the construction direction is restricted. Is done. Further, since the bending stress in the lateral direction of the core member is weak, the stress is easily applied to the apex portion forming the hollow structure of the core material when a load is applied in the lateral direction, and the core member is relatively easily broken.

The sheet described in Patent Document 2 has no air permeability in the thickness direction because the plastic plate is formed into a cone. Furthermore, since the conical protrusion itself does not have elasticity, if the weight of the craftsman riding on the slate roof tile is added to this sheet during the operation of rolling the slate roof tile, the slate roof tile breaks without any stress being released. Or the sheet itself is destroyed. Similarly, the sheet having a cylindrical cavity described in Patent Document 2 is not air permeable in the thickness direction and has no or even low elasticity.
Furthermore, in the sheet | seat which has a cylindrical cavity part of patent document 2, since the monofilament made from a hard plastic is accumulated in the loop shape, air permeability is ensured. However, since the cylindrical hollow portion formed by spirally winding the filaments is arranged in the horizontal direction with respect to the surface direction of the sheet, it is weak against stress from the thickness direction and the sheet itself is destroyed. There is a fear.

  The present invention has been made in view of the problems of conventional sheet-like materials, and after being constructed, it ensures good air permeability, is easy to construct itself, and has other members on it. It aims at providing the sheet-like material laid in the back of a ceiling which is hard to be damaged when constructing.

The present invention is a network composed of a plurality of continuous filaments having a thickness of 0.1 to 10 mm, and the filaments are bonded to each other at at least some of the intersections of the continuous filaments,
It has a plurality of protrusions made of continuous filaments that meander irregularly,
There is provided a ceiling laying material (hereinafter sometimes simply referred to as “laying material”) including a net-like body having a protrusion having a height of 5 mm or more.

  The ceiling laying material of the present invention has a mesh body composed of continuous filaments having a specific thickness, and the mesh body is a protrusion formed by irregularly meandering continuous filaments and having a height of 5 mm or more. It is characterized by having. This net has a net as a whole, and has air permeability in any direction. Further, the projections in the net-like body act like a cushion and give appropriate elasticity. Therefore, the ceiling laying material is not easily damaged even if a force is applied during the construction, and after the construction, a good air permeability is ensured in the ceiling.

  The present invention is a sheet laid on the back of a ceiling. Here, “behind the ceiling” is used to indicate a space between the ceiling and the roof and a space between the ceiling and the floor of the upper floor. When the ceiling and the roof are integrally formed, between the layer formed on the outside (for example, tile or roofing material) and the layer formed on the inside (side seen from inside the building) It shall refer to a place.

  The ceiling laying material of the present invention further includes a sheet, and the mesh body is bonded to one surface of the sheet by thermally bonding a part of continuous filaments constituting the mesh body. preferable. Such a ceiling laying material is easy to handle and can exhibit various functions depending on the function of the sheet.

  In the ceiling laying material of the present invention, the protrusions may be independent from each other. “The protrusions are independent of each other” means that the protrusions are not connected to other protrusions, and one protrusion forms a dot or a closed contour when viewed from above. Such a ceiling laying material is easy to disperse the force applied on it uniformly and is not easily damaged. The independent protrusions are preferably of a pyramidal shape.

  Alternatively, in the ceiling laying material of the present invention, the mesh body has the first ridge and the second ridge as protrusions, and the first ridge extends intermittently in one direction, and the direction in which the ridge extends. In the direction orthogonal to each other, the second ridges are preferably parallel to each other and branched from the first ridge. According to such a protrusion, since a large flow of air flowing between the ridges is branched, the entire mesh body can be easily dispersed and a good heat insulating effect can be obtained.

  The present invention also provides a roof structure in which the ceiling laying material of the present invention is disposed between a field board and a tile. In this roof structure, since the ceiling laying material of the present invention, which serves as a ventilation layer, is disposed between the field board and the tile, the air permeability under the tile is improved, thereby improving the durability of the house. At the same time, the indoor environment is improved. In the present specification, the “tile” includes what is provided as a so-called roofing material (including a metal material).

  When the ceiling laying material of the present invention is laid on the ceiling, the portion of the net-like body becomes a portion having air permeability. This net-like body has a three-dimensional structure and has a net as a whole, and can be ventilated in any direction. Therefore, if the ceiling laying material of the present invention is used, good air permeability is ensured in the ceiling. Further, even when a force in the thickness direction is applied, the protrusion formed on the mesh body acts like a cushion and hardly destroys itself or a member adjacent thereto. Therefore, the ceiling laying material of the present invention is suitably used for forming a ventilation layer under a roof tile, for example, in a general house. In that case, the laying material of the present invention only needs to be laid on the base plate or another member (for example, a waterproof sheet) laid on the base plate. In addition, even when the roof tile is rolled, even if the roof tile is stepped on from the roof tile, the laying material or roof tile of the present invention is not damaged, and the floor laying material of the present invention is excellent in workability. Alternatively, the laying material of the present invention may be disposed between the ceiling and the floor of the upper floor, and in that case, the indoor environment on the ceiling side and the floor side is also improved by the air permeability of the laying material of the present invention. It becomes good.

