JP7837814B2 - Laminated member - Google Patents

Description

Applicable under Article 30, Paragraph 2 of the Patent Law. Date of sale: March 28, 2022. Place of sale: Yasumizu Construction Co., Ltd.

This invention relates to a laminated member.

As a laminated component, Patent Document 1 discloses an elastic paving material with artificial turf, comprising: a permeable cushioning material layer (cloth, cheesecloth, etc.) consisting of at least the vulcanized rubber sponge powder among the vulcanized rubber sponge powder, with the powders bonded together; a permeable sheet layer bonded to the lower surface of the cushioning material layer; and a permeable artificial turf layer bonded to the upper surface of the cushioning material layer.

Japanese Patent Application Publication No. 5-247904

In the laminated member disclosed in Patent Document 1 mentioned above, water could permeate the permeable cushioning material layer through the permeable sheet layer and the permeable artificial turf layer. This permeation could cause the permeable cushioning material layer to change shape, and consequently, the laminated member itself could change shape.

This invention was made to solve the above-mentioned problems and aims to provide a laminated member that can suppress shape changes due to water infiltration.

To solve the above problems, the laminated member according to the present invention is characterized by comprising an upper layer member and a waterproof member provided on the lower surface of the upper layer member.

According to this invention, since a waterproofing member is provided on the lower surface of the upper layer member, water infiltration (penetration) from the lower surface of the upper layer member can be suppressed. Therefore, changes in the shape of the upper layer member due to water infiltration can be suppressed, and consequently, changes in the shape of the laminated member can be suppressed.

Furthermore, in the laminated member according to the present invention, it is preferable that the upper layer member comprises a base member and a surface member provided on the upper surface side of the base member. This makes it possible to protect the upper surface of the base member, where water infiltration from the lower side is suppressed by the waterproofing member, with the surface member.

Furthermore, in the laminated member according to the present invention, it is preferable that the upper layer member further comprises an adhesive assisting member provided between the base member and the surface member to assist in the adhesion of the base member to the lower surface of the surface member. This allows the adhesive assisting member to assist in the adhesion between the base member and the surface member, thereby enabling the base member and the surface member to be properly bonded with a desired adhesive strength.

Furthermore, in the laminated member according to the present invention, it is preferable that the base member comprises crushed material. This allows for the provision of a waterproofing member on the lower surface of the base member comprising the crushed material, thereby suppressing water infiltration from the lower surface of the upper layer member comprising the crushed material, which is relatively prone to expansion due to infiltration. Therefore, changes in the shape of the upper layer member due to water infiltration can be suppressed, and consequently, changes in the shape of the laminated member can be suppressed.

Furthermore, in the laminated member according to the present invention, the surface member is preferably artificial turf. This is because, when artificial turf is used as the surface member, deformation can be absorbed by the surface member layer even if expansion occurs in the base member, thus suppressing changes in the overall shape of the laminated member.

Furthermore, in the laminated member according to the present invention, it is preferable that the adhesive auxiliary member has waterproof properties. This makes it possible to provide a waterproof adhesive auxiliary member on the upper surface of the base member, thereby suppressing water infiltration from the upper surface of the base member. Therefore, it is possible to suppress changes in the shape of the base member and, consequently, the upper layer member due to water infiltration.

This invention makes it possible to provide a laminated member that can suppress shape changes due to water infiltration.

This is a cross-sectional view showing one embodiment of the laminated member 10 according to the present invention. This is a cross-sectional view showing one embodiment of a method for manufacturing a laminated member 10 according to the present invention. This is a cross-sectional view showing one embodiment of a method for manufacturing a laminated member 10 according to the present invention. This is a cross-sectional view showing the laminated member 110 according to the first modified example. This is a cross-sectional view showing a laminated member 210 according to a second modified example.

Hereinafter, an embodiment of the laminated member 10 and its manufacturing method according to the present invention will be described with reference to the drawings. However, the present invention is not limited to this embodiment, and can be implemented in various forms with various modifications and improvements based on the knowledge of those skilled in the art.

(Laminated material)
As shown in Figure 1, the laminated member 10 comprises an upper layer member 20 and a waterproof member 30 provided on the lower surface of the upper layer member 20. The upper layer member 20 comprises a surface member 21, a base member 22, and an adhesive auxiliary member 23. The upper layer member 20 is constructed by laminating these surface member 21, adhesive auxiliary member 23, and base member 22 in this order. The surface member 21 is bonded to the adhesive auxiliary member 23 via a first adhesive layer 24, and the base member 22 is bonded to the adhesive auxiliary member 23 via a second adhesive layer 25. The waterproof member 30 is bonded to the base member 22 via a third adhesive layer 26.

The surface member 21 is an artificial turf formed in a plate shape. The surface member 21 comprises a turf section 21a, a sheet section 21b, and a raised ridge section 21c. The turf section 21a has numerous lanceolate linear members. These lanceolate linear members are flat, elongated, pointed at the end, and slightly wider at the base, and are made of materials such as polyethylene or polypropylene.

