JPS6192853A - Manufacture of soundproof floor material - Google Patents

Abstract

(57) [Summary] This bulletin contains application data before electronic filing, so abstract data is not recorded.

Description

[Detailed description of the invention] 〔Technical field〕 TECHNICAL FIELD This invention relates to a method for manufacturing a flooring material having a soundproofing effect.

[Background technology]

2. Description of the Related Art Floors of buildings made of steel frames, reinforcing bars, etc. are often made by laying floor finishing materials such as wooden tiles, synthetic resin tiles, rubber tiles, etc. on a floor base made of concrete or the like.

Using wooden tiles as a floor finishing material has the advantage of giving rooms a calmer feel and adding a sense of luxury to buildings, but wooden tiles have poor sound absorption properties, so the sound of footsteps echoes. There are disadvantages such as: On the other hand, synthetic resin tiles and rubber tiles have higher sound absorption properties than wooden tiles, so using them as floor finishing materials has the advantage of not making the sound of footsteps as loud, but it also gives the building a luxurious feel. The disadvantage is that it is difficult to provide

As a solution to this disadvantage, there is a soundproof flooring material as shown in FIG. In this soundproof flooring material 1, the wooden pieces 1b are adhered to the surface of a sheet 1a made of a sound absorbing material so that the wooden pieces 1b are laid out in a small checkerboard pattern or the like without any gaps. The wood piece 1b has a thickness of 3.0 to 8.01 mm.
The sheet 1a has a thickness of about 2.0 mm. When such soundproof flooring material 1 is laid and fixed on the floor base as shown in the figure, the upper surface of the wooden piece 1b constitutes the floor surface, making the room etc. calm and giving the building a luxurious look. You can also give Moreover, since the sheet 1a made of a sound absorbing material is provided on the back side of the wooden piece 1b, a soundproofing effect can also be obtained.

However, such soundproof flooring materials have the following problems: ■ The soundproofing effect is low; ■ The wooden piece easily peels off from the sheet; ■ The wooden piece has a large dimensional change due to humidity, etc. There have been problems such as problems such as the appearance of cracks in the floor surface and the appearance of gaps in the floor surface, which impairs the aesthetic appearance of the floor surface.

Therefore, an improved soundproof flooring material as shown in FIGS. 2 and 3 was developed. As shown in the figure, this soundproof flooring material 2
The sheets 2a made of sound absorbing material are spaced apart from each other,
A predetermined number of wooden pieces 2b... are embedded and joined together so that the front side portions protrude.

This soundproof flooring material has spaces between the wooden pieces,
In addition, since the base of the wooden piece is embedded in the sheet, as shown in FIG. 3, one wooden piece 2
The sound A, such as the sound of walking, passing through the interior of the wooden piece 2b is blocked by the sound absorbing material surrounding the wooden piece 2b, and is difficult to be transmitted to the adjacent wooden piece 2b. Therefore, compared to a soundproof flooring material in which wooden pieces are spread tightly over the sheet surface, sound is less likely to be transmitted in the lateral direction, and the sound absorption effect is higher. Even if the dimensions of the wooden pieces change, the sheet portion between the wooden pieces expands and contracts to absorb the dimensional change of the wooden pieces, so that the wooden pieces do not push up or a gap is created between the wooden pieces and the sheet. Moreover, since there are gaps between the wooden pieces that serve as joints from the beginning, even if the wooden pieces change in size, this gap absorbs the dimensional change, so the aesthetic appearance of the floor is not impaired. Since the wooden piece is embedded in the sheet, the contact area between the wooden piece and the sheet is larger than when the wooden piece is simply glued to the surface of the sheet. Therefore, it is difficult to peel off from the sheet. By appropriately determining the intervals and protruding heights of the wooden pieces, it is possible to eliminate troubles such as people tripping on the end faces of the wooden pieces, even if the heights of the wooden pieces are slightly different. On the other hand, if there are no gaps between the wooden pieces, as with conventional soundproof flooring, and the heights of the wooden pieces are different, there is a high risk of problems such as people tripping over the protruding parts of the wooden pieces. . This soundproof flooring material does not require nailing and can be fixed to the subfloor with adhesive, making it easy to install.