  The ceiling laying material of the present invention is a net-like body composed of a plurality of continuous filaments having a thickness of 0.1 to 10 mm, and the filaments are bonded to each other at at least some of the intersections of the continuous filaments. In addition, it includes a net having a plurality of protrusions made of continuous filaments that meander irregularly, and the protrusions have a height of 5 mm or more. In this network, the filaments are three-dimensionally arranged (that is, the orientation of the filaments has a vertical and horizontal height direction). That is, the network has a three-dimensional structure. As will be described later, the reticulate body is obtained by melt spinning a resin and accumulating filaments discharged from a nozzle on a moving carrier having a projecting portion. Alternatively, the net-like body is a method in which the filaments discharged from the nozzles are collected on a flat plate or dropped into water and processed into a shape having protrusions by applying an external force in a subsequent process. can get.

  The thickness (diameter) of the continuous filament is 0.1 to 10 mm. The thickness of the reticulated filament is measured using calipers. The thickness of the filament is preferably 0.2 mm to 5 mm, and most preferably 0.3 mm to 3 mm. If the thickness is less than 0.1 mm, the stiffness of the filament is lost, the mesh body does not have elasticity, and it may be difficult for the mesh body to maintain a three-dimensional structure. If the thickness exceeds 10 mm, voids may decrease in the inside of the three-dimensional structure of the net, and the air pressure loss may increase, or sufficient elasticity may not be obtained.

  The continuous filaments are bonded to each other at at least some of the intersections of the continuous filaments. This is because continuous filaments are melt-spun and placed on the carrier, and when the filaments are overlapped, the filaments in a molten or softened state are bonded to each other. Adhesion between continuous filaments improves the strength of the network.

  The material of the continuous filament is not particularly limited as long as it is composed of a resin that can be melt-spun. Olefin resin (for example, polypropylene, polyethylene, propylene copolymer, ethylene-vinyl alcohol copolymer), polyester resin (For example, polyethylene terephthalate, polybutylene terephthalate), polyamide resins (for example, nylon 6, nylon 66), and engineer plastic resins (for example, polycarbonate, polyacetal) may be used.

  In the present invention, the continuous filament is preferably made of an olefin resin. Since the olefin resin is excellent in weather resistance and chemical resistance and has a relatively low melting point, as described later, it is easy to process when integrated with a sheet. The olefin resin preferably includes at least a polypropylene resin, and more preferably includes 90% by mass or more of the polypropylene resin in the resin. By containing the polypropylene resin, the filament is prevented from becoming too brittle, it is difficult to break even when stress is applied, the filament is prevented from becoming too soft, and the voids in the network are not easily crushed. That is, by using a polypropylene resin, a filament having an appropriate elasticity can be obtained. The polypropylene resin here includes not only polypropylene but also a propylene copolymer containing 50% by mass or more of a propylene component.

  A member laid at a high place like a ceiling laying material is generally required to be lightweight and have no water absorption. Polypropylene resin is also preferable in these respects. That is, the specific gravity of polypropylene resin is 0.91, which is small among thermoplastic resins. Polypropylene resin is non-water-absorbing.

  The continuous filament is preferably made black by adding carbon black. By adding carbon black to the resin, the weather resistance of the filament is improved. Further, since carbon black is inexpensive, it is preferably used as an additive for improving weather resistance. The amount of carbon black added is not particularly limited as long as productivity is not impaired. For example, carbon is preferably added so as to occupy 0.1 to 5% by mass, more preferably 0.5 to 2% by mass of the entire olefin resin. If the amount of carbon black added is less than 0.1% by mass, the weather resistance cannot be sufficiently improved, and if it exceeds 5% by mass, the productivity may be deteriorated.

  The net has protrusions made of continuous filaments that meander irregularly. “Consisting of irregularly meandering continuous filaments” means that when individual continuous filaments are viewed, each filament is not regularly curved in a fixed direction to form protrusions, but continuous filaments. Is a state in which filaments extending in various directions and curved in various directions and at various angles gather to form a protrusion. An example of a mesh having such protrusions is shown in FIG.

  FIG. 1 shows a reticulate body 1 in which quadrangular pyramid-shaped protrusions 2 having approximately the same dimensions are regularly arranged. As shown in the drawing, the protrusions are preferably independent from each other, and more preferably have substantially the same dimensions and are regularly arranged. This is because, for example, when a slate roof tile is placed on the net having such protrusions, the stress tends to be dispersed.

  It is preferable that the protrusions having substantially the same dimensions have a spindle shape. When the protrusion is a weight, the filament density in the height direction of the protrusion does not decrease at a high position (that is, as it approaches the tip of the protrusion), so that the strength of the protrusion tip is ensured. Here, the weight refers to a cone, a triangular pyramid, a quadrangular pyramid, a polygonal pyramid, or the like having a shape in which the area decreases and tapers as the height proceeds from the bottom surface. Also included in the weight herein are stars, moons, and the like that have an irregular bottom surface and a tapered shape. Further, the platform weight is also included in the weight here. In the present invention, it is more preferable that the protrusion has a shape of a cone, a truncated cone, a quadrangular pyramid, or a quadrangular pyramid, and most preferably a cone or a quadrangular pyramid.

The bottom area of the weight is preferably 9 to 400 mm ² . More preferably 25~255mm ^2. When the bottom area is less than 9 mm ² , the tip of the protrusion tends to be an acute angle, and the protrusion is easily broken. Moreover, when it exceeds 400 mm < ² >, the front-end | tip of a processus | protrusion tends to become an obtuse angle, and effects, such as stress dispersion | distribution by providing a processus | protrusion, may be hard to be exhibited.