The sheet portion 21b is a sheet-like (or plate-like) member on which the grass portion 21a is planted, and is made of, for example, polypropylene. The base of the lanceolate linear material of the grass portion 21a is planted in the sheet portion 21b. For example, the base of the lanceolate linear material is sewn to the sheet portion 21b. The sewn portion protrudes from the back surface (bottom surface) of the sheet portion 21b, forming a raised ridge portion 21c. Thus, the raised ridge portion 21c is provided on the back surface of the surface member 21, i.e., the back surface of the sheet portion 21b. It is preferable that the raised ridge portion 21c is made of the same material as the sheet portion 21b or the same material as the grass portion 21a. It is preferable that the raised ridge portion 21c is a linear protrusion. Note that the raised ridge portion 21c may be made of multiple protrusions intermittently arranged in a straight line.

Furthermore, the raised portion 21c protrudes from the back surface of the sheet portion 21b in order to plant the grass portion 21a. For example, the base of the grass portion 21a may penetrate the sheet portion 21b, and the raised portion 21c may be formed to fix the protruding portion. In addition, the protruding portion may form the raised portion 21c as is, or the raised portion 21c may be formed to cover the protruding portion.

Furthermore, the back surface of the surface member 21 is preferably coated with a rubber material, for example. Examples of rubber materials include natural rubber and synthetic rubber. Examples of synthetic rubbers include isoprene rubber, butadiene rubber, styrene-butadiene rubber, acrylic rubber, urethane rubber, and silicone rubber.

Furthermore, the surface member 21 is not limited to artificial turf; other materials such as outdoor or indoor flooring materials with impact-absorbing properties may also be used. The surface member 21 may be formed in a sheet shape rather than a plate shape.

The base member 22 is the member to which the surface member 21 is bonded. The base member 22 is a component that maintains high strength of the surface member 21 by being bonded to it. The base member 22 is formed in the shape of a plate or sheet.

The base member 22 is preferably made of natural rubber or synthetic rubber such as ethylene propylene diene rubber (EPDM), styrene butadiene rubber (SBR), nitrile rubber (NBR), butadiene rubber (BR), butyl rubber (isobutylene/isoprene rubber) (IIR), silicone rubber, or fluororubber. The base member 22 is preferably made of foamed rubber obtained by foaming rubber material, rubber pellets obtained by crushing rubber material or foamed rubber and forming them into granules of a predetermined shape such as spherical or cylindrical, and then solidifying them, or pellet aggregates obtained by aggregating these pellets. Thus, it is preferable for the base member 22 to include crushed material. Furthermore, the base member 22 may be formed as a single piece.

Furthermore, a shade cloth may be provided on the base member 22. For example, it is preferable to laminate the shade cloth on the underside of the base member 22. This makes it possible to suppress swelling caused by water infiltration into the base member 22, thereby suppressing deformation (warping) of the base member 22.

The adhesive assist member 23 is a member that assists in the adhesion between the surface member 21 and the base member 22. That is, the adhesive assist member 23 can also be described as a member provided on the back surface (bottom surface) of the surface member 21 to assist in the adhesion of the base member 22 to the bottom surface of the surface member 21. In this case, the base member 22 is the member to be adhered to the surface member 21. Alternatively, the adhesive assist member 23 can also be described as a member provided on the surface (top surface) of the base member 22 to assist in the adhesion of the surface member 21 to the top surface of the base member 22. In this case, the surface member 21 is the member to be adhered to the base member 22.

The adhesive support member 23 is formed in a plate shape. Preferably, the thickness of the adhesive support member 23 is set to a value greater than the height of the raised portion 21c. In this embodiment, since the height of the raised portion 21c is approximately 3 mm, it is preferable that the thickness of the adhesive support member 23 be set to a value greater than 5 mm. The adhesive support member 23 is formed from a soft material with a hardness lower than a predetermined value. The hardness is preferably, for example, 80 (Shore A) or less, and more preferably 60 (Shore A) or less. Examples of soft materials include polyurethane, polystyrene, polyethylene (PE, including foamed), polypropylene (PP, including foamed), nonwoven fabric, ethylene vinyl acetate (EVA), and thermoplastic elastomers. Examples of thermoplastic elastomers include olefin-based thermoplastic elastomer (TPO), polyurethane-based thermoplastic elastomer (TPU), styrene-based thermoplastic elastomer (TPS), and flexible polyvinyl chloride (PVC).

Furthermore, it is preferable that the adhesive auxiliary member 23 is waterproof. This means that the adhesive auxiliary member 23 provided on the upper surface of the base member 22 is waterproof, thus preventing water from seeping in from above the base member 22. Therefore, it becomes possible to suppress changes in the shape of the base member 22 and, consequently, the upper layer member 20 due to water infiltration, and furthermore, to suppress changes in the shape of the laminated member 10.

