Building soundproofing material and usage thereof

Abstract

To provide a building soundproofing material that is both easy to install and has soundproofing properties.SOLUTION: A soundproofing material with a soundproof layer formed of a soundproofing composition containing hollow fine particles and a binder is disposed in a building. The soundproofing composition may further contain a filler. The density of the soundproofing material may be 1.3 g / cm3 or less. The hollow fine particles may have an average particle size of 150 μm or less, and the bulk density of the hollow fine particles may be 0.5 g / cm3 or less. The hollow fine particles may be inorganic balloon particles. The binder may contain asphalt. The soundproofing material may further include a surface layer and a back layer, and the soundproofing layer may be interposed between the surface layer and the back layer. The surface layer and the back layer may contain a fibrous structure. The soundproofing material may be disposed on the floor of a multi-story wooden building or house to reduce the transmission of floor weight impact noise.SELECTED DRAWING: None

Description

[Technical Field]

[0001] The present invention relates to a soundproofing material used as a component of a floor, wall, or the like that constitutes a building, and to uses thereof. [Background technology]

[0002] There are various noise sources within buildings (structures) such as houses. For example, the sound of walking on the floor, the sound of things falling on the floor, and impact sounds propagate to the floor below, causing noise. These noises are primarily caused by structure-borne sound. However, there is also airborne sound, which is sound transmitted through the air between adjacent rooms or between upper and lower floors, causing noise. To combat this type of noise, soundproofing materials have traditionally been used for sound insulation and sound absorption. Increasing the sound transmission loss of soundproofing materials improves their soundproofing function, and it is widely known that sound transmission loss is proportional to the surface density of the material (following the so-called mass law).

[0003] In recent years, floor impact noise from upper floors has become a common problem in multi-story buildings such as apartment complexes (condominiums, buildings, etc.) and ordinary homes. For example, in wooden buildings, the impact noise of a child jumping off a sofa or impact noise (relatively low-frequency sound waves) caused by heavy walking is often a problem. Such impact noise is called heavy floor impact noise, and one known method for reducing heavy floor impact noise is to place vibration-damping sound-insulating materials between the floor material and the underfloor material. Note that the amount of reduction in heavy floor impact noise is proportional to the surface density of the floor and follows the law of mass, so heavy vibration-damping sound-insulating materials are widely used as a countermeasure against heavy floor impact noise.

[0004] For example, Japanese Patent No. 3013023 (Patent Document 1) discloses a sound-insulating component for reducing floor impact noise, which is formed by sandwiching a mixture of 100 parts by mass of petroleum-based asphalt, 2 to 10 parts by mass of thermoplastic elastomer, 100 to 400 parts by mass of mineral particles, 100 to 800 parts by mass of iron powder, and 0.1 to 1 part by mass of surfactant between sheets of felt paper or nonwoven fabric and molding the mixture into a plate. Specifically, a mixture of 270 parts by mass of petroleum-based asphalt, 8 parts by mass of thermoplastic elastomer, 850 parts by mass of mineral particles, 820 parts by mass of iron powder, and 2 parts by mass of surfactant was sandwiched between felt paper and molded into a plate with a density of 2.35 g / cm. 3 , thickness 8mm, surface density 18.8kg / m 2 The sound-insulating components have been prepared.

[0005] On the other hand, methods that utilize vibration-damping properties have been considered as methods for reducing the weight of vibration-damping sound-insulating materials. For example, Japanese Patent Application Laid-Open No. 2023-061874 (Patent Document 2) discloses a sound-insulating structure that utilizes vibration-damping properties, and that has a pair of plate-like base materials that are arranged so as to overlap with a gap between them, a plurality of support columns that are arranged between the pair of base materials, and a plurality of columnar resonating sections that are arranged between the pair of base materials and are shorter in height than the support columns. Specifically, the sound-insulating structure has an areal density of 3.72 kg / m 2 The following sound insulation structures have been produced. [Prior art documents] [Patent documents]

[0006] [Patent Document 1] Patent No. 3013023 [Patent Document 2] Japanese Patent Publication No. 2023-061874 Summary of the Invention [Problem to be solved by the invention]

[0007] However, the sound-insulating component of Patent Document 1 is heavy, posing significant problems in terms of installation and transportation. Furthermore, the sound-insulating structure of Patent Document 2 requires space for vibration, and therefore cannot be installed between the floor material and the underfloor material, resulting in installation problems. Furthermore, conventional sound-insulating materials follow the mass law, which states that sound insulation increases as surface density increases, so they cannot simultaneously achieve light weight and soundproofing properties such as sound insulation when reducing heavy floor impact noise.

[0008] Therefore, an object of the present invention is to provide a soundproofing material for construction that is both easy to install and has soundproofing properties, and uses thereof.

[0009] Another object of the present invention is to provide a soundproofing material for construction that can increase sound transmission loss in violation of the mass law and reduce the propagation of heavy floor impact noise even when lightweight, and to provide uses thereof.

[0010] A further object of the present invention is to provide a soundproofing material for construction that can reduce the propagation of heavy floor impact noise from upper floors in a multi-story wooden building with a simple structure, and uses thereof.

[0011] Another object of the present invention is to provide a soundproofing material for construction that is excellent in formability and handling properties, and uses thereof.