  The weight-shaped projections are preferably aligned. If there is unevenness in the arrangement of the protrusions, there is a possibility that stress concentrates on a portion where the protrusions are few. Moreover, it is preferable to arrange | position a protrusion with a space | interval so that the distance between a vertex of a spindle shape may become 0.3-5 cm. The distance between the vertices of the spindle shape is the distance between a certain vertex and the nearest vertex among the plurality of adjacent vertices. If the distance between the protrusions is less than 0.3 cm, the protrusion moves to the next protrusion before the cone slope reaches the bottom, and the protrusion height tends to decrease. When an object is placed on the net, a gap is formed between the apex of the spindles and the apex. Therefore, when the distance between the vertices exceeds 5 cm, the area where the object is not supported by the net is widened, and there is a possibility that structural destruction of the object occurs when force is applied in the thickness direction.

  Or it is preferable that a processus | protrusion is a hook shape and it was formed intermittently, while a wrinkle branched. The mesh body with protrusions made of ridges with branches branches or blocks the rough flow of air passing therethrough, allowing the air to flow uniformly in the surface direction of the sheet, uniform heat insulation effect or heat insulation It can exhibit sex.

  Such a ridge is specifically formed by a first ridge and a second ridge, and the first ridge extends intermittently in one direction and in a direction perpendicular to the direction in which the ridge extends, The second ridges are preferably parallel to each other and branched from the first ridge. Such a protrusion is schematically shown in a plan view in FIG. As shown in FIG. 2, the first ridge 11 extends intermittently (that is, in a broken line shape). Further, the first ridges 11 extend in parallel to each other. The second ridge 12 branches off from the first ridge and extends between the two first ridges 11. Each of the scissors has a slope on its side surface, and has a shape as shown in FIG. 3 when a cross section in the thickness direction is viewed along line XX.

  The number of first ridges is preferably 2 to 30 and more preferably 5 to 20 per 10 cm long × 10 cm wide of the net. When the number of the first ridges is 1, the rigidity of the mesh body is small, and when it is 31 or more, the rigidity of the mesh body becomes too high, and the protrusion may not be able to absorb the stress.

  Without the second wrinkle, the first wrinkle tends to bend, and when a bending stress is applied, the mesh body bends along the first wrinkle and absorbs the stress. May decrease. The second kite need not extend from one first kite to the other first kite. In that case, a T-shape is formed. Alternatively, the second ridge may be branched from one first ridge in two directions to form a cross. Alternatively, the second ridge may extend from one point of the first ridge in two or more directions to reach the adjacent first ridge.

  The number of the second ridges is preferably 2 to 25, more preferably 5 to 15 per 10 cm long × 10 cm wide of the net. If the number is less than 2, the rigidity of the mesh body becomes small, and if it is 26 or more, the rigidity of the mesh body becomes too high, and the protrusion may not be able to absorb the stress.

  The distance D between the first ridge 11 and the ridge 11 extending in parallel is preferably 0.3 to 5 cm, and more preferably 1 to 3 cm. If the distance between the first collar 11 and the collar 11 is less than 0.3 cm, the height of the projection tends to be lowered because the collar moves to the next collar before the bottom of the collar reaches the bottom. When an object is placed on the net, a gap is formed with the object between the bag. Therefore, if the distance between the first ridge and the ridge exceeds 5 cm, the area in which the object is not supported by the mesh body increases, and when the force is applied in the thickness direction, the structure is destroyed. May happen.

  The first wrinkles are discontinuous in one direction, preferably every 1.5 to 20 cm, more preferably every 5 to 15 cm. Moreover, in FIG. 2, it is preferable that the distance shown by L is 0.5-5 cm, and it is more preferable that it is 1-4 cm. If L is less than 0.5 cm, the wrinkles are not substantially discontinuous, and one wrinkle becomes too long, which can cause problems as described above when there is no second wrinkle. When L exceeds 5 cm, as described above, problems such as when the distance between the first ridge 11 and the ridge 11 is large may occur.

The height of any protrusion is 5 mm or more. The height of the protrusion is obtained by determining the difference between the thickness of the entire mesh body (hereinafter referred to as “the thickness of the mesh body”) and the thickness of the bottom of the mesh body. The thickness of the mesh is measured according to JIS-L1906 (however, the load is 294 N / m ² and the diameter of the pressurizer is 50.5 mm). The thickness of the bottom of the mesh body is measured by the same measurement method as the thickness of the entire mesh body except that the diameter of the pressurizer is 5 mm and the load is 20 KN / m ² . The height of the protrusion is obtained by obtaining the difference between the thickness of the mesh body thus obtained and the thickness of the bottom of the mesh body. When measuring the thickness of the bottom of the mesh body, if the pressurizer does not enter the bottom, the largest pressurizer among the pressurizers entering the bottom is used.

  The height of the protrusion is preferably 8 mm or more, more preferably 10 mm or more. Since the effect obtained by forming the protrusion does not change even if the protrusion is too high, the upper limit of the height of the protrusion is preferably 30 mm, more preferably 25 mm.