Nonwoven fabrics include short-fiber nonwoven fabrics and long-fiber nonwoven fabrics. Short-fiber nonwoven fabrics include spunlace nonwoven fabrics, which are manufactured by entangling the fibers (especially short fibers) in the web with a high-pressure water flow without using a binder (adhesive); needle-punched nonwoven fabrics, which entangle the fibers by moving a needle back and forth; and thermal-bonded nonwoven fabrics, which use heat-welded fibers. Long-fiber nonwoven fabrics include spunbond nonwoven fabrics, meltblown nonwoven fabrics, and flash-spun nonwoven fabrics. Spunbond nonwoven fabrics are made by laminating continuous fibers (filaments) spun from a nozzle by melting or dissolving a polymer onto a moving screen using one or more bonding methods. Meltblown nonwoven fabrics are made by spinning a polymer into fibers in a high-speed hot gas flow, which are then cooled and accumulated on a moving screen using one or more bonding methods. Flash-spun nonwoven fabrics are nonwoven fabrics made from highly fibrillated filaments created by spinning a polymer solution from a nozzle under specific conditions, immediately evaporating the solvent, and laminating these fibers onto a moving screen using one or more bonding methods. The aforementioned polymers are high-molecular-weight organic compounds, such as polyamides, polyethylene, polypropylene, and polyurethanes, which are thermoplastic resins (synthetic resins).

Furthermore, it is preferable that the strain of the adhesive auxiliary member 23 is set to a value greater than the strain of the base member 22. The adhesive auxiliary member 23 is a member whose strain is within a predetermined range. The predetermined range is preferably 25-75%, and more preferably 40-60%. Note that strain is the ratio of the deformation amount ΔL to the original (pre-deformation) length L (strain = ΔL/L).

The first adhesive layer 24 is a layer formed with the first adhesive. Preferably, the first adhesive is an adhesive that does not contain organic solvents. For example, a hot-melt adhesive can be used as the first adhesive. A hot-melt adhesive is an adhesive that adheres by melting with heat, and as the material, a thermoplastic synthetic resin such as ethylene vinyl acetate (EVA) is used. In this embodiment, a moisture-curing hot-melt adhesive is used as the hot-melt adhesive. The second adhesive layer 25 is a layer formed similarly to the first adhesive layer 24 and is formed with the same second adhesive as the first adhesive. The third adhesive layer 26 is a layer formed similarly to the first adhesive layer 24 and is formed with the same third adhesive as the first adhesive.

The moisture-curing hot-melt adhesive is a urethane-based moisture-curing hot-melt adhesive, mainly composed of a urethane prepolymer. The moisture-curing hot-melt adhesive is obtained by the reaction of a polyester polyol with an isocyanate compound and has isocyanate groups (NCOs) at its terminals. Particularly preferred are those with a terminal NCO content of 1-3%. Examples of polyester polyols include those obtained by polycondensation of aliphatic carboxylic acids such as malonic acid, succinic acid, and adipic acid, or aromatic carboxylic acids such as phthalic acid, with aliphatic glycols such as ethylene glycol, diethylene glycol, and propylene glycol. The polyester polyol is preferably made of a dicarboxylic acid with 6 or more carbon atoms (e.g., adipic acid, sebacic acid), and more preferably contains 80% or more by weight of crystalline ester polyol with a melting point of 45°C or higher as the polyol component. The glycol constituting the polyester polyol can be an alcohol with 4 or more carbon atoms (e.g., 1,4-butanediol, 1,6-hexanediol). Furthermore, aromatic isocyanates are preferred as the isocyanate compound, and diphenylmethane diisocyanate (MDI) is particularly preferred. The moisture-curing hot-melt adhesive may also contain additives such as tackifiers, waxes, nucleating agents, and antioxidants, as needed. Moreover, the moisture-curing hot-melt adhesive is not limited to urethane-based adhesives; polyester-based or acrylic-based adhesives may also be used.

When bonding the surface member 21 and the adhesive auxiliary member 23, the moisture-curing hot melt adhesive is applied to the back surface (the surface to be coated) of the surface member 21 using a roll coater (roll coating). Alternatively, the moisture-curing hot melt adhesive may be applied only to the surface (the surface to be coated) of the adhesive auxiliary member 23, or to both the back surface of the surface member 21 and the surface of the adhesive auxiliary member 23. Furthermore, when bonding the adhesive auxiliary member 23 to the base member 22, the moisture-curing hot melt adhesive may be applied to the back surface of the adhesive auxiliary member 23 and/or the surface of the base member 22. Finally, when bonding the base member 22 to the waterproofing member 30, the moisture-curing hot melt adhesive may be applied to the back surface of the base member 22 and/or the surface of the waterproofing member 30.

