JP2002103450A - Manufacturing method of damping sheet - Google Patents

Abstract

(57) [Summary] [PROBLEMS] A polyethylene terephthalate film can be laminated during the formation of a vibration damping sheet, the process can be unified, and the obtained vibration damping sheet exhibits excellent vibration damping performance. Provided is a method for manufacturing a vibration sheet. SOLUTION: A resin composition 1 containing a rubber or a thermoplastic elastomer, a thermoplastic resin and an inorganic powder is charged between a first roll 2 and a second roll 3, heated and rolled to form a third roll. When the vibration-damping layer 6 is inserted between the third roll 4 and the fourth roll 5, the prepared polyethylene terephthalate film 7 is simultaneously inserted into the third roll 4. By heating and rolling with the fourth roll 5 and the fourth roll 5, a vibration damping sheet 8 in which a vibration damping layer 6 and a polyethylene terephthalate film 7 are laminated is obtained.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for manufacturing a vibration damping sheet suitably used for a steel sheet.

[0002]

2. Description of the Related Art Conventionally, as a roof material for buildings such as houses, a folded plate roof having a corrugated shape made of a steel plate has been used. However, it is difficult to obtain sufficient sound insulation performance by using a folded plate roof alone. In particular, it was not possible to isolate the sound of rain. As a measure for imparting sound insulation performance to the folded plate roof, for example, a method of laminating a vibration damping sheet on the back surface of the folded plate roof has been studied.

[0003] The performance required of the vibration-damping sheet used for the folded-plate roof is, for example, that the vibration-damping performance is excellent even if the thickness is reduced, Deformation follows shaping and does not cause peeling or breakage.

As such a vibration damping sheet, for example, Japanese Patent Laid-Open Publication No. 3-287661 proposes a sheet made of an elastomer and an inorganic powder. However, when the damping material obtained by laminating the damping sheet and the steel plate is formed into a folded plate roof using roll forming or the like, the damping at the contact surface of the forming die or the contact surface with the forming roll is required. There is a problem that shaping is difficult due to insufficient slipperiness of the surface of the vibration material, and abrasion is generated on the obtained folded plate roof.

In order to prevent such abrasion, for example, a method of laminating a polyethylene terephthalate (hereinafter referred to as PET) film on the mold contact side of the vibration damping material has been proposed (JP-A-10-183883). Reference).

[0006] However, in the conventional method of laminating a PET film, for example, after forming and processing a vibration damping sheet or a vibration damping material, an adhesive is applied in a separate step, and a laminating machine or a hand bonding roll is used. A method such as bonding a PET film has been adopted. As a result, the manufacturing process becomes complicated, manual work is often performed, and high productivity cannot be obtained.

[0007]

As a solution to the above-mentioned problems, the present inventor has focused on a molding method using a roll calender in order to obtain the above-mentioned vibration-damping sheet with high productivity.
For example, using a reverse L-type four-roll calender, an attempt was made to mold a resin composition containing rubber or a thermoplastic elastomer, a thermoplastic resin, an inorganic powder, and the like. However, in this case, as shown in the comparative example, a problem that the vibration damping layer obtained from the resin composition adheres to the third roll, winds around the roll, and circulates around the roll occurs, and it is found that molding is difficult. Was.

An object of the present invention is to solve the above problems of the prior art and to provide a production method using a roll calender having high productivity, wherein the obtained vibration damping sheet exhibits excellent vibration damping performance. An object of the present invention is to provide a method of manufacturing a vibration damping sheet.

[0009]

According to a first aspect of the present invention, there is provided a method for manufacturing a vibration damping sheet, comprising: a vibration damping layer obtained from a resin composition containing rubber or a thermoplastic elastomer, a thermoplastic resin, and an inorganic powder. What is claimed is: 1. A method for producing a vibration damping sheet, comprising laminating and forming a PET film using a roll calender, wherein the vibration damping layer comprises one of a final roll and a final roll of a roll calender.
When inserted between the rolls just before, the PET film is inserted at the same time, and the vibration damping layer and the PET film are laminated.

[0010] The method for manufacturing a vibration-damping sheet according to claim 2 comprises
The method for manufacturing a vibration-damping sheet according to claim 1, wherein the roll calender is an inverted L-shaped four-roll calender. The manufacturing method of the vibration damping sheet according to claim 3 is:
The method for producing a vibration-damping sheet according to claim 1 or 2, wherein the resin composition is 20 to 5,000 parts by weight of a thermoplastic resin and 200 to 10,000 parts by weight of an inorganic powder with respect to 100 parts by weight of a rubber or a thermoplastic elastomer. It is characterized by consisting of parts by weight.