[0012] A further object of the present invention is to provide a soundproofing material for construction that can maintain soundproofing properties for a long period of time and has excellent durability, and uses thereof. [Means for solving the problem]

[0013] As a result of intensive research to achieve the above-mentioned object, the inventors discovered that by disposing a soundproofing material including a soundproofing layer formed from a soundproofing composition containing hollow microparticles and a binder in a building, it is possible to achieve both ease of installation and soundproofing properties, and thus completed the present invention.

[0014] That is, the present invention includes the following aspects.

[0015] Aspect [1]: A soundproofing material to be installed in a building, the soundproofing material comprising a soundproofing layer formed of a soundproofing composition including hollow fine particles and a binder.

[0016] Aspect [2]: The soundproofing material according to aspect [1], wherein the soundproofing composition further comprises a filler.

[0017] Aspect [3]: Density is 1.3 g / cm 3 The soundproofing material according to the above aspect [1] or [2], which is as follows:

[0018] Aspect [4]: ​​The soundproofing material according to any one of Aspects [1] to [3], which has an average thickness of 1.5 mm or more.

[0019] Aspect [5]: The hollow fine particles have an average particle size of 150 μm or less, and a bulk density of 0.5 g / cm 3 The soundproofing material according to any one of the above aspects [1] to [4], which is as follows:

[0020] Aspect [6]: The soundproofing material according to any one of Aspects [1] to [5], wherein the hollow fine particles are inorganic balloon particles.

[0021] Aspect [7]: The soundproofing material according to any one of Aspects [1] to [6], wherein the binder contains asphalt.

[0022] Aspect [8]: A soundproofing material according to any one of aspects [1] to [7], which is a laminated sheet further comprising a surface layer and a back layer, with the soundproofing layer interposed between the surface layer and the back layer.

[0023] Aspect [9]: The soundproofing material according to aspect [8], wherein the surface layer and the back layer include a fibrous structure.

[0024] Aspect

[10] : The soundproofing material according to any one of Aspects [1] to [9], wherein the proportion of the hollow fine particles is 1 to 50 parts by mass per 100 parts by mass of the binder.

[0025] Aspect

[11] : The soundproofing material according to any one of Aspects [2] to

[10] , wherein the proportion of the filler is 300 parts by mass or less per 100 parts by mass of the binder.

[0026] Aspect

[12] : A soundproofing material according to any one of aspects [1] to

[11] , which is a vibration-damping sound-insulating material.

[0027] Aspect

[13] : The soundproofing material according to any one of Aspects [1] to

[12] , which is disposed on the wall or floor of a multi-story building or house.

[0028] Aspect

[14] : The soundproofing material according to any one of Aspects [1] to

[13] , which is disposed on the floor of a multi-story wooden building or house.

[0029] Aspect

[15] : A soundproof floor structure comprising a floor underlayment, a floor finishing material, and the soundproofing material according to any one of aspects [1] to

[14] interposed between the floor underlayment and the floor finishing material.

[0030] Aspect

[16] : A method for reducing propagating sound within a building, comprising disposing the soundproofing material according to any one of aspects [1] to

[14] in the building.

[0031] Aspect

[17] : The method according to aspect

[16] , in which the soundproofing material is arranged on the walls or floors of a multi-story wooden building or house to reduce floor-weight impact noise from upper floors. [Effects of the Invention]

[0032] In the present invention, a soundproofing material including a soundproofing layer formed from a soundproofing composition containing hollow fine particles and a binder is disposed in a building, thereby achieving both ease of installation and soundproofing. In particular, contrary to the law of mass, sound transmission loss can be increased, and even though the material is lightweight, the propagation of heavy floor impact noise can be effectively reduced. Therefore, despite the simple structure of the soundproofing material, the propagation of heavy floor impact noise from upper floors in multi-story wooden buildings can be effectively reduced. Furthermore, by combining hollow fine particles and a binder with a filler, the moldability (processability) of the soundproofing material can be improved, and by sandwiching the soundproofing layer between the surface layer and the back layer, the handleability of the soundproofing material can also be improved. Furthermore, because the soundproofing material has a simple composition and structure, it is also highly durable, and soundproofing properties can be maintained for a long period of time. DETAILED DESCRIPTION OF THE INVENTION

[0033] The soundproofing material of the present invention includes a soundproofing layer formed from a soundproofing composition, which includes hollow fine particles and a binder. In particular, the soundproofing material of the present invention can increase sound transmission loss in violation of the mass law, thereby achieving both ease of installation and soundproofing properties. The mechanism by which the soundproofing material of the present invention exhibits soundproofing properties that violate the mass law is unknown, but it is presumed that the presence of hollow fine particles is involved.

[0034] [Hollow fine particles] The hollow shape of the hollow microparticles may be a porous shape like pumice powder or an interconnected hollow shape (or open-cell shape). However, from the viewpoint of high soundproofing properties and the ability to exhibit soundproofing properties that violate the mass law, a hollow shape having one or more sealed hollow portions (cavities) inside the microparticles (closed hollow shape or closed-cell shape) is preferred, and a balloon shape is particularly preferred.

[0035] In this specification and claims, the term "balloon shape" means a hollow shape having a single sealed cavity like a balloon.