An example of a roll coater used in roll coating is the roll coater described in Japanese Patent Publication No. 2018-184000. This roll coater comprises a feed roll, a supply roll, a coating roll, and a hot melt adhesive storage tank. The molten moisture-curing hot melt adhesive stored in the hot melt adhesive storage tank is supplied from the discharge section between the supply roll and the coating roll while the object to be coated is being fed in one direction by the feed roll. The molten moisture-curing hot melt adhesive supplied between the supply roll and the coating roll is supplied to the upper surface (coating surface) of the object to be coated by the rotation of the supply roll and the coating roll. The molten moisture-curing hot melt adhesive supplied to the upper surface of the object to be coated comes into contact with the lower end of the outer circumference of the rotating coating roll and is applied to the upper surface of the object to be coated.

To facilitate and ensure good roll coating, the moisture-curing hot melt adhesive is preferably solid at room temperature, molten at 100°C or higher, and has a melt viscosity (JIS K 6862) of 5 to 15 Pa·s (Pascal-seconds) at 140°C. Note that "solid at room temperature" means solid at 20°C. The molten temperature range can be appropriately set within the range of 100 to 160°C. Furthermore, the moisture-curing hot melt adhesive is preferably a urethane prepolymer containing a crystalline ester polyol. The crystalline polyester polyol is preferably (1) solid at room temperature with a melting point of 45°C or higher, and (2) has a solidification time of 1 to 5 minutes at room temperature after melt coating, even considering seasonal variations. In other words, for a moisture-curing hot-melt adhesive to be applied to a long sheet while being rolled up, and to dry and cure rapidly at room temperature within a predetermined equipment length, it is preferable that the adhesive contains a crystalline ester polyol, has an NCO content of 1-3% in the urethane prepolymer, and has a number-average molecular weight of 1000-4000, more preferably 1500-2500.

Furthermore, the amount of moisture-curing hot melt adhesive applied is preferably 30 to 200 g/ ^m² , and more preferably 50 to 150 g/ ^m² . Note that the application method is not limited to roll coating; spray coating may also be used.

As a spray coating method, a curtain spray method is particularly preferred, in which a moisture-curing hot-melt adhesive is extruded from multiple nozzles arranged in a row under heated and pressurized conditions, and sprayed onto the surface while being spun into threads to create layers. According to the curtain spray method, thread-like molten resin is spun and stretched using a high-temperature, high-speed airflow, and then directly sprayed onto the surface material to create layers.

In spray coating, hot melt adhesive is applied using a well-known spray coating apparatus. A known spray coating apparatus is disclosed in Japanese Patent Application Publication No. 2017-136735. The spray coating apparatus applies molten moisture-curing hot melt adhesive, supplied from a moisture-curing hot melt adhesive storage tank, to the surface to which the adhesive is to be applied.

The waterproof member 30 is formed from a waterproof material in the form of a plate or sheet. The thickness of the waterproof member 30 is preferably set to 3 mm to 7 mm, depending on the material. In this embodiment, the thickness of the waterproof member 30 is set to 5 mm. The waterproof material is a material with waterproof properties, and examples of waterproof materials include polyurethane, polystyrene, polyethylene (PE, including foamed), polypropylene (PP, including foamed), nonwoven fabric, ethylene vinyl acetate (EVA), and thermoplastic elastomer. Examples of thermoplastic elastomers include olefin-based thermoplastic elastomer (TPO), polyurethane-based thermoplastic elastomer (TPU), styrene-based thermoplastic elastomer (TPS), and flexible polyvinyl chloride (PVC).

The waterproofing member 30 suppresses water intrusion into the foundation member 22 from the underside, thereby suppressing changes in the shape of the foundation member 22 (for example, warping of the four corners, warping of the central part, overhang, undulation, depression, etc.), and consequently suppressing changes in the shape of the laminated member 10.

(Manufacturing method for laminated components (manufacturing process))
Next, the manufacturing method (manufacturing process) for the laminated member 10 described above will be explained with reference to Figures 2A and 2B. The manufacturing method for the laminated member 10 comprises a first coating step S1, a first pressing step S3, a second coating step S5, a second pressing step S7, a third coating step S9, a third pressing step S11, and a curing step S13.

(First coating process, first pressing process)
The first coating step S1 involves applying hot melt adhesive 25a to at least one of the surface (upper surface) of the base member 22 and the back surface (lower surface) of the adhesive auxiliary member 23. In this case, it is preferable that the hot melt adhesive 25a is applied by roll coating (as described above). In this embodiment, the hot melt adhesive 25a is applied to both the surface of the base member 22 and the back surface of the adhesive auxiliary member 23. In roll coating, the hot melt adhesive 25a is applied by a well-known roll coating device (roll coater). The application amount is preferably 30 to 200 g/ ^m² , and more preferably 50 to 150 g/ ^m² . In addition, the application method may be spray coating instead of roll coating.