Hereinafter, the present invention will be described in detail. The rubber contained in the resin composition according to the present invention includes, for example, butyl rubber, urethane rubber, silicone rubber, EPDM, and the like, and can be used regardless of the presence or absence of vulcanization. Examples of the thermoplastic elastomer contained in the resin composition include isoprene-based, olefin-based, and ester-based elastomers. Among these, a styrene-isoprene block copolymer is particularly preferably used.

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

When the second component of the styrene-isoprene block copolymer is composed of isoprene alone or a mixture with butadiene, the content of the 3,4 bond and the 1,2 bond in the block portion of the second component is preferable. Is preferably 40% or more. The content of 3.4 bonds and 1.2 bonds is 40
%, The obtained damping sheet may not exhibit sufficient damping performance in a normal use temperature range.

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

The thermoplastic resin contained in the resin composition includes, for example, ethylene-vinyl acetate copolymer, polyolefin, vinyl chloride resin, polyester and the like. In particular, among these, an ethylene-vinyl acetate copolymer is preferable because of its high adhesiveness to a PET film.

The ethylene-vinyl acetate copolymer preferably has a vinyl acetate content of 2 to 40% by weight. If the vinyl acetate content is less than 2% by weight, the flexibility of the obtained vibration damping sheet may be insufficient, and if it exceeds 40% by weight, the viscosity of the vibration damping layer becomes too high, which hinders molding and storage. May occur.

Examples of the inorganic powder contained in the resin composition include metal oxides such as iron oxide, titanium oxide and magnesium oxide, particulate metals, clay, talc, mica,
In addition to crushed minerals such as quartz powder, glass fiber, glass powder,
Examples include calcium carbonate and gypsum. Among these,
In particular, mica and calcium carbonate are preferred from the viewpoint of vibration damping characteristics and cost.

The particle size of the inorganic powder is not particularly limited, but is preferably from 1 to 500 μm. If the particle size is less than 1 μm, the surface area increases and the number of particles per unit weight increases, so that the mixing step takes time. In addition, the particle size is 50
If the thickness exceeds 0 μm, the surface may be roughened or the sheet may be broken during molding of the vibration damping sheet.

[0019] Ethylene contained in the above resin composition
The compounding amount of the vinyl acetate copolymer is determined by the compounding amount of the inorganic powder described below, the shape of the folded plate roof, and the thickness of the steel sheet used for the folded plate roof. The styrene-isoprene block copolymer is preferably used in an amount of 20 to 5,000 parts by weight, more preferably 100 to 1,000 parts by weight. Parts by weight.

However, the content of the styrene-isoprene block copolymer is 1% by weight based on the total amount of the resin composition.
When it is less than or equal to 1,000, it is preferred to blend the ethylene-vinyl acetate copolymer in an amount of 1,000 parts by weight or more.

When the amount of the inorganic powder contained in the resin composition is small, the thickness of the vibration damping sheet may need to be increased in order to exhibit the vibration damping performance. Since the strength of the sheet may decrease,
The amount is preferably 200 to 10,000 parts by weight, more preferably 500 to 3,000 parts by weight, based on 100 parts by weight of the styrene-isoprene block copolymer.

The amount of the inorganic powder is 1,000
When the amount is more than 100 parts by weight, it is preferable to mix 200 parts by weight or more of the ethylene-vinyl acetate copolymer in order to secure the mechanical strength of the resin sheet.

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

The vibration damping sheet according to the present invention is formed using a roll calender. The roll calender according to the present invention is not particularly limited as long as the number of rolls is three or more. However, an inclined three roll calender, an L-shaped four roll calender, an inverted L-shaped four roll calender, a Z-shaped four calender
A roll calender, an inclined Z-type four roll calender, or the like is preferably used. Among them, the inverted L-type four-roll calender is more preferable because the raw material can be easily supplied and the film can be easily laminated.

In the present invention, the names of the first roll, the second roll, and the third roll are defined according to the order of the forming direction from the raw material supply side in the same manner as the generally used name.
It will be called in the order of roll, fourth roll, and so on. Therefore, in the case of a three-roll calendar, the third roll is the final roll, and in the case of a four-roll calendar, the fourth roll is the final roll. Note that the roll according to the present invention has a heating function and a rolling function, and an auxiliary roll that complements the forming function is not included in the above-mentioned name.

In the molding method according to the present invention, the vibration-damping layer obtained by using a roll calender from a resin composition containing rubber or a thermoplastic elastomer, a thermoplastic resin, and an inorganic powder is used to form When inserted between the rolls immediately before the final roll, the PET film is inserted at the same time, and the vibration damping layer and the PET film are laminated. In particular, by simultaneously inserting the PET film between the rolls as described above, it becomes possible to mold a highly adhesive resin composition.