[0036] The material of the hollow fine particles may be inorganic or organic.

[0037] Examples of inorganic materials include inorganic oxides or metal oxides (e.g., beryllium oxide, magnesia, silicon oxide or silica, aluminum oxide or alumina, titania, zirconia, magnesia, manganese oxide, zinc oxide, tin oxide, antimony oxide, cerium oxide, tin-doped indium oxide (ITO), etc.), nitrogen compounds (e.g., boron nitride, aluminum nitride, silicon nitride, carbon nitride, titanium nitride, etc.), carbon compounds (e.g., silicon carbide, fluorine carbide, boron carbide, titanium carbide, carbide, etc.), and the like. tungsten, diamond, etc.), carbonates (e.g., calcium carbonate, barium carbonate, magnesium carbonate, etc.), minerals (e.g., talc, mica, zeolite, ferrite, tourmaline, diatomaceous earth, calcined silica earth, activated clay, kaolin, pyrophyllite, sericite, bentonite, smectite, montmorillonite, clay, red iron oxide, quartz, wollastonite, etc.), glasses (e.g., soda-lime glass, lead glass, borosilicate glass, silica glass, etc.), silicon, etc.

[0038] These hollow fine particles made of inorganic materials can be used alone or in combination. Among the hollow fine particles made of inorganic materials, hollow inorganic oxide fine particles such as silica balloons, alumina balloons, and zirconia balloons; and hollow mineral fine particles such as shirasu balloons and aluminosilicate balloons are preferred.

[0039] Examples of organic materials include polyolefin resins (e.g., polyethylene, polypropylene, etc.), styrene resins (e.g., polystyrene, ABS resin, etc.), (meth)acrylic resins (e.g., polymethyl methacrylate, etc.), vinyl chloride resins (e.g., polyvinyl chloride, polyvinylidene chloride, etc.), polyamide resins (e.g., polyamide 6, polyamide 66, etc.), polyester resins (e.g., polyethylene terephthalate, polybutylene terephthalate, etc.), and cellulose resins (e.g., cellulose, cellulose acetate, etc.).

[0040] These hollow microparticles made of organic materials can be used alone or in combination. The hollow microparticles made of organic materials may be microcapsules. Microcapsules may be made of vinyl homopolymers or copolymers containing, as polymerization components, olefins (e.g., ethylene, propylene, etc.), aromatic vinyl compounds (e.g., styrene, etc.), (meth)acrylonitrile, (meth)acrylic acid, (meth)acrylic acid esters (e.g., ethyl acrylate, butyl acrylate, methyl methacrylate, ethyl methacrylate, etc.), vinyl chloride, vinylidene chloride, vinyl acetate, etc. Furthermore, the vinyl homopolymers or copolymers constituting the microcapsules may be partially or entirely crosslinked with a crosslinking agent such as divinylbenzene or ethylene glycol di(meth)acrylate.

[0041] As the hollow fine particles, inorganic balloon particles are preferred from the viewpoint of facilitating improvement in soundproofing, silica balloons, shirasu balloons, and glass balloons are more preferred, and glass balloons are even more preferred from the viewpoint of facilitating improvement in soundproofing and cost efficiency.

[0042] The hollow fine particles may have an average particle size (volume average particle size) of 500 μm or less, for example, 300 μm or less, preferably 200 μm or less, further preferably 150 μm or less, and more preferably 100 μm or less, and specifically 10 to 300 μm, preferably 15 to 200 μm, further preferably 20 to 150 μm, more preferably 30 to 100 μm, and most preferably 50 to 80 μm. If the average particle size is too small, the soundproofing properties may be reduced, and if it is too large, the formability of the soundproofing material may be reduced.

[0043] The maximum particle size of the hollow fine particles may be 5 mm or less, preferably 3 mm or less, and more preferably 1 mm or less.

[0044] In this specification and claims, the average particle size and maximum particle size of the hollow fine particles can be measured on a volume basis using a laser diffraction particle size distribution analyzer.

[0045] The external shape of the hollow fine particles may be granular, and examples thereof include spherical or approximately spherical, ellipsoidal or rod-like, polyhedral (e.g., cubic, rectangular, tetrahedral (pyramidal)), flat (plate-like, scaly, or thin), and irregular shapes. Among these shapes, spherical or approximately spherical, ellipsoidal, and polyhedral shapes are preferred from the viewpoints of handleability and dispersibility, and spherical or approximately spherical shapes are particularly preferred.

[0046] The bulk density of hollow particles is 1 g / cm 3 or less (especially 0.5g / cm 3 or less), e.g., 0.05 to 1 g / cm 3 , preferably 0.08 to 0.5 g / cm 3 , and more preferably 0.1 to 0.4 g / cm 3 , more preferably 0.15 to 0.3 g / cm 3 , and most preferably 0.18 to 0.25 g / cm 3 If the bulk density is too low, there is a risk that the soundproofing properties will be reduced, and if it is too high, there is a risk that the lightness will be reduced.

[0047] In this specification and claims, the bulk density of hollow fine particles can be measured in accordance with JIS Z 2504:2020 using a funnel with an orifice diameter of 2.5 mm and a funnel angle of 60 degrees.