The first pressing step S3, performed after the first coating step S1, involves pressing the base member 22 and the adhesive auxiliary member 23 together. In the first pressing step S3, the base member 22 and the adhesive auxiliary member 23 are first stacked with the adhesive-coated surfaces (adhesive-coated surfaces) facing each other (if adhesive is applied to only one side, the surface of the base member 22 and the back surface of the adhesive auxiliary member 23 are aligned). Then, the stacked base member 22 and adhesive auxiliary member 23 are compressed to a predetermined amount using a press device. This forms the first-stage base member 41, which is the base member 22 with the adhesive auxiliary member 23 bonded to it.

Furthermore, the predetermined compression amount is preferably such that it is 40-60% of the thickness of the object being compressed. In this embodiment, this ratio is set to 50%. The compression is performed for a predetermined time (for example, 40 seconds). The predetermined time is preferably set to 40-80 seconds.

(Second coating process / Second pressing process)
The second coating step S5 involves applying hot melt adhesive 26a to at least one of the surfaces of the waterproofing member 30 and the back surface of the base member 22. In this case, it is preferable that the hot melt adhesive 26a is applied by roll coating (as described above). In this embodiment, the hot melt adhesive 26a is applied to both the surface of the base member 22 and the back surface of the waterproofing member 30. The application amount is preferably 30 to 200 g/ ^m² , and more preferably 50 to 150 g/ ^m² . In addition, the application method may be spray coating instead of roll coating.

The second compression step S7, performed after the second coating step S5, involves pressing the first-stage base member 41 and the waterproof member 30 together. In the second compression step S7, first, the first-stage base member 41 and the waterproof member 30 are stacked with the adhesive-coated surfaces (adhesive-coated surfaces) facing each other (if adhesive is applied to only one side, the surface of the waterproof member 30 is aligned with the back surface of the base member 22). Then, the stacked first-stage base member 41 and waterproof member 30 are compressed to a predetermined amount using a press device. This causes the waterproof member 30 to adhere to the lower surface of the first-stage base member 41 (base member 22), forming the second-stage base member 42. In the second-stage base member 42, the adhesive auxiliary member 23 is adhered to the upper surface of the base member 22, and the waterproof member 30 is adhered to the lower surface of the base member 22. It is preferable that the predetermined compression amount and compression time be set in the same way as in the first compression step S3 described above.

Furthermore, it is preferable to cure the adhesives 25a and 26a of the second-stage base member 42 laminated in the second-stage base member 42 after the second-stage bonding step S7. In this curing step, for example, the second-stage base member 42 after the second-stage bonding step S7 is stored at a predetermined temperature and humidity for a predetermined time, allowing the hot-melt adhesive to react with natural cooling and moisture (humidification) in the air, thus promoting curing. The curing time required for the hot-melt adhesive to completely solidify by moisture curing is, for example, several hours to over ten hours. The predetermined time is preferably set to 24 to 72 hours, and in this embodiment, it is set to 24 hours. The predetermined temperature is preferably set to 5 to 40°C, and in this embodiment, it is set to 15 to 30°C (so-called room temperature). The predetermined humidity is preferably set to a relative humidity of 40 to 95%, and in this embodiment, it is set to 45 to 85% (so-called normal humidity).

(Third coating process, third pressing process)
The third coating step S9 involves applying hot melt adhesive 24a to at least one of the surfaces of the adhesive auxiliary member 23 (second stage base member 42) and the surface of the surface member 21. In this case, the hot melt adhesive 24a is preferably applied by roll coating (as described above). In this embodiment, the hot melt adhesive 24a is applied to both the surface of the adhesive auxiliary member 23 and the surface of the surface member 21. The application amount is preferably 30 to 200 g/ ^m² , and more preferably 50 to 150 g/ ^m² . The application amount is preferably set to an amount that can achieve the desired adhesive strength and does not fill the gaps between the protrusions 21c, i.e., the recesses of the surface member 21. Furthermore, the application method may be spray coating instead of roll coating.

The third pressing step S11, following the third coating step S9, involves pressing the second-stage base member 42 and the surface member 21 together. In the third pressing step S11, first, the second-stage base member 42 and the surface member 21 are stacked with the adhesive-coated surfaces (adhesive-coated surfaces) facing each other (if adhesive is applied to only one side, the surface of the adhesive auxiliary member 23 is aligned with the back surface of the surface member 21). Then, the stacked second-stage base member 42 and surface member 21 are compressed by a press device to a predetermined compression amount. This causes the surface member 21 to adhere to the second-stage base member 42, forming the stacked member 10. It is preferable that the predetermined compression amount and compression time be set in the same way as in the first pressing step S3 described above.

The curing step S13 cures the adhesive 24a of the laminated members 10 that were laminated in the third compression step S11, thereby completing the laminated members 10. In the curing step S13, the laminated members 10 after the third compression step S11 are stored at a predetermined temperature and humidity for a predetermined time. This allows the hot-melt adhesive to react with natural cooling and moisture (humidification) in the air, promoting curing. The curing step S13 is carried out in the same manner as the curing step performed after the second compression step S7 described above.