The method of constructing improved soundproof flooring materials with such excellent characteristics is to pour liquid sound-absorbing material into a box-shaped frame, and then place a predetermined number of wooden pieces on top of the sound-absorbing material so that the base is embedded. However, depending on the viscosity and other properties of the liquid sound-absorbing material, the wooden pieces may sink, so the amount of protrusion of the wooden pieces from the sheet cannot be determined. Problems arise, such as not being able to strictly determine the sound absorbing material, and the liquid sound-absorbing material adhering to the front side of the wooden piece, damaging the aesthetic appearance of the wooden piece.

[Purpose of the invention]

This invention was made in view of the above circumstances, and provides an improved soundproof flooring material that allows the amount of protrusion of the wooden piece from the sheet to be strictly determined and that does not cause the aesthetic appearance of the wooden piece to be impaired. The purpose is to provide a manufacturing method.

[Disclosure of the invention]

In order to achieve the above object, the present invention provides a soundproof flooring material in which a predetermined number of wooden pieces are embedded in sheets of sound-absorbing material, spaced apart from each other and with the front side protruding. A box-shaped mold is used in which a soft mold is provided at the bottom of the frame, in which a large number of recesses corresponding to the arrangement of the wooden pieces are formed on the flat mold surface, and each of the recesses is filled with a mold on the front side. To provide a method for producing a soundproof flooring material, in which a wooden piece is fitted with the wood piece facing toward the back and the base protruding from the recess, then a liquid sound-absorbing material is poured into the formwork, and the material is cured. The purpose is The present invention will be described in detail below based on examples.

The manufacturing method of the soundproof flooring material according to the present invention will be explained with reference to FIG. First, as shown in the figure, a box in which a sheet-like soft mold (releasing soft mold) 3 having a large number of recesses 3a provided at predetermined intervals on a flat mold surface is placed on the bottom of a rigid box frame 4. A shaped formwork 5 is prepared. As the sheet-like flexible mold 3, one made of silicone rubber or the like is used, for example. Next, the wooden piece 2b is fitted into the recess 3a with the front side facing inwards and the base protruding. At this time, wood piece 2
There should be no gap between the circumferential surface of b and the circumferential surface of the recess 3a. The circumferential length of the recess is preferably 0.5 to 1.0 ++n shorter than the circumferential length of the wooden piece 2b. Next, the liquid sound absorbing material 6 is poured into the mold 5 and the liquid sound absorbing material 6 is hardened. Thereafter, by removing the formwork 5, a soundproof flooring material in which wood pieces are integrally bonded to the sheet as shown in FIG. 2 is obtained.

As the sound absorbing material, for example, soft rubber such as silicone rubber, soft plastics, and others are used. When using soft rubber or soft plastic, it is preferable to use one whose hardness (Shore hardness) after curing is lθ to 70°. As for the wooden piece, the entire piece may be a single piece, but a piece in which an artificial decorative veneer or a natural decorative veneer is bonded to a substrate made of two plywood boards is used. As for the wood pieces, reinforced wood (WPC) is used, which is impregnated with 7-mers and then chemically polymerized using radiation or catalysts to strengthen it with resin. is preferred. This is because properties such as strength, two-dimensional stability, weather resistance, corrosion resistance, and abrasion resistance of the wooden piece are improved. The thickness of the sheet is preferably 3.0 to 20.0 m, considering the sound absorption effect, the feeling of walking, and the ability to absorb some unevenness in the flooring, and the thickness of the wooden piece is 1 to 20 m. It is preferable that Also, the distance between the wooden pieces is 0.5
(2) It is preferable to separate them by 1 or more. The size of the sheet and wooden pieces, and the number of wooden pieces to be joined to the sheet are determined as appropriate depending on the installation location, etc. For example, the sheet is 180
The size of the wooden pieces is 1OcII+X10cm, and the space between the wooden pieces is 1c+n. However, in order to meet these conditions, it is necessary to decide the position and number of recesses to be provided in the soft mold, the depth and shape of the recesses, the thickness of the liquid sound-absorbing material to be poured, etc.