[0048] The proportion of the hollow fine particles relative to 100 parts by mass of the binder is, for example, 0.1 to 100 parts by mass, preferably 1 to 50 parts by mass, further preferably 5 to 40 parts by mass, even more preferably 10 to 35 parts by mass, and most preferably 20 to 30 parts by mass. If the proportion of the hollow fine particles is too low, there is a risk that the soundproofing properties and workability (or lightness) will decrease, and if it is too high, there is a risk that the formability of the soundproofing material will decrease.

[0049] The proportion of hollow fine particles in the soundproofing composition can be selected from a range of about 1 to 70 mass %, for example, 3 to 50 mass %, preferably 5 to 40 mass %, further preferably 7 to 30 mass %, even more preferably 10 to 25 mass %, and most preferably 15 to 20 mass %.

[0050] [binder] The binder is not particularly limited as long as it can be combined with the hollow fine particles to form a soundproofing material into a sheet, and may be either an inorganic binder or an organic binder, but organic binders are preferred from the viewpoints of handling ease and formability of the soundproofing material, etc. Examples of organic binders include bituminous substances, soft resins, and elastomer components.

[0051] Examples of bituminous materials include asphalt, coal tar, pitch, etc. These bituminous materials can be used alone or in combination. Among these, asphalt is preferred.

[0052] The asphalt is not particularly limited, and examples thereof include common asphalts such as natural asphalt (e.g., lake asphalt, rock asphalt, oil sand, asphaltite, etc.) and petroleum asphalt (e.g., straight asphalt, blown asphalt, etc.). These asphalts can be used alone or in combination of two or more. Of these, petroleum asphalts such as blown asphalt are preferred.

[0053] The penetration of the asphalt (1 / 10 mm) can be selected from a range of about 0 to 300 in accordance with a method in accordance with JIS K2207-1996, and is, for example, 5 to 200, preferably 8 to 80, and more preferably 10 to 20. If the penetration is too small, it may be difficult to mold the soundproofing material, and if it is too large, the mechanical properties of the soundproofing material may be reduced.

[0054] The softening point of the asphalt can be selected from a range of about 50 to 200° C. in a method conforming to JIS K 2207-1996, and is, for example, 70 to 180° C., preferably 80 to 150° C., and more preferably 100 to 120° C. If the softening point is too low, the mechanical properties of the soundproofing material may be reduced, and if it is too high, it may be difficult to mold the soundproofing material.

[0055] Examples of soft resin or elastomer components include polyolefins, vinyl polymers (e.g., polyvinyl chloride, ethylene-vinyl acetate copolymer, ethylene-vinyl alcohol copolymer, ethylene-acrylic acid copolymer, ethylene-methyl acrylate copolymer, ethylene-ethyl acrylate copolymer, etc.), polyamide elastomers, polyester elastomers, synthetic rubbers (e.g., polybutadiene, polyisoprene, styrene-butadiene copolymer, etc.), natural rubber, and rosin resins (e.g., natural rosin, modified rosin, etc.). These soft resin or elastomer components can be used alone or in combination. Of these, styrene-diene copolymers such as styrene-butadiene block copolymers are preferred.

[0056] These binders can be used alone or in combination of two or more. Among these, the binder with a mass per unit area of ​​0.9 kg / m is preferred because it can achieve both sound insulation and ease of application of the soundproofing material. 2 The above is preferable, and it is preferable that the mixture contains asphalt in view of its viscoelasticity.

[0057] The proportion of asphalt in the binder may be 10% by mass or more, for example, 30% by mass or more, preferably 50% by mass or more, further preferably 70% by mass or more, more preferably 80% by mass or more, most preferably 90% by mass or more, and may be 100% by mass. If the proportion of asphalt in the binder is too low, the soundproofing properties and workability of the soundproofing material may be reduced.

[0058] The binder may be a combination of asphalt and a soft resin or elastomer component, and the proportion of the soft resin or elastomer component may be 100 parts by mass or less per 100 parts by mass of asphalt, for example, 1 to 80 parts by mass, preferably 3 to 50 parts by mass, and more preferably 5 to 40 parts by mass.

[0059] It is most preferable that the binder consists of asphalt alone, since this makes it easier to achieve both soundproofing properties and ease of application of the soundproof material.

[0060] The density of the binder is, for example, 0.5 to 2 g / cm 3 , preferably 0.7 to 1.5 g / cm 3 , and more preferably 0.8 to 1.3 g / cm 3 , and most preferably 0.9 to 1.1 g / cm 3 If the density of the binder is too low, there is a risk that the soundproofing properties will be reduced, and if it is too high, there is a risk that the lightness will be reduced.

[0061] The proportion of the binder in the soundproofing composition can be selected from a range of about 5 to 95 mass%, for example, 10 to 90 mass%, preferably 20 to 85 mass%, further preferably 30 to 80 mass%, more preferably 50 to 75 mass%, and most preferably 60 to 70 mass%. If the proportion of the binder is too low, workability may be reduced, and if it is too high, soundproofing properties may be reduced.

[0062] [Filler] In addition to the hollow fine particles and binder, the soundproofing composition may further contain a filler (a non-hollow filler or a solid filler) to improve the moldability of the soundproofing material. The filler includes inorganic fillers and organic fillers.