The present invention will be further described below with reference to examples. However, the present invention is not limited to these examples and can be implemented in various forms with various modifications and improvements based on the knowledge of those skilled in the art.

Using the surface member 21, base member 22, adhesive auxiliary member 23 (waterproof), waterproof member 30, and adhesive shown in Table 1, the laminated member 10 of Comparative Example 1 and the laminated members 10 of Examples 1 and 2 were fabricated.

Comparative Example 1's laminated member comprises a surface member 21, a base member 22, and an adhesive auxiliary member 23, but does not include a waterproof member 30. The surface member 21 is artificial turf, and the base member 22 is foamed rubber pellets (with a thickness of 15 mm). The adhesive auxiliary member 23 is made of foamed polyethylene and has a thickness of 5 mm. The surface member 21 and the adhesive auxiliary member 23, and the adhesive auxiliary member 23 and the base member 22 are bonded together with a urethane-based hot-melt adhesive. The urethane-based hot-melt adhesive is applied using the method described above.

Unlike Comparative Example 1, the laminated member 10 of Example 1 includes not only a surface member 21, a base member 22, and an adhesive auxiliary member 23, but also a waterproof member 30. The surface member 21 is artificial turf, and the base member 22 is foamed rubber pellets (15 mm thick). The adhesive auxiliary member 23 is made of foamed polyethylene and has a thickness of 5 mm. The waterproof member 30 is also made of foamed polyethylene and has a thickness of 5 mm. The surface member 21 and the adhesive auxiliary member 23, and the adhesive auxiliary member 23 and the base member 22 are bonded together with an organic solvent-free urethane-based hot melt adhesive. The base member 22 and the waterproof member 30 are bonded together with an organic solvent-free urethane-based hot melt adhesive.

The laminated member of Example 2 comprises a surface member 21, a base member 22, and a waterproof member 30. Unlike Example 1, it does not include an adhesive auxiliary member 23. The surface member 21 is artificial turf, and the base member 22 is foamed rubber pellets (15 mm thick). The waterproof member 30 is made of foamed polyethylene and has a thickness of 5 mm. The surface member 21 and the base member 22 are bonded together with a chloroprene rubber-based solvent adhesive. The base member 22 and the waterproof member 30 are bonded together with a urethane-based hot-melt adhesive that does not contain organic solvents.

The deformability due to infiltration was evaluated for each example and comparative example of the laminated member 10. Specifically, the laminated member 10 of Example 2 and the laminated members of Comparative Examples 1 and 2 (of predetermined dimensions (e.g., 50 cm x 50 cm)) were placed in a constant temperature and humidity chamber at a predetermined temperature (e.g., 90°C) and humidity (e.g., 95%). Afterward, the change in shape of the laminated member 10 (especially the amount of warping) was observed (the change over time was checked).

In Comparative Example 1, all three test samples exhibited warping at all four corners. The amount of warping varied from 5 to 17 mm, with an average warping of 9.8 mm per sample. In Comparative Example 1, a waterproof adhesive auxiliary member 23 is laminated on the upper surface of the base member 22. While this can suppress water ingress from the upper surface of the base member 22, it cannot suppress water ingress from the lower surface. Therefore, the base member 22 is infiltrated from the lower side. At this time, the adhesive auxiliary member 23 and surface member 21 are laminated on the upper surface of the base member 22, but nothing is laminated on the lower surface. As a result, the infiltrated and expanded base member 22 expands more on the lower side than on the upper side, causing the upper side of the base member 22 to warp.

On the other hand, in Example 1, although warping occurred in all four corners of almost all three test samples, the amount of warping for each sample was 1 to 4 mm, and the average amount of warping per sample was 2.9 mm. In Example 1, a waterproof adhesive auxiliary member 23 is laminated on the upper surface of the base member 22, and a waterproof member 30 is laminated on the lower surface of the base member 22, making it possible to suppress water ingress from both the upper and lower surfaces of the base member 22. As a result, the overall expansion of the base member 22 due to water ingress (soaking) can be suppressed (and consequently, the expansion of the lower side more than the upper side can be suppressed), and deformation that causes the upper side of the base member 22 to warp can be suppressed.

Furthermore, in Example 2, while warping did not occur in the four corners of almost all three test samples, warping (convex portion) occurred in the central part of the samples. The amount of warping in each sample was about half that of Comparative Example 1, and the average amount of warping per sample was about 5 mm. In Example 2, the waterproofing member 30 is laminated on the lower surface of the base member 22, which can suppress water ingress from the lower surface of the base member 22, but it cannot suppress water ingress from the upper surface of the base member 22, so the base member 22 is infiltrated from the upper side. At this time, since the waterproofing member 30 is laminated on the lower surface of the base member 22 and the surface member 21 is laminated on the upper surface, the base member 22 that is infiltrated and expanded expands more on the upper side than on the lower side, and deforms so that the lower side of the base member 22 warps (i.e., the central part becomes convex).