  The thickness of the net-like body is preferably more than 5 mm, and preferably less than 35 mm. The thickness of the net-like body is more preferably 8 to 20 mm. If the thickness of the net-like body is 5 mm or less, the number of filaments is reduced, the rigidity is reduced, the elasticity may be poor when subjected to stress, and / or the height of the protrusion is 5 mm. This is impossible or difficult. When the thickness of the net-like body exceeds 35 mm, for example, when it is laid under the roof, it may be too thick for the roof and may not be suitable for use.

  Furthermore, when the ceiling laying material of the present invention is positioned between the roof tile and the base plate to ensure air permeability under the roof (back of the ceiling), if the thickness of the mesh is less than 5 mm, ventilation is performed. Since the capacity is insufficient and the ventilation resistance increases, there is a risk that natural ventilation is hardly performed. Further, when the thickness of the mesh body exceeds 35 mm, the ventilation capacity increases, but the ventilation resistance almost reaches equilibrium, so it is meaningless to make the thickness larger than this, and it is economically disadvantageous.

Next, other preferable physical properties of the network will be described.
The basis weight (unit area mass) of the network is measured according to JIS-L1908. The basis weight of the network is preferably 100 to 1000 g / m ² . When the basis weight of the mesh body is below 100 g / m ² reduces the configuration number of filaments, may resilient mesh body becomes insufficient, exceeds the 1000 g / m ^2, the density is increased, tertiary meshwork In the original structure, voids may be reduced, air pressure loss may be increased, and rigidity may be increased, but elasticity may be decreased.

  The 10 mm compressive stress of the network is preferably 300N to 800N. When the 10 mm compressive stress of the mesh body is less than 300 N, the mesh body may be crushed when a person gets on or when a strong stress is applied, and sufficient voids may not be maintained. When the 10 mm compressive stress of the mesh body exceeds 800 N, it is difficult to obtain a cushioning effect due to the elasticity of the mesh body, and when a force is applied from the outside, the side to which the force is applied (for example, the mesh body There is a risk of damage to the object placed on top. More specifically, when the ceiling laying material of the present invention is used so as to be positioned between the field board and the slate roof tile, the roof tile laying work is performed on the ceiling lining material of the present invention. Will be implemented. At that time, if the compressive strength of the mesh body is below 300 N, the mesh body may be crushed when an operator gets on the slate roof tile. If it exceeds 800 N, the roof tile may be broken when the worker works on the slate roof tile.

In addition, the 10 mm compressive stress of the mesh body is measured as follows.
A direction in which the sample is compressed (thickness direction) using a constant-speed mechanical tester (for example, UCT-1T manufactured by Orientec Co., Ltd.) ) Compress the sample at a head speed of 1 mm per minute. At that time, the jig for compressing the sample has a square surface of 20 cm in length and 20 cm in width so that the net-like body as the sample is completely covered. Then, the load applied when 10 mm is compressed from the initial load point is measured as 10 mm compressive stress.

The tensile strength of the network is measured according to JIS-L1908.
The tensile strength of the network is preferably 30 N / 5 cm or more. When the tensile strength of the net-like body is less than 30 N / 5 cm, for example, when the ceiling laying material of the present invention is laid so as to be inclined with respect to gravity along the inclination of the roof, the upper part is due to its own weight. A large load is applied. As a result, the net body itself is cut, and there is a possibility that the structure of the sheet itself cannot be maintained.

  Moreover, it is preferable that the value which remove | divided the longitudinal tensile strength of the net-like body by the transverse tensile strength is 0.5-2. If the value obtained by dividing the longitudinal tensile strength of the net by the lateral tensile strength is outside the range of 0.5 to 2, the tensile strength in a specific direction tends to be small, and the construction direction (or laying direction) is limited. There is a fear.

  The network may be a functional network having other characteristics in addition to its physical characteristics. Specifically, various functions can be imparted to the network by adding an agent that exhibits one or more functions to the resin that constitutes the continuous filament. For example, more specifically, while the resin constituting the continuous filament is not yet spun, it functions as a method of mixing a functional material that exhibits some function into the resin, or a master batch for constituting the filament. A function can be added to the network by a method in which the conductive particles are mixed and melt-spun together with the base polymer (raw resin). Alternatively, after the mesh body is produced, the function may be imparted to the mesh body by post-treatment such as spreading, dipping, or attaching an agent (liquid or powder) having a desired function.

  In the case of imparting a function at the resin stage, for example, by adding a hindered amine flame retardant (hereinafter referred to as HALS) or a phosphorus flame retardant, flame retardancy can be imparted, and by adding carbon, Conductivity can be imparted, heat resistance and heat resistance can be imparted by adding inorganic particles such as calcium carbonate, and deodorant and harmful substances can be imparted by adding an adsorbent such as activated carbon. The property of adsorbing can be imparted, and insects and small animals (for example, moths) can be kept away by adding insect repellents and repellents such as pyrethroids. Alternatively, weather resistance, water repellency, heat storage, soundproofing, and antifungal properties can be imparted to the network by kneading other components at the resin stage or imparting them by post-treatment.

  The ceiling laying material of the present invention further includes a sheet, and is provided in a form in which the mesh body is bonded to one surface of the sheet by thermally bonding a part of continuous filaments constituting the mesh body. Good. Such a ceiling laying material is easy to handle and can exhibit various functions by utilizing the function of the sheet.

  A sheet | seat means what is equipped with the wide surface which can have a contact with a mesh body over the whole mesh body, such as a nonwoven fabric, a woven fabric, a film, a board, a board. Even if the sheet has some unevenness on the surface, the sheet may be used as it is unless there is any particular problem in practical use or manufacturing process.