In the method for manufacturing soundproof flooring materials according to the present invention, the wooden pieces are fixed in the recesses of the soft mold, and the liquid sound-absorbing material is poured into the formwork, so it is not possible to precisely determine the amount of protrusion of the wooden pieces. can. Since the front side of the wooden piece is hidden within the recess, there is no risk of it becoming contaminated with liquid sound absorbing material. Since the liquid sound-absorbing material is poured into the formwork, by adjusting the shape and width of the formwork, it is possible to obtain soundproof flooring material of the shape and width that meet your needs. Moreover, if the peripheral surface of the sheet-like flexible mold used in the example is brought into pressure contact with the inner peripheral surface of the box frame,
Since no dust is formed around the resulting soundproof flooring material, no dust removal operation is required (it can be used as a product as is).

Note that, as shown in FIG. 5, if a wooden piece 7 is used in which a substrate 7a made of plywood or the like and a decorative veneer 7b having a butthole pattern reinforced with resin are joined and integrated. Using the obtained soundproof flooring material 8, it becomes possible to arrange a wood grain pattern on the floor surface. In the figure, 9 is a sheet.

When a wood piece with a butthole pattern is made by cutting wood into rings, the wood fibers are cut into short pieces, so when dried, cracking, chipping, warping, etc. are very likely to occur. 1
．． When the thickness is about 0 to io, o mm, cracks are more likely to occur because it is thin. Therefore, it is difficult to use such a wooden piece for the soundproof flooring material according to the present invention. However, as mentioned above, when decorative veneer with a wood edge pattern is reinforced with resin, it is less prone to cracking, chipping, warping, curling, etc., and has good water resistance, so it can be used for soundproof flooring. A totally acceptable wooden piece can be made, for example, as follows. First, a veneer is made by slicing hardwoods such as Nara, Kaji, Sen, Lauan, etc., coniferous trees such as Matsu, Sugi, fir, Hinoki, other logs, and square lumber into rounds. The thickness is 1
．． It is preferable to set it as 0-10.0+zs. next,
The veneer is impregnated with a thermosetting resin such as polyester resin, melamine resin, or phenol resin by vacuum pressure impregnation.

The amount of impregnation is preferably 100 to 120%. After that, the veneer is adhered to a substrate such as plywood, and the impregnated resin is cured. After adhering the veneer to the substrate, it may be integrally molded with the sound absorbing material and the impregnated resin may be cured.

It is preferable to use plywood as the substrate. This is because plywood usually has rough conduits, which improves the bonding (adhesion) of the wooden piece to the sound absorbing material.

Wooden pieces are not limited to square shapes;
It is also not necessary for the wooden pieces to be arranged parallel to the sheet, as shown in FIG. For example, as shown in Figure 6, a rectangular wooden piece l
O may be arranged on the sheet 11.

If you use a wooden piece whose base is wider than the front side, and when molding it with the sound-absorbing material, apply a mold release agent to the base of the wooden piece to prevent it from adhering to the sound-absorbing material. , it becomes possible to obtain a soundproof flooring material with wood pieces that are difficult to peel off when installed, but can be removed from the sheet if necessary. By using a wooden piece with dovetail grooves on the back surface, it is possible to obtain a soundproof flooring material in which the wooden piece is firmly bonded to the sheet. By impregnating the sound absorbing material with a flame retardant or impregnating the wood piece with the flame retardant, it becomes possible to obtain a flame retardant soundproof flooring material. If a wooden piece is used that is provided with a notch on the end face of the part to be embedded in the sheet, which increases the distance between the wooden pieces in the same part when placed on the sheet, it is possible to use an adsorbent in the notch. Filling reduces the risk of the wood pieces coming off the sheet. After pouring the liquid sound absorbing material into the formwork, a panel heater with a heat medium passage, a heat medium passage,
By burying a heating means such as a heater wire in the sound absorbing material, it is possible to obtain a soundproof flooring material equipped with a heating means.