As is clear from the above description, in the laminated member of Comparative Example 1, the four corners of the sample warp relatively significantly due to infiltration, so the deformability cannot be said to be good from the standpoint of appearance and usability. On the other hand, in the laminated member of Example 1, although the four corners of the sample warp due to infiltration, the amount of warping is reduced to a small extent, so the deformability can be said to be good from the standpoint of appearance and usability. Furthermore, in the laminated member of Example 2, although the central part of the sample warps due to infiltration, the warping of the four corners can be suppressed, so the deformability can be said to be good from the standpoint of appearance and usability.

(First variation)
In the above-described embodiment, a raised ridge 21c is formed on the back surface of the surface member 21 and the surface of the adhesive auxiliary member 23 is formed flat. However, a raised ridge 123c may be formed on the surface of the adhesive auxiliary member 23 and the back surface of the surface member 121 may be formed flat. In this case, as shown in Figure 3, the laminated member 110 comprises an upper layer member 120 and a waterproof member 30, similar to the laminated member 10 described above. The upper layer member 120 comprises a surface member 121, a base member 22, and an adhesive auxiliary member 123. The surface member 121 is bonded to the adhesive auxiliary member 123 via a first adhesive layer 24, and the base member 22 is bonded to the adhesive auxiliary member 123 via a second adhesive layer 25. The waterproof member 30 is bonded to the base member 22 via a third adhesive layer 26.

The surface member 121 is a plate-shaped shock-absorbing member. The surface member 121 is a member with at least a flat back surface, and is made of, for example, polyethylene, polypropylene, or the like. The adhesive auxiliary member 123 comprises a sheet-shaped sheet portion 123b and a protruding ridge portion 123c extending from the surface of the sheet portion 123b. The protruding ridge portion 123c is formed in the same manner as the protruding ridge portion 21c described above. The adhesive auxiliary member 123 is made of the same material as the adhesive auxiliary member 23 described above.

Furthermore, the aforementioned laminated member 110 is manufactured using the same manufacturing method (manufacturing process) as the laminated member 10 described above.

(Second variation)
Furthermore, in the embodiment described above, a water channel 51 may be formed on the lower surface of the waterproof member 30 described above. Specifically, as shown in Figure 4, the laminated member 210 comprises an upper member 20, a waterproof member 230, and a water channel 51, similar to the laminated member 10 described above.
The upper layer member 20 is bonded to the waterproof member 230 via the third adhesive layer 26.

The waterproof member 230, like the adhesive auxiliary member 123 described above, comprises a sheet portion 230b formed in a sheet shape, and a plurality of protruding ridges 230c projecting from the back surface (bottom surface) of the sheet portion 230b. The protruding ridges 230c are formed in the same manner as the protruding ridges 21c described above. The waterproof member 230 also includes grooves 230d formed between adjacent protruding ridges 230c and a water channel 51.

The water channel 51 is formed between the waterproofing member 230 (groove 230d) and the installation surface SF on which the waterproofing member 230 is installed. The water channel 51 extends horizontally along the protruding ridge 230c and has openings (not shown) at both ends. In other words, the laminated member 210 has multiple water channels 51 that are parallel to each other. This water channel 51 makes it possible to improve drainage between the laminated member 210 and the installation surface SF.

Furthermore, the waterproofing member 230 may be provided with connecting passages that link adjacent water channels 51. This would further improve drainage between the laminated member 210 and the installation surface SF. Additionally, water channels (formed similarly to the water channels 51) may be formed on the lower surface of the surface member 21, or on the upper surface of the adhesive auxiliary member 23. Furthermore, water channels may be formed on the upper surface of the base member 22, or on the lower surface of the base member 22.

Furthermore, although the aforementioned water channels were formed along the horizontal direction of the laminated member, through-holes may be formed to connect these horizontally formed water channels in the vertical direction.

(Other forms of torture)
Furthermore, in the laminated member 10 described above, the adhesive auxiliary member 23 may be omitted. In this case, the modified laminated member will include a surface member 21, a base member 22, and a waterproof member 30. Because it has a waterproof member 30, it can suppress water penetration into the base member 22 and, consequently, the laminated member.
Furthermore, in the laminated member 10 described above, the surface member 21 can also be omitted. In this case, the modified laminated member will include a base member 22 and a waterproof member 30, but because it has a waterproof member 30, it can suppress water infiltration into the base member 22 and, consequently, the laminated member.

Furthermore, the surface member described above may be made waterproof. In this case, the laminated member preferably comprises a surface member, a base member, and a waterproof member. This arrangement allows the base member to be sandwiched between the waterproof surface member and the waterproof member, thereby suppressing water infiltration from both sides (top and bottom) of the base member and preventing deformation of the laminated member. For example, the laminated member comprises the aforementioned surface member 121 (which is waterproof), a base member 22, and a waterproof member 30. In this case, the adhesive auxiliary member 123 can be omitted.