  The form and material of the sheet are not particularly limited. For example, nonwoven fabrics such as air-through nonwoven fabrics, thermal bond nonwoven fabrics, spunbond nonwoven fabrics, melt blown nonwoven fabrics, wet papermaking nonwoven fabrics, hydroentangled nonwoven fabrics, needle punch nonwoven fabrics, and resin bond nonwoven fabrics; woven fabrics such as plain weaves, twill weaves, and satin weaves; A film, a slate board, a plywood board, a gypsum board, etc. can be used as a sheet. In particular, a nonwoven fabric is preferably used, and a spunbond nonwoven fabric or a hydroentangled nonwoven fabric is particularly preferable in consideration of the strength and price of the sheet.

  When using a nonwoven fabric as a sheet, the fiber which comprises a nonwoven fabric is not specifically limited. For example, the fibers constituting the nonwoven fabric may be any of synthetic fibers, natural fibers, and recycled fibers. Synthetic fibers include polyester resins such as polyethylene terephthalate, polybutylene terephthalate, and polytrimethylene terephthalate, olefin resins such as polypropylene, polyethylene, ethylene propylene, and ethylene vinyl alcohol, and amides such as nylon 6, nylon 66, and nylon 12. You may consist of 1 or several resin selected from type | system | group resin. The recycled fiber is, for example, rayon. Natural fibers include cotton, hemp, wool, glass fiber, metal fiber and pulp. These fibers may be used alone or in combination to form a nonwoven fabric. The fibers constituting the nonwoven fabric may be composite fibers made of a plurality of resins or split-type composite fibers (including ultrafine fibers formed by splitting).

  When a nonwoven fabric is constituted by using a plurality of types of fibers, it may be used by mixing, may be laminated so as to form a layer structure, or a combination of mixing and lamination may be used. . Depending on the application, the form of the sheet is appropriately selected.

  In the case where the continuous filaments of the network are made of a thermoplastic resin, the network can be bonded to the sheet by melting a part of the continuous filaments. When so joined, a firm bond is obtained between the mesh and the sheet. In addition, when the continuous filaments are melted and joined, it is not necessary to use an adhesive containing an organic solvent component, so that problems due to the use of the organic solvent (for example, sick house syndrome) can be avoided.

  In the ceiling laying material of the present invention, when the sheet is composed of fibers (for example, non-woven fabric, woven fabric), it is preferable that continuous filaments thermally bonded to the sheet enter between the fibers of the sheet. . In such a form, a part of continuous filament melts into the sheet and exhibits an anchor effect. Due to the anchor effect, the bond between the mesh body and the sheet becomes stronger. In order to realize such joining, the sheet is preferably a nonwoven fabric.

  When joining the mesh body and the sheet, at least a part of the mesh body is heated and melted, the sheet is pressed against the mesh body (or the mesh body is pressed against the sheet), and pressure is applied. At this time, by controlling the temperature, pressing, and the like, it is possible to adjust the degree to which the reticulated filament enters between the fibers of the sheet. That is, if both are integrated in this way, the adhesive strength between the sheet and the net-like body can be freely adjusted.

  If the net-like body is strongly bonded to the sheet, the bonded portion serves as a fulcrum, and the net-like body is hardly crushed as a whole, and the rigidity of the ceiling laying material tends to increase. On the other hand, when the mesh body is weakly bonded to the sheet, it is considered that when a strong stress is applied, the bonded portion is easily separated and the mesh body is crushed, thereby reducing the stress. Also, during construction, when laying a plurality of ceiling laying materials side by side, the mesh body is peeled from the sheet so that no gap is generated between the mesh body and the mesh body, and the sheet is placed on the sheet. May need to be superimposed. In that case, if the adhesive strength between the sheet and the net is adjusted to such an extent that it can be easily peeled off, the convenience at the construction site is good. As described above, the characteristics or handleability of the sheet can also be changed by integrating the two by pressure bonding and appropriately adjusting the adhesive strength.

When a sheet | seat consists of fibers (especially when it is a nonwoven fabric), the fabric weight is measured according to JIS-L1906.
Preferably the basis weight of the sheet is 15~1000g / ^{m 2,} and more preferably 20 to 100 g / ^{m 2.} When the basis weight of the sheet is less than 15 g / m ² , the strength of the sheet is reduced and breakage is likely to occur. Moreover, if the basis weight of the sheet exceeds 1000 g / m ² , the ceiling laying material becomes heavy, which is contrary to the demand for weight reduction.

When the sheet is made of fibers (particularly when it is a nonwoven fabric), the thickness of the sheet is measured according to JIS-L1906. However, the load is 2.94 cN / cm ² .
The thickness of the sheet is preferably 0.01 to 50 mm, and more preferably 0.1 to 3 mm. When the thickness of the sheet is less than 0.01 mm, the strength of the sheet is small and breakage tends to occur. When the thickness of the sheet exceeds 50 mm, workability is deteriorated in the step of bonding the net and the sheet. Specifically, for example, in the process of reversing or winding up the sheet, there is a possibility that curling will occur on the front surface or the back surface of the sheet.