The soundproof flooring material obtained by the manufacturing method of this invention can also be used as wall material, ceiling material, etc.

〔Effect of the invention〕

In the soundproof flooring material according to the present invention, in order to obtain a soundproofing flooring material in which a predetermined number of wooden pieces are embedded in sheets made of sound absorbing material, spaced apart from each other and with the front side portions protruding, Using a box-shaped formwork in which a soft mold, in which a large number of recesses corresponding to the arrangement of the wooden pieces are formed on the mold surface, is provided at the bottom of the frame, fill each recess with the front side facing toward the back, In addition, after fitting the wooden piece so that the base protrudes from the recess, liquid sound-absorbing material is poured into the formwork and cured, so the amount of protrusion of the wooden piece from the sheet must be strictly controlled. You can decide, and what's more, you won't have to worry about the beauty of wooden pieces.

[Brief explanation of the drawing]

Figure 1 is a perspective view of a conventional soundproof flooring material, Figure 2 is a perspective view of an improved soundproofing flooring material, Figure 3 is a longitudinal cross-sectional view of a portion of the same soundproofing flooring material, and Figure 4 is a perspective view of this soundproofing flooring material. An explanatory diagram of one embodiment of the method for manufacturing soundproof flooring materials according to the invention, FIG.
The figure is a plan view of another example of soundproof flooring material obtained by the same manufacturing method. 2b, 7.10...Wood piece 3...Sheet-like soft mold 3a...Recess 4...Hard box frame 5...Box-shaped formwork 6...Sound absorbing material 8...Soundproofing Flooring material 9,11・
... Sheet agent Patent attorney Takehiko Matsumoto Figure 1 Figure 2 Figure 3 a Figure 4 Figure 5 Figure 6 Figure 1゜

Claims (10)

[Claims] (1) To obtain a soundproof flooring material in which a predetermined number of wooden pieces are embedded in a sheet of sound-absorbing material, spaced apart from each other and with the front side protruding, place the wooden pieces on a flat mold surface. A box-shaped formwork is used, in which a flexible mold having a large number of recesses corresponding to the arrangement of the recesses is installed at the bottom of the frame. A method for manufacturing soundproof flooring materials in which a wooden piece is fitted so that it protrudes from the outside, then liquid sound-absorbing material is poured into the formwork and allowed to harden. (2) The method for manufacturing a soundproof flooring material according to claim 1, wherein the box-shaped frame is one in which a sheet-like flexible mold having a predetermined number of recesses is laid on the bottom of the box frame. (3) The method for producing a soundproof flooring material according to claim 2, wherein the sheet-like flexible mold is made of silicone rubber. (4) The method for manufacturing a soundproof flooring material according to any one of claims 1 to 3, wherein the wooden piece is a decorative veneer integrally bonded to the surface of a substrate made of plywood. Manufacturing method. (5) The method for manufacturing a soundproof flooring material according to claim 4, wherein the decorative veneer has a wood grain pattern. (6) The method for producing a soundproof flooring material according to any one of claims 1 to 5, wherein the wood piece is made of reinforced wood. (7) The method for producing a soundproof flooring material according to any one of claims 1 to 6, wherein the wood piece has a thickness of 1 to 20 mm. (8) The method for manufacturing a soundproof flooring material according to any one of claims 1 to 7, wherein the interval between the wooden pieces is 0.5 mm or more. (9) The method for manufacturing a soundproof flooring material according to any one of claims 1 to 8, wherein the sound absorbing material is one of soft rubber and soft plastics. (10) The method for producing a soundproof flooring material according to any one of claims 1 to 9, wherein the sheet has a thickness of 3.0 to 20.0 mm.