[0063] Examples of inorganic fillers include metal particles or powders (e.g., iron, copper, tin, zinc, nickel, stainless steel, etc.), metal oxide particles (e.g., iron oxide, ferric oxide, iron tetraoxide, ferrite, tin oxide, zinc oxide, zinc oxide, copper oxide, aluminum oxide, etc.), metal salt particles (e.g., barium sulfate, calcium sulfate, aluminum sulfate, calcium sulfite, calcium carbonate, calcium bicarbonate, barium carbonate, magnesium hydroxide, etc.), mineral particles (e.g., mica, clay, talc, wollastonite, diatomaceous earth, silica sand, etc.), and inorganic fibers (e.g., carbon fiber, glass fiber, etc.). These inorganic fillers can be used alone or in combination. Of these, metal salt particles such as calcium carbonate are preferred because of their excellent moldability into soundproofing materials.

[0064] Examples of organic fillers include wood flour, pulp, natural fibers (cotton, hemp, etc.), recycled fibers (rayon, etc.), cross-linked resin particles (cross-linked polyethylene particles, cross-linked polystyrene particles, cross-linked acrylic particles, etc.), and synthetic fibers (polyester fibers, polyamide fibers, etc.). These organic fillers can be used alone or in combination. Among these, organic fillers containing plant-derived cellulose such as wood flour are particularly preferred because of their light weight and excellent moldability into soundproofing materials.

[0065] These fillers can be used alone or in combination of two or more. Among these fillers, inorganic fillers are preferred, metal salt particles are more preferred, and metal carbonates such as calcium carbonate are even more preferred, from the viewpoint of improving the moldability of the soundproofing material and easily achieving both workability and soundproofing properties.

[0066] The average particle size (volume average particle size) of the filler (particularly, inorganic filler) is, for example, 10 to 300 μm, preferably 20 to 200 μm, further preferably 30 to 150 μm, and even more preferably 50 to 100 μm. If the average particle size of the filler is too small, the moldability of the soundproofing material may decrease, while if it is too large, the mechanical properties of the soundproofing material may decrease.

[0067] The maximum particle size of the filler (particularly, inorganic filler) may be 5 mm or less, preferably 3 mm or less, and more preferably 1 mm or less.

[0068] In this specification and claims, the average particle size and maximum particle size of the filler can be measured on a volume basis using a laser diffraction particle size distribution analyzer.

[0069] The shape of the filler is not particularly limited and may be, for example, granular, irregular, fibrous, etc., but granular is preferred from the standpoint of handling and dispersibility.

[0070] The density of the filler (particularly, inorganic filler) is, for example, 1 to 10 g / cm 3 , preferably 1.2 to 5 g / cm 3, and more preferably 1.5 to 4 g / cm 3 , more preferably 2 to 3.5 g / cm 3 , and most preferably 2.5 to 3 g / cm 3 If the density of the filler is too low, there is a risk that the soundproofing properties will be reduced, and if it is too high, there is a risk that the lightness will be reduced.

[0071] The proportion of the filler may be 500 parts by mass or less (particularly 300 parts by mass or less) per 100 parts by mass of the binder (particularly asphalt), for example 200 parts by mass or less, preferably 1 to 100 parts by mass, further preferably 5 to 80 parts by mass, even more preferably 10 to 50 parts by mass, and most preferably 20 to 30 parts by mass. If the proportion of the filler is too high, there is a risk that workability and soundproofing properties will decrease.

[0072] [Other ingredients] In addition to the hollow microparticles and binder, the soundproofing composition may further contain conventional additives as other components. Examples of conventional additives include stabilizers (heat stabilizers such as copper compounds, UV absorbers, light stabilizers, antioxidants, etc.), thickeners, flame retardants, plasticizers, antistatic agents, colorants, surfactants, dispersants, lubricants, crystallization rate retarders, glidants, antibacterial agents, insect repellents (termite repellents, mite repellents, etc.), preservatives (mold inhibitors, etc.), matting agents, heat storage agents, fragrances, fluorescent brighteners, and wetting agents. These additives can be used alone or in combination. The total proportion of the additives may be 100 parts by weight or less, preferably 50 parts by weight or less, more preferably 30 parts by weight or less, more preferably 20 parts by weight or less, and most preferably 10 parts by weight or less (e.g., 0.1 to 10 parts by weight) per 100 parts by weight of the binder (e.g., asphalt).

[0073] [Soundproofing material] The soundproofing material of the present invention may include a soundproofing layer formed from the soundproofing composition. The soundproofing material may be a single-layer sheet formed solely of the soundproofing layer, or a laminate sheet of the soundproofing layer and another layer. The other layer may be laminated on at least one side of the soundproofing layer, or may be a combination of a surface layer laminated on one side of the soundproofing layer and a back layer laminated on the other side. Furthermore, the surface layer and the back layer may each have a single-layer structure or a laminate structure of two or more layers. When the surface layer and the back layer each have a laminate structure, an adhesive layer may be provided between the outermost layer and the soundproofing layer. Furthermore, the surface layer and the back layer may be functional layers such as vibration-damping layers or sound-absorbing layers, and when the surface layer and the back layer have a laminate structure of two or more layers, the functional layer may be included.