  In the above, the form which joined the sheet | seat and the mesh body by thermal bonding of a part of filament of the mesh body was demonstrated. The ceiling laying material of the present invention is not limited to such a form, and in some cases, the mesh body may be attached to the sheet with an adhesive and integrated. Alternatively, the mesh body and the sheet may be integrated by a mechanical joining method (for example, nails, staples, push pins, etc.). Alternatively, the sheet and the mesh body may be easily separated, the sheet may be laid first at the construction site, and the mesh body may be laid thereon, and then both may be joined with an adhesive or a molten resin.

  Alternatively, the ceiling laying member of the present invention may be provided in a form in which a net is sandwiched between two sheets. Even in that case, it is preferable to join the mesh body to the sheet by thermal bonding of a part of the filament.

  The sheet may also perform itself. For example, if the sheet has air permeability, air permeability is ensured in all directions of 360 degrees. Alternatively, as a sheet, a functional sheet such as a filter, a heat insulating sheet, a soundproof sheet, a water shielding sheet, a moisture proof sheet, and an electromagnetic wave shielding sheet is singly or overlaid, or bonded to both surfaces of a net-like body The ceiling laying member of the present invention can exhibit various functions in addition to ensuring air permeability.

Next, the manufacturing method of the ceiling laying material of this invention is demonstrated. Initially, the manufacturing method of a mesh body is demonstrated.
As described above, the net-like body is manufactured by accumulating filaments obtained by a melt spinning method in which a molten resin is discharged from a spinning nozzle on a moving conveyance body. The spinning process is performed using a known spinning system. The resin used for spinning is preferably a resin having a melt flow rate (MFR) measured by JIS-K6758 of 2 to 20 g / 10 min.

  When the MFR is less than 2, since the resin is hard, it is difficult to discharge from the nozzle, and it is necessary to raise the spinning temperature. However, the resin is likely to be thermally decomposed. On the other hand, considering that the resin discharged from the nozzle during spinning is normally discharged while swirling, the MFR is preferably 20 g / 10 min or less. If the MFR is higher than this, the speed at which the filament is discharged from the nozzle is increased, and the time to reach the carrier is shortened. As a result, overlap with filaments ejected from adjacent nozzle holes is reduced, and the number of intersections is reduced. In such a case, the mesh body may have fewer irregular meshes, and a mesh body suitable for a ceiling laying material may not be configured.

  Spinning is performed by the following procedure. First, the resin is melted at a temperature 50 to 120 ° C. higher than the melting point and extruded by an extruder. At that time, two or more different resins may be mixed, or two or more extruders may be used to obtain a monofilament in a composite form or a split composite form. Moreover, in this extrusion process, in order to provide a predetermined function to a mesh body, you may add suitably the masterbatch which mixed the additive etc. The resin discharged from the extruder passes through the nozzle and is spun in the shape of a filament. The nozzle to be used may have a nozzle diameter of 0.2 to 3 mm and a nozzle pitch of 0.5 to 20 mm, for example. The shape of the nozzle may be appropriately selected according to the application, such as a single type, a core-sheath composite type, a side-by-side composite type, a sea-island type, a wedge-shaped divided type, a slit-shaped divided type, and a modified shape.

  Next, the filaments ejected from the nozzles are placed on the traveling carrier and accumulated. At this time, the filament in a molten state is thermally bonded at at least a part of the intersection of two or more filaments. The carrier has a protruding portion according to the shape of the protrusion to be formed on the mesh body. Therefore, the carrier used for manufacturing the mesh body of the present invention is also referred to as a mold. In forming the mesh body, the value of c / d is preferably 1.1 to 10, preferably 2 to 5, where c is the resin discharge speed and d is the moving speed of the carrier. It is more preferable. When c / d is less than 1.1, the spun resin does not rotate, does not form an intersection with the filament discharged from the adjacent nozzle, and a desired network may not be obtained. If it exceeds 10, the number of intersections of filaments may increase so that the voids formed in the network may be reduced.

  As described above, in order to form undulations (that is, protrusions) in the height direction (thickness direction) on the mesh body, the transport body has a protruding portion. The shape of the protruding portion on the carrier has substantially the same shape as the protrusion to be formed on the mesh body, although it depends on the shape. That is, in order to obtain a net-like body as shown in FIG. 1, the projecting portions having a quadrangular pyramid shape are regularly provided. Further, in order to obtain a net-like body having protrusions as shown in FIG. 2, hook-like protruding portions arranged in a pattern as shown in FIG. 2 are provided, or a thin plate is formed so as to have such a pattern. Are arranged vertically as projecting portions (that is, the main surface of the thin plate is parallel to the thickness direction of the mesh).

  In the case where the protruding portion having any shape is provided on the transport body, the height of the protruding portion is preferably 2 to 40 mm. If the height of the protruding portion is less than 2 mm, there is substantially no undulation, which is disadvantageous for obtaining a net-like body having sufficient elasticity. When the height of the protruding portion exceeds 40 mm, the height of the protrusion of the net-like body obtained becomes high, and when used as a ceiling lining material, breakage of the filament is likely to occur due to stress concentration. Further, the distance between the protruding portions is determined according to the shape and size of the protruding portions and the interval between the protrusions of the protrusions to be formed. For example, the distance between the protruding portions (hereinafter, this distance is also referred to as “pitch”) is preferably 0.3 to 5 cm. When the pitch is less than 0.3 cm, there is substantially no projecting portion (that is, undulation), and the resulting mesh may not exhibit sufficient elasticity. If the pitch exceeds 5 cm, when the mesh is formed, stress concentrates on the top of the protrusions and the filament may be damaged. Note that the pitch is the distance between the apexes of the projecting portions of the weight-like body when forming projections as shown in FIG. 1, and the first hook-like shape when forming projections as shown in FIG. This corresponds to the distance between the protruding portions (main protruding portions).

  When the ceiling laying material of the present invention includes a sheet, the sheet is laminated while the filamentous resin accumulated on the transport body is melted or softened, and the sheet and the net are formed by the filament. Adhesion is preferred. Adhesion is performed so that a desired adhesive strength can be obtained by applying a load with a mangle roll or the like and adjusting the amount of the load. When the load is large, for example, when the sheet is a fiber sheet such as a nonwoven fabric, a part of the filament enters the sheet, and both can be firmly bonded. The load is preferably applied as a linear pressure of 9.8 N / cm to 1.96 KN / cm. If the linear pressure is less than 9.8 N / cm, the adhesive strength is weak and the sheet is easily peeled off. If it exceeds 1.96 KN / cm, the reticulate may be destroyed.

  In addition, the method of joining a mesh body and a sheet | seat is not restricted above. For example, a thermal calendar processing machine may be used. Alternatively, after the net-like body is produced, the adhering step may be performed while applying a load by reheating separately in a later step.

  Next, the net-like body obtained by melt spinning, or the sheet-like material in which the net-like body is bonded to the sheet is wound up to a predetermined length through a cooling step, or cut and stacked. . As a cooling method, there are natural cooling, a method of indirectly cooling the mold by water cooling or the like, and a method of cooling the resin indirectly by air cooling or water cooling. The cooling method is preferable in the order of natural cooling> indirect cooling> direct cooling. This is because when the resin is rapidly cooled, crystals in the resin become small and become brittle. On the contrary, by slowly cooling, crystals in the resin grow and become sticky filaments, and the rigidity and elasticity of the network are further improved.

  The ceiling lining material of the present invention described above is provided with a ceiling that can be roughly accessed by humans, such as detached houses, condominiums, apartments, buildings, warehouses, factories, gymnasiums, offices, halls, hotels, and underground shopping areas. Used in building. In particular, the ceiling laying material of the present invention is preferably disposed between a roof tile and a roof tile of a building (in particular, a detached house) having a cover corresponding to the roof tile or roof tile.

  The ceiling laying member of the present invention is laid on a base plate or other member (for example, a water shielding sheet) when another member is positioned on the base plate, and a tile is spread on the member. Thus, the roof structure in which the ventilation of the ceiling (or the attic) is ensured is provided. When the ceiling laying material of the present invention includes a sheet, and the sheet has water shielding properties, the ceiling lining material of the present invention will also function as a water shielding sheet, without substantially increasing the number of steps. Allowing the roofing work to be completed.

Hereinafter, the present invention will be described in more detail with reference to examples.
First, the performance evaluation test method implemented in the present invention will be described.
[Destructive testing]
A ceiling laying material cut to 1 m × 1 m on a flat cement floor, and a type in which a sheet is bonded to one side of a mesh body, the sheet is on the lower side (that is, in contact with the cement floor) The flat roof slate material (manufactured by Kubota Matsushita Electric Industrial Co., Ltd., trade name: Colonial NEO model number KLCC362) was placed thereon. Then, a person with a weight of 100 kg wearing general work safety shoes (Midori Safety Co., Ltd., product name: Ecospec Model No. ES210 28 cm) jumped off from a height of 50 cm to the center of the slate material. This was repeated five times for each sample at the same location, and the damage situation of the slate material and the damage condition of the ceiling laying material were confirmed.
The evaluation criteria are as follows.
○: The slate is not broken, and the ceiling laying material is not destroyed.
Δ: Either the slate or the ceiling lining material was destroyed.
×: Both the slate and the ceiling laying material were destroyed.

  The basis weight, thickness, protrusion height, filament diameter, compressive strength, and tensile strength of the network were measured by the methods described above. The basis weight and thickness of the sheet are measured by the method described above, and the tensile strength is determined by using a constant speed tension type tensile tester according to JIS L 1096 6.12.1 A method (strip method). The measurement was performed under the conditions of a piece width of 5 cm, a holding interval of 10 cm, and a tensile speed of 30 ± 2 cm / min.

[Example 1]
A mixture of 99% by mass of polypropylene resin (MFR12.5) and 1% by mass of carbon black PP masterbatch was prepared. This mixed resin was extruded at a spinning temperature of 260 degrees, a nozzle diameter of 1.0 mm, and a nozzle pitch of 5 mm to obtain a resin having a diameter of 1.0 mm. Filaments were accumulated on the transport body, which was traveling at a moving speed of 4.5 m / min, thereby obtaining a net-like body having protrusions having the same shape as the protruding portions provided on the transport body. The c / d calculated from the resin discharge speed c (m / min) and the transport speed d (m / min) of the transport body was 3.3. The protrusion provided on the transport body was formed so as to obtain a ridge as shown in FIG. 2, and the extending direction of the ridge portion was inclined 30 degrees with respect to the width of the net-like body. The height of the protruding portion was 10 mm, the length of the protruding portion was 85 mm, the interval between the protruding portions extending in one direction was 15 mm, and the pitch was 15 mm.

