JP2003251736A - Fire-resistant structure - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a fire-resistant structure which is excellent in outward appearance by having high design properties obtained by coloring the surface and which reveals high fire-resisting and heat-insulating effects due to thermal foaming in a fire and can be manufactured and constructed easily at a low cost. <P>SOLUTION: A fire-resistant base layer 2 constituted of a thermally foamable inorganic material containing a water-soluble alkali silicate and inorganic powder is formed on a base 1, and a fire-resistant colored layer 3 having chromatic inorganic aggregates compounded in the thermally foamable inorganic material is formed on the fire-resistant base layer 2. <P>COPYRIGHT: (C)2003,JPO

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention provides a fireproof coating on the surface of various base materials such as inner and outer walls and ceilings of buildings and general houses, outdoor passage walls, tunnel inner walls, various building materials, fittings, and equipment walls. Fireproof structure.

[0002]

2. Description of the Related Art In recent years, the heights of buildings in cities and the scale of underground shopping centers have increased, and along with this, the need for disaster prevention measures has increased, and in particular, preparation for fire is important.
However, asbestos, which has been widely used as a fireproof coating for various structural materials, cannot be used because of its carcinogenicity due to inhalation of dust, and rock wool is also annoying because it has the same concern of health damage. In addition, these are not sufficient in terms of fire resistance.

[0003] Therefore, as a fire resistant coating material replacing the asbestos and rock wool, various thermal foaming fire resistant paints which foam by heat received during a fire to form a heat insulating foam layer and exhibit flame and heat shielding action are proposed. Has been done. Such a heat-foaming fire-resistant paint contains a water-soluble alkali silicate as a main component, a curing agent and an aggregate component, and an inorganic one that causes foaming due to vaporization of water content, a binder resin and a carbonizing agent. An organic compound containing a foaming agent such as ammonium polyphosphate to form a carbonized layer when foaming, a compound mainly composed of a reaction product of a water-soluble silicate and an alkoxysilane derivative or an organosilica sol, a water-soluble alkali silicate and an ultraviolet ray. Although there are those in which a curable resin component is mixed, most of these have not been put into practical use, and the actual use examples are only organic ones.

[0004] However, the above-mentioned organic type, which has been used in the past, generates a carbonized layer expanded into a foam due to the generation of gas due to the decomposition of the foaming agent as the binder resin melts during a fire. Since the component contains toxic ammonia gas at a high rate, there is a concern that it may harm the disaster environment and the essential fire resistance is not sufficient. By the way, the heat resistant temperature of ordinary steel is 350 ° C, and even fireproof steel is 600 ° C
However, since it softens at higher temperatures, it is necessary to have a fireproof coating exhibiting extremely strong heat insulation in order to withstand a fire temperature of 1000 ° C. as a steel structure.

In view of the above situation, one of the inventors of the present invention firstly pioneered an epoch-making process capable of exhibiting a sufficient heat insulating property as a fireproof coating for a steel frame structure based on long-term and thorough experimental research. An inorganic inorganic fire-resistant coating agent was investigated, and one of the present applicants is applying for it as Japanese Patent Application No. 2001-354858. This fire-resistant coating agent is composed of a water-soluble paste containing a water-soluble alkali silicate and a holmite-based mineral powder, and an SiO ₂ -providing component other than these as essential components, and the coating film is foamed by heat reception during a fire. An adiabatic foam layer is generated, but due to the extremely delicate balance of the timing and speed of foaming, the entire coating film expands uniformly with the stable growth of fine air bubbles that are generated evenly throughout the coating film. In addition to producing a uniform and thick foam insulation layer without creating cavities or cracks, it has the characteristics that it does not easily sag due to the high pour point after foaming, and it can maintain excellent heat insulation properties for a long time. There is.

[0006]

The above-mentioned refractory coating agent was developed for the purpose of imparting excellent fire resistance performance to steel materials such as steel frames as described above, but is not limited to the surface of steel materials. However, even if it is applied to the surface of other various metal articles or the article surface made of a material other than metal such as slate, concrete, wood, plywood, corrugated board, compressed paperboard, synthetic resin, FRP, the heat generated By the foamable coating layer,
These articles can be extremely fire resistant. However, the coating layer of this fire resistant coating is
Since the inorganic powder is bound with a water-soluble alkali silicate as a binder, the surface is generally white to gray and poor in design, for example, the inner and outer walls and ceilings of buildings and general houses, outdoor passage walls, tunnel inner walls, It was not suitable for applications where appearance is important, such as fittings and articles installed indoors and outdoors.

Of course, if a colorant such as a pigment is blended with the fire-resistant coating agent, a colored heat-foamable coating layer can be formed, but a thick heat-insulating foam layer exhibiting sufficient fire resistance and heat-insulating properties in case of fire is produced. In addition, since the heat-foamable coating layer also needs to be thicker from several mm to several tens of mm, the amount of the colorant used increases and the cost increases, and the paste containing solid powder in a high ratio is used. It is difficult to uniformly disperse the colorant, uneven coloring occurs due to insufficient dispersion, disintegration of paste particles due to excessive mixing, and a large amount of colorant disrupts the balance of foaming timing and speed during a fire, There is a concern that the properties of the heat insulating foam layer formed may deteriorate and the fire resistance and heat insulating performance may deteriorate. In addition, it is possible to paint by coating a general coloring paint on the surface of the heat-foamable coating film layer,
In this case, the colored coating film on the surface does not contribute to fire resistance, and in case of fire, combustion of the colored coating film will generate toxic