[0074] Among these, a laminate sheet in which another layer is laminated on at least one surface of an antiglare layer is preferred from the viewpoint of improving workability, and a laminate sheet in which a surface layer is laminated on one surface of a soundproof layer and a back layer is laminated on the other surface is particularly preferred from the viewpoint of improving workability and formability of the soundproof material. In particular, in the soundproof material of the present invention, since the soundproof layer contains a binder, the soundproof layer can be adhered to the single-layer surface layer or back layer without the need for an adhesive layer.

[0075] The front and back layers may be wood-based boards (solid wood, plywood, wood fiber boards, etc.), inorganic boards (gypsum boards, calcium silicate boards, etc.), synthetic resin sheets or films (polyolefin sheets, acrylic sheets, polyvinyl chloride sheets, polyester sheets, polyamide sheets, polyurethane sheets, etc.), but are preferably fiber layers containing a fiber structure in order to improve soundproofing. The fiber layer can be firmly integrated with the soundproof layer by impregnating the binder of the soundproof layer into the fiber structure.

[0076] The fiber layer may contain a fiber structure, and is usually a fabric formed from the fiber structure. Examples of fabrics include woven fabric, knitted fabric, net, paper, and nonwoven fabric. Among these, nonwoven fabric is preferred from the viewpoints of soundproofing properties and formability of the soundproofing material.

[0077] Examples of fibers contained in nonwoven fabrics include natural fibers (cotton, hemp, etc.), regenerated fibers (rayon, etc.), semi-synthetic fibers (cellulose ester fibers, etc.), synthetic fibers [polyolefin fibers (polyethylene fibers, polypropylene fibers, etc.), styrene fibers, tetrafluoroethylene fibers, acrylic fibers, vinyl alcohol fibers (ethylene vinyl alcohol fibers, etc.), polyester fibers (poly-C such as polyethylene terephthalate, polyethylene naphthalate, etc.], 2-4 Examples include alkylene arylate fibers, wholly aromatic polyester fibers such as liquid crystal polyester fibers, polyamide fibers (aliphatic polyamide fibers such as polyamide 6 and polyamide 66, wholly aromatic polyamide fibers such as aramid fibers), polyurethane fibers, and inorganic fibers (carbon fibers, glass fibers, etc.).

[0078] These fibers can be used alone or in combination. Among these fibers, cellulosic fibers such as cotton and rayon, polyolefin fibers such as polyethylene fibers and polypropylene fibers, polyester fibers such as polyethylene terephthalate fibers, and polyamide fibers such as polyamide 6 fibers are commonly used, and polypropylene fibers and polyester fibers (particularly polyester fibers) are preferred from the viewpoint of strength.

[0079] The average fineness of the fibers is about 0.1 denier or more, for example, about 0.1 to 5 denier, preferably about 0.2 to 4 denier, and more preferably about 0.5 to 3 denier.

[0080] The average fiber length of the fibers may be, for example, 10 to 150 mm, preferably 20 to 80 mm, and more preferably 30 to 60 mm, and may be infinite in direct spinning methods such as spunbonding, meltblowing, and flash spinning. From the viewpoint of strength, a long-fiber nonwoven fabric is preferred as the nonwoven fabric.

[0081] The weight of the nonwoven fabric is 10g / m 2 or more (e.g., 10 to 500 g / m 2For example, the density may be 10 to 100 g / m 2 , preferably 20 to 80 g / m 2 , and more preferably 30 to 70 g / m 2 , more preferably 40 to 60 g / m 2 If the basis weight is too small, even if a fiber layer is provided, there is a risk that the effect of improving the handleability of the soundproof layer will be small, and if it is too large, there is a risk that the workability will be reduced.

[0082] The nonwoven fabric can be prepared by a conventional method, for example, by forming a web containing the fibers and bonding the web, specifically by spunbonding, meltblowing, flash spinning, chemical bonding, thermal bonding, heat embossing, spunlace, needle punching, stitch bonding, etc. Among these, the spunbonding method is preferred from the viewpoint of strength, etc. In particular, the nonwoven fabric may be a polyester spunbonded nonwoven fabric.

[0083] The fiber structure may contain additives inside or on the fiber surface. Examples of additives include the fillers exemplified in the section on soundproofing compositions and conventional additives. The additives may be used alone or in combination of two or more. The total proportion of the filler and additives is 50% by mass or less, preferably 0.01 to 30% by mass, and more preferably 0.1 to 10% by mass, based on the total mass of the fiber structure.

[0084] The thickness (average thickness) of the front or back layer may be 0.01 mm or more, for example, 0.01 to 1 mm, preferably 0.05 to 0.5 mm, and more preferably 0.1 to 0.3 mm.

[0085] The thickness (average thickness) of the soundproofing material of the present invention may be 1.5 mm or more (particularly 2 mm or more), preferably 3 mm or more, more preferably 4 mm or more, and even more preferably 5 mm or more, and specifically, for example, 1.5 to 20 mm, preferably 2 to 15 mm, even more preferably 3 to 10 mm, more preferably 5 to 8 mm, and most preferably 6 to 7 mm. If the thickness of the soundproofing material is too thin, there is a risk that the soundproofing properties will decrease.