The thickness of the above-mentioned vibration damping layer is appropriately determined depending on the resin composition, vibration damping performance and the like, but is usually preferably 10 mm or less, more preferably 2 mm or less. Thickness 10
If it exceeds mm, when a vibration damping material in which a vibration damping sheet described later and a steel plate are laminated is formed into, for example, a folded plate having a corrugated cross section, the resin sheet may be broken or peeled off.

The thickness of the PET film is appropriately determined depending on the molding conditions and required performance to be applied.
500 μm is preferred, and more preferably 15 to 100 μm
m. When the thickness of the PET film is less than 5 μm, formation of the PET film becomes difficult, and the surface slipperiness of the PET film may be insufficient or the PET film may be broken when formed into a folded plate roof described later. . If the thickness of the PET film exceeds 500 μm, a large amount of PET resin is required for the surface slipperiness, which is uneconomical. In addition, the rigidity of the PET film becomes too large, and it is formed into a folded plate roof. It may be an obstacle when processing.

The surface of the PET film to be bonded to the vibration damping layer may be provided with a hot-melt type (hereinafter, referred to as hot melt type) adhesive layer (hereinafter, referred to as primer layer) in advance. This case is preferable because the bonding strength between the vibration damping layer and the PET film can be further increased. The activation temperature of the primer layer is 100 to 140
C. is preferable, and particularly preferably 120 to 130 C. because it is close to the molding temperature of the vibration damping layer. The surface opposite to the bonding surface of the PET film may be subjected to a surface treatment such as a silicone release treatment or an embossed rough surface treatment, if necessary.

(Function) In the method for producing a vibration damping sheet of the present invention, a roll calender is used to insert a vibration damping layer and a PET film between rolls at the same time, thereby heating and rolling the characteristic of calendering. By utilizing the adhesiveness of the vibration damping layer obtained from the resin composition according to the present invention, the vibration damping layer and the PET film can be laminated and bonded. On the other hand, by inserting the PET film, it is possible to prevent the vibration damping layer from sticking and winding on the roll surface in contact with the film. This provides a method for manufacturing a vibration damping sheet having high productivity.

[0031]

Embodiments of the present invention will be described below with reference to the drawings. FIG. 1 is a schematic view of an apparatus using an inverted L-type four-roll calender illustrating an embodiment of the present invention. As shown, inverted L-type 4
This roll calendar includes a first roll 2, a second roll 3,
It is composed of four rolls, a third roll 4 and a fourth roll 5.

In the method for producing a vibration damping sheet of the present invention, first, a resin composition 1 containing rubber or a thermoplastic elastomer, a thermoplastic resin, and an inorganic powder is placed between a first roll 2 and a second roll 3. It is charged, heated and rolled, inserted between the second roll 3 and the third roll 4, and further heated and rolled to obtain the vibration damping layer 6. Next, when inserting the obtained vibration damping layer 6 between the third roll 4 and the fourth roll 5, the PET film 7 prepared in advance is inserted simultaneously, and the third roll 4 and the fourth roll 5 are inserted. By heating and rolling, the vibration damping layer 6 and the PET film 7 are laminated to obtain the desired vibration damping sheet 8.

At this time, the vibration damping layer 6 at the portion outside the width of the PET film 7 adheres to and winds on the third roll 4, and circulates through the third roll 4. Only the circulation is performed, so that the obtained vibration damping sheet 8 is not affected. The molding temperature of the vibration damping layer is not particularly limited as long as the effect of the present invention is not impaired, but 110 to 160 ° C. is preferable.

Examples, comparative examples and reference examples will be described below with reference to the drawings. Example 1 13% by weight of a styrene-isoprene block copolymer (“HIBLER” manufactured by Kuraray Co., Ltd., molecular weight: about 140,000), 13% by weight of an ethylene-vinyl acetate copolymer (vinyl acetate content: 30% by weight), mica (100 mesh pass) A composition consisting of 25% by weight was mixed with a Banbury mixer to prepare a resin composition A. The resin composition A is put between the first roll 2 and the second roll 3 shown in FIG. 1, heated and rolled, inserted between the second roll 3 and the third roll 4, and further heated and rolled. Thus, a damping layer 6 was obtained.
Next, the obtained vibration damping layer 6 is applied to the third roll 4 and the fourth roll 5.
When the PET film 7 is inserted at the same time, the PET film 7 is simultaneously inserted and heated and rolled by the third roll 4 and the fourth roll 5, so that the vibration damping layer 6 and the PET film 7 are laminated, Sheet I was obtained. At this time, the forming temperature condition of each roll is such that the first roll 2 and the second roll 3
° C, the temperature of the third roll 4 was 120 ° C, the temperature of the fourth roll 5 was 80 ° C, and the molding temperature of the vibration damping layer 6 was 130 ° C. The thickness of the damping layer of the obtained damping sheet I was 0.5 mm, and the thickness of the PET film was 25 μm.