(Effects and benefits of the embodiment)
The laminated members 10, 110, and 210 according to the above-described embodiment include upper members 20 and 120, and waterproof members 30 and 230 provided on the lower surfaces of the upper members 20 and 120.

With these laminated members 10, 110, and 210, waterproof members 30 and 230 are provided on the lower surfaces of the upper members 20 and 120, thus suppressing water infiltration (penetration) from the lower side of the upper members 20 and 120. Therefore, changes in the shape of the upper members 20 and 120 due to water infiltration can be suppressed, and consequently, changes in the shape of the laminated members 10, 110, and 210 can be suppressed.

Furthermore, in the laminated members 10, 110, and 210, it is preferable that the upper members 20 and 120 comprise a base member 22 and surface members 21 and 121 provided on the upper surface side of the base member 22. This allows the upper surface of the base member 22, which is protected from water infiltration from the lower side by the waterproofing member, to be protected by the surface members 21 and 121. For example, by providing the surface members 21 and 121 with functions such as abrasion resistance and waterproofing, it becomes possible to protect the base member 22 from the viewpoint of abrasion resistance and waterproofing.

Furthermore, in the laminated members 10, 110, and 210, it is preferable that the upper members 20 and 120 further include adhesive assist members 23 and 123 provided between the base member 22 and the surface members 21 and 121 to assist in the adhesion of the base member 22 to the lower surface of the surface members 21 and 121. This allows the adhesive assist members 23 and 123 to assist in the adhesion between the base member 22 and the surface members 21 and 121, thereby enabling proper adhesion of the base member 22 and the surface members 21 and 121 with the desired adhesive strength.

Furthermore, in the laminated members 10, 110, and 210, it is preferable that the base member 22 is equipped with crushed material. This allows for the provision of waterproof members 30 and 230 on the lower surface of the base member 22 equipped with crushed material, thereby suppressing water infiltration from the lower side of the upper layer members 20 and 120, which are relatively prone to expansion due to water infiltration. Therefore, changes in the shape of the upper layer members 20 and 120 due to water infiltration can be suppressed, and consequently, changes in the shape of the laminated members 10, 110, and 210 can be suppressed.

Furthermore, in the laminated members 10 and 210, the surface member 21 is preferably artificial turf. This is because, when artificial turf is used as the surface member 21, deformation can be absorbed by the surface member 21 layer even if expansion occurs in the base member 22 (the thickness and elasticity of the artificial turf are utilized), thus suppressing changes in the overall shape of the laminated members 10 and 210.

Furthermore, in the laminated members 10, 110, and 210, it is preferable that the adhesive auxiliary members 23 and 123 have waterproof properties. This allows for the provision of waterproof adhesive auxiliary members 23 and 123 on the upper surface of the base member 22, thereby suppressing water infiltration from the upper surface of the base member 22. Therefore, it is possible to suppress changes in the shape of the base member 22 and, consequently, the upper layer members 20 and 120 due to water infiltration.

10, 110, 210…Laminated members; 20, 120…Upper layer members; 22…Base members; 21, 121…Surface members; 23, 123…Adhesive auxiliary members; 30, 230…Waterproofing members.

Claims (8)

Upper layer member,
A waterproof member provided on the lower surface of the upper layer member,
Equipped with ,
The upper layer member comprises a base member, a surface member provided on the upper side of the base member, and an adhesive assisting member provided between the base member and the surface member to assist in the adhesion of the base member to the lower side of the surface member.
The aforementioned adhesive auxiliary member has waterproof properties,
The laminated member is characterized in that the surface member includes a sheet portion and a plurality of protruding ridges that protrude from the lower surface of the sheet portion and are arranged on the upper surface side of the adhesive auxiliary member while maintaining a distance from each other . The laminated member according to claim 1 , characterized in that the adhesive auxiliary member is formed of a soft material . The laminated member according to claim 2, characterized in that the soft material includes polyurethane, polystyrene, polyethylene (including foamed), polypropylene (including foamed), ethylene vinyl acetate, and thermoplastic elastomer . The laminated member according to claim 1 or 2, characterized in that the base member is formed from natural rubber, synthetic rubber such as ethylene propylene diene rubber (EPDM), styrene butadiene rubber (SBR), nitrile rubber (NBR), butadiene rubber (BR), butyl rubber (isobutylene/isoprene rubber) (IIR), silicone rubber, fluororubber, foamed rubber obtained by foaming rubber material, rubber pellets obtained by crushing rubber material or foamed rubber and forming it into granules of a predetermined shape, and then solidifying them, or pellet aggregates obtained by agglomerating these pellets. The laminated member according to claim 1 or 2, characterized in that the surface member is artificial turf. The laminated member according to claim 1 or 2, characterized in that a plurality of water channels are provided on the lower surface of the waterproofing member . The laminated member according to claim 6, characterized in that a connecting passage is provided that connects adjacent waterways. The laminated member according to claim 1 or 2, characterized in that the thickness of the adhesive auxiliary member is set to a value greater than the height of the protruding portion.