[0086] In a soundproofing material that combines a soundproofing layer with a surface layer and a back layer, the thickness ratio of the soundproofing layer (average thickness) to the surface layer or back layer (average thickness) is 1 / 0.005 to 1 / 0.5, preferably 1 / 0.01 to 1 / 0.3, more preferably 1 / 0.015 to 1 / 0.1, and even more preferably 1 / 0.02 to 1 / 0.05.

[0087] The soundproofing material of the present invention is excellent in lightness and has a density of 2.5 g / cm 3 or less (especially 2g / cm 3 or less), for example 1.5 g / cm 3 or less, preferably 1.3 g / cm 3 More preferably, 1 g / cm or less 3 or less, more preferably 0.8 g / cm 3 Below 0.7 g / cm, most preferably 0.7 g / cm 3 The specific density range is, for example, 0.1 to 1.3 g / cm 3 , preferably 0.3 to 1 g / cm 3 , and more preferably 0.4 to 0.9 g / cm 3 , more preferably 0.5 to 0.8 g / cm 3 , and most preferably 0.6 to 0.7 g / cm 3 If the density of the soundproofing material is too high, there is a risk that the soundproofing properties and light weight will be reduced.

[0088] In this specification and claims, the density of the soundproofing material can be measured by the method described in the examples below.

[0089] The soundproofing material of the present invention can reduce propagated sound over a wide frequency range, but is effective in reducing propagated sound in a relatively low frequency range, for example, sound with a natural frequency of 5 to 100 Hz, preferably 10 to 80 Hz, and more preferably 20 to 70 Hz.

[0090] The soundproofing material of the present invention may be any of a vibration-damping sound-insulating material, a sound-insulating material, and a sound-absorbing material, and is preferably a vibration-damping sound-insulating material or a sound-insulating material.

[0091] The method for producing the soundproofing material of the present invention is not particularly limited. For example, when the binder contains asphalt and the soundproofing material is a laminated sheet having a surface layer and a back layer, the surface layer and the back layer may be laminated on both sides of the soundproofing layer by sandwiching a mixture obtained by melt-mixing the binder and hollow fine particles between the surface layer and the back layer.

[0092] The soundproofing material of the present invention can be used to soundproof buildings (structures), and can be disposed in, for example, structural components of buildings such as floors, ceilings, walls, and doors, or can be used as at least a part of the structural components. Among these, the soundproofing material is preferably disposed on the floor or wall of a building. In particular, since the soundproofing material of the present invention is effective in reducing the low-frequency propagated sound, it is particularly preferable to dispose it on a floor to reduce floor-weight impact noise, which is a low-frequency noise. Therefore, a soundproof floor structure may be formed by interposing the soundproofing material of the present invention between a floor underlayment and a floor finishing material, and it is particularly preferable to form a soundproof floor structure on the floor of a multi-story wooden building that reduces the propagation of floor-weight impact noise from upper floors. [Example]

[0093] The present invention will be described in more detail below based on examples, but the present invention is not limited to these examples. Details of the soundproofing materials used in the examples and the methods for evaluating soundproofing properties are shown below.

[0094] [Soundproofing materials] Blown asphalt: Idemitsu Kosan Co., Ltd. "Blown Asphalt 10-20", penetration (25°C) 16 (1 / 10 mm), softening point 110°C, elongation (25°C) 2 cm, toluene soluble content 99.77% Calcium carbonate: manufactured by Kochi Heavy Carbon Co., Ltd., passed 200 mesh Hollow particles: Tomoe Engineering Co., Ltd. "Glass Balloon C20", median diameter 70 μm, bulk density 0.2 g / cm 3 PET nonwoven fabric: Asahi Kasei Corporation, basis weight 50g / m 2

[0095] [Floor impact sound test using two-by-four construction floors] Acoustic laboratory (volume 61.6m) 3 A two-by-four construction floor was constructed in an opening (dimensions 2740 x 3650 mm) in a building with a floor slab thickness of 250 mm, and a tire with standard weight impact characteristics as specified in JIS A 1418-2:2000 was used as the sound source, and floor impact sound levels were measured at five impact points and five sound receiving points. The two-by-four construction floor consisted of floor joists: 210 material [455 mm intervals] and 15 mm thick tongued plywood, the independent ceiling consisted of ceiling joists: 206 material and 12.5 mm thick gypsum board, and the ceiling space was covered with 50 mm thick glass wool [density 24 kg / m 3 ] was inserted.

[0096] [Density of soundproofing material] The mass of the test specimen cut into 100 mm square was measured, and the density [g / cm 3 ] was calculated.

[0097] Density [g / cm 3 ] = specimen mass [g] / (10 × 10 × specimen thickness [cm])

[0098] [Example 1] 100 parts by mass of blown asphalt was heated and melted at 200°C, and 27 parts by mass of calcium carbonate and 27 parts by mass of hollow fine particles were added. The resulting composition was uniformly kneaded and sandwiched between PET nonwoven fabrics to form a sheet. The resulting sheet-like molded product was cut into plates (910 mm long x 455 mm wide x 6 mm thick) and used as soundproofing material (density 0.65 g / cm). 3 , areal density 3.9kg / m 2 The resulting soundproofing material was laid over the entire surface of the tongue-and-groove plywood of a two-by-four construction floor, and flooring was laid over the soundproofing material and secured in place at 303 mm intervals using wood screws (diameter φ3.3 mm x length L45 mm).

[0099] [Example 2] A soundproofing material (density 0.97 g / cm) was prepared in the same manner as in Example 1, except that the blending amount of calcium carbonate was changed to 134 parts by mass and the blending amount of hollow fine particles was changed to 24 parts by mass relative to 100 parts by mass of blown asphalt. 3 , areal density 5.8kg / m 2 ) was manufactured and fixed to the tongue and groove plywood of the two-by-four construction floor in the same manner as in Example 1.

[0100] [Example 3] A soundproofing material (density 1.29 g / cm) was prepared in the same manner as in Example 1, except that the blending amount of calcium carbonate was changed to 201 parts by mass and the blending amount of hollow fine particles was changed to 14 parts by mass relative to 100 parts by mass of blown asphalt. 3 , areal density 7.7kg / m 2 ) was manufactured and fixed to the tongue and groove plywood of the two-by-four construction floor in the same manner as in Example 1.

[0101] [blank] Flooring was laid on top of the tongue-and-groove plywood of the two-by-four construction floor and fixed in place at 303mm intervals using wood screws (diameter φ3.3mm x length L45mm).

[0102] The reduction in heavy-duty floor impact sound level compared to the blank in Examples 1 to 3 is shown in Table 1. Note that "reduction in heavy-duty floor impact sound level = heavy-duty floor impact sound level in blank - heavy-duty floor impact sound level in each specification" was defined, and the frequency band was the 63 Hz band, which is the frequency band that determines the heavy-duty floor impact sound level.

[0103] [Table 1]

[0104] As is clear from the results in Table 1, Example 1 has a larger reduction in heavy-duty floor impact sound levels than Examples 2 and 3, despite having a lower density. In other words, unexpectedly, the reduction in heavy-duty floor impact sound levels increased in Examples, contrary to the law of mass. Therefore, the soundproofing material of the present invention can improve soundproofing properties even though it is lightweight, and can achieve both ease of installation and soundproofing properties. [Industrial Applicability]

[0105] The soundproofing material of the present invention can be used for soundproofing buildings, and can be disposed in, for example, structural components of buildings such as floors, ceilings, walls, and doors, or can be used as at least a part of the structural components. Furthermore, because the soundproofing material of the present invention is lightweight yet capable of reducing the propagation of heavy floor impact noise, it can be suitably used for floors or walls (particularly floors) of buildings or houses such as apartment buildings (condominiums, buildings, etc.) and ordinary houses, or for floors or walls of soundproof rooms. In particular, the soundproofing material of the present invention can be used for floors (particularly floors on at least the second floor or higher) of multi-story buildings (multi-story buildings) such as apartment buildings and ordinary houses, and can significantly improve workability, durability, and soundproofing, making it particularly useful as a vibration-damping and sound-insulating material to be disposed on floors of wooden buildings (multi-story buildings) or houses constructed using wooden frame construction methods (two-by-four construction methods) or wooden framework construction methods.

Claims

1. A soundproofing material to be installed in a building, comprising a soundproofing layer formed from a soundproofing composition containing hollow fine particles and a binder.

2. 10. The acoustic insulation material of claim 1, wherein the acoustic composition further comprises a filler.

3. Density is 1.3 g / cm ３ 3. The soundproofing material according to claim 1 or 2, wherein:

4. 3. The soundproofing material according to claim 1, which has an average thickness of 1.5 mm or more.

5. The hollow fine particles have an average particle size of 150 μm or less, and a bulk density of 0.5 g / cm ３ 3. The soundproofing material according to claim 1 or 2, wherein:

6. 3. The soundproofing material according to claim 1, wherein the hollow fine particles are inorganic balloon particles.

7. 3. The soundproofing material according to claim 1, wherein the binder comprises asphalt.

8. 3. The soundproofing material according to claim 1, which is a laminated sheet further comprising a surface layer and a back layer, with the soundproofing layer interposed between the surface layer and the back layer.

9. The soundproofing material according to claim 8 , wherein the surface layer and the back layer include a fibrous structure.

10. 3. The soundproofing material according to claim 1, wherein the proportion of the hollow fine particles is 1 to 50 parts by mass per 100 parts by mass of the binder.

11. 3. The soundproofing material according to claim 2, wherein the ratio of the filler is 300 parts by mass or less per 100 parts by mass of the binder.

12. 3. The soundproofing material according to claim 1, which is a vibration-damping sound-insulating material.

13. 3. The soundproofing material according to claim 1 or 2, which is disposed on the walls or floors of a multi-story building or house.

14. 3. The soundproofing material according to claim 1 or 2, which is disposed on the floor of a multi-story wooden building or house.

15. A soundproof floor structure comprising an underfloor material, a floor finishing material, and the soundproof material according to claim 1 or 2 interposed between the underfloor material and the floor finishing material.

16. A method for reducing sound propagation within a building, comprising disposing the soundproofing material according to claim 1 or 2 in the building.

17. The method of claim 16, wherein the soundproofing material is disposed on the floor of a multi-story wooden building or house to reduce floor weight impact noise from upper floors.

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