Example 2 Except that a PET film 7 was used as a primer layer by previously applying an EVA (ethylene-vinyl acetate) -based hot melt type adhesive to the surface to be bonded to the vibration damping layer. Obtained a damping sheet II in the same manner as in Example 1.

Comparative Example Resin composition A similar to that of Example 1
Example 1 was repeated except that the PET film 7 was not used.
However, the vibration damping layer 6 was stuck to the third roll 4 and wrapped around the third roll 4 to form a vibration damping sheet.

Reference Example In the following evaluation method,
Without attaching the damping sheet to the steel plate, the loss coefficient and noise level were measured.

[Evaluation method] (1) Loss coefficient A solvent-type chloroprene-based adhesive was applied to one side of a 0.6 mm-thick steel plate (JIS G 3141), dried, and then a PET film of a vibration damping sheet was applied to the adhesive-applied surface. Is attached to a surface on which is not laminated to produce a vibration damping material composed of a laminated body of a vibration damping sheet and a steel plate, and the obtained vibration damping material is 15 mm width × 2.
JIS for test pieces cut to a length of 50 mm
According to the central excitation method according to G0602, the frequency 5
The loss coefficient at 00 Hz was measured. A larger value indicates better vibration damping performance.

(2) Measurement of Noise Level After a solvent-type chloroprene-based adhesive was applied to the steel sheet side of a 0.6 mm-thick vinyl chloride steel sheet and dried, a PET film of a vibration damping sheet was laminated on the adhesive applied surface. Then, a damping material composed of a laminated body of a damping sheet and a steel plate is prepared by sticking the non-formed surface, and the damping material is formed into a folded plate roof having the dimensions and shape shown in FIG. the fixed damping sheet side as the lower, 1 m ² per 10 vinyl chloride steel plate side upper
Rain artificially so that the rainfall is 0 mm / hour,
The noise level at a position 3 m below the folded roof was measured by a sound level meter. A smaller value indicates a lower noise level.

(3) Peeling strength of PET film In order to evaluate the bonding strength between the vibration damping layer of the vibration damping sheet and the PET film, the vibration damping sheet was cut to a width of 25 mm.
One end of the ET film was peeled off, and a resistance was measured when a tensile test was performed in a direction of 180 degrees at a speed of 200 mm / min.

[0041]

[Table 1]

As shown in Table 1, the adoption of the method for producing a vibration damping sheet according to the present invention makes it possible to mold materials which could not be molded conventionally, and to obtain the obtained vibration damping sheet. It has been found that the vibration sheet exhibits excellent vibration damping performance.

[0043]

According to the method of manufacturing a vibration-damping sheet according to the present invention, the vibration-damping layer is prevented from winding around the roll by laminating and forming the vibration-damping layer and the PET film using a roll calender. And a high peel strength at the surface where the vibration damping layer obtained from the highly adhesive resin composition is bonded to the PET film. From the above, PE
A vibration damping sheet in which a T film is laminated can be manufactured in a single step, and high productivity can be obtained. In the present invention, when the roll calender is an inverted L-type four-roll calender, the above effects can be more reliably achieved. Further, when the resin composition is a rubber or a thermoplastic elastomer 10
If the thermoplastic resin is composed of 20 to 5,000 parts by weight and 200 to 10,000 parts by weight of the inorganic powder with respect to 0 parts by weight, more excellent effects can be exhibited.

[Brief description of the drawings]

FIG. 1 is a schematic view of an apparatus using an inverted L-shaped four-roll calender illustrating an embodiment of the present invention.

FIG. 2 is a schematic sectional view showing a vibration damping sheet according to the present invention.

FIG. 3 is a schematic cross-sectional view showing a half-roof.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Resin composition 2 1st roll 3 2nd roll 4 3rd roll 5 4th roll 6 Damping layer 7 Polyethylene terephthalate (PET) film

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Claims (3)

[Claims] 1. Production of a vibration damping sheet in which a vibration damping layer obtained from a resin composition containing a rubber or a thermoplastic elastomer, a thermoplastic resin and an inorganic powder and a polyethylene terephthalate film are laminated and formed using a roll calender. A method wherein, when a vibration damping layer is inserted between a final roll and a roll immediately before the final roll of a roll calender, a polyethylene terephthalate film is simultaneously inserted, and the vibration damping layer and the polyethylene terephthalate film are And a method of manufacturing a vibration damping sheet. 2. The method for producing a vibration damping sheet according to claim 1, wherein the roll calender is an inverted L-shaped four-roll calender. 3. A resin composition comprising 100 parts by weight of rubber or thermoplastic elastomer and 20 to 5 thermoplastic resins.
The method for producing a vibration damping sheet according to claim 1 or 2, comprising 000 parts by weight and 200 to 10,000 parts by weight of an inorganic powder.