Furthermore, immediately after the resin is accumulated on the carrier, a polyester spunbond nonwoven fabric (manufactured by Toyobo Co., Ltd., trade name Ecule, basis weight 40 g / m ² , thickness 0.25 mm) is overlaid, and a mangle roll is used. A load was applied at a linear pressure of 49.0 N / cm to join the net and the spunbond. Then, after naturally cooling, the obtained ceiling laying material was wound up. The basis weight of the mesh was 500.3 g / m ² and the thickness was 11.5 mm. The protrusion has a first ridge 11 and a second ridge 12 as shown in FIG. 2, the distance D between the first ridges 11 is 15 mm, and the length of L in the first ridge 11 is 15 mm and the height of each ridge were 10.1 mm. The length of the first ridge was 85 mm, and the length of the second ridge was 15 mm. Moreover, the number of the first ridges per 10 cm long × 10 cm wide of the mesh body was 12, and the number of the second ridges was 7.

[Example 2]
Except that the carrier is provided with a quadrangular pyramid-shaped projecting portion so that a net-like body as shown in FIG. 1 is obtained, the procedure is the same as that employed in Example 1, and the ceiling A lining member was produced. The quadrangular pyramid, which is a protruding portion, had a vertex-to-vertex interval of 1.5 cm and a height of 10 mm. The basis weight of the mesh was 500 g / m ² and the thickness was 11 mm. The protrusions had a quadrangular pyramid shape as shown in FIG. 1, the height was 10 mm, and the distance between the vertices was 10 mm. The bottom area of the quadrangular pyramid was 100 mm ² .

[Comparative Example 1]
A commercially available laying material (BWK (Germany), trade name Difflex Convec-Blech) in which a net and a nonwoven fabric sheet made of polypropylene (a three-layer structure of spunbond nonwoven fabric / meltblown nonwoven fabric / spunbond nonwoven fabric) are integrated. Prepared. In this laying material, the mesh body was made of polypropylene, the basis weight was 54.6 g / m ² , and the thickness was 6 mm. In addition, pleated projections with peaks extending in the longitudinal direction were formed throughout, and the height of the projections was 4 mm.

The physical properties of Examples 1 and 2 and Comparative Example 1 are shown in Table 1.
In Comparative Example 1, since the sheet and the mesh were bonded, the performance of the mesh and the sheet was measured by the following procedure. First, the sheet (nonwoven fabric) was carefully peeled off from the mesh. At that time, it peeled off slowly so that the mesh was not damaged or the filament was not broken. The comparative example 1 used this time was relatively easy to peel off the sheet. If the adhesion is strong and the sheet is difficult to peel off, it is preferable to cut the sheet with scissors or the like so as not to leave the sheet on the net as much as possible.

  In the ceiling laying materials of Examples 1 and 2, when stress was applied in the destructive test, the filaments and the like were not broken, and the net was not broken. Further, due to the elasticity of the ceiling laying material, the stress of the roofing material is absorbed (that is, the ceiling lining material acts as a cushion), and the roofing material is not broken. The laying material of Comparative Example 1 has insufficient elasticity and the roof material has been broken.

  The ceiling laying material of the present invention can be suitably used in a residence or building in general to ensure good air permeability in the ceiling (or under the roof).

It is a perspective view which shows typically an example of the mesh body which comprises the ceiling laying material of this invention. It is a top view which shows typically the protrusion of a net-like body. It is sectional drawing which shows a cross section when it cut | disconnects along line XX of FIG.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Net body 2 Protrusion 11 1st cage | basket 12 2nd cage | basket

Claims (10)

It is composed of a plurality of continuous filaments having a thickness of 0.1 to 10 mm, and is a network in which filaments are bonded to each other at least at some of the intersections of the continuous filaments,
It has a plurality of protrusions made of continuous filaments that meander irregularly,
A ceiling laying material including a net-like body having a protrusion having a height of 5 mm or more.   The ceiling laying material according to claim 1, further comprising a sheet, wherein the mesh body is bonded to one surface of the sheet by thermally bonding a part of continuous filaments constituting the mesh body.   The ceiling laying material according to claim 2, wherein the sheet is made of fibers, and continuous filaments thermally bonded to the sheet are interposed between the fibers of the sheet.   The ceiling laying material according to any one of claims 1 to 3, wherein the protrusions are independent of each other.   The ceiling laying material according to claim 4, wherein the protrusion has a weight shape. The net has a first ridge and a second ridge as protrusions,
The first ridges extend intermittently in one direction, and are parallel to each other in a direction orthogonal to the direction in which the ridges extend,
The second kite branches off from the first kite,
The ceiling laying material according to any one of claims 1 to 3.   The ceiling laying material according to any one of claims 1 to 6, wherein a thickness of the entire mesh body is larger than 5 mm and smaller than 35 mm. It is composed of a plurality of continuous filaments having a thickness of 0.1 to 10 mm, and is a network in which filaments are bonded to each other at least at some of the intersections of the continuous filaments,
It has a plurality of protrusions made of continuous filaments that meander irregularly,
The protrusion is formed by accumulating continuous filaments on the carrier from above the carrier while moving the carrier having the protruding portion.
Ceiling laying materials, including nets.   The ceiling laying material according to claim 8, wherein the height of the protruding portion is 2 mm to 40 mm.   A roof structure in which the ceiling laying material according to any one of claims 1 to 9 is disposed between a field plate and a roof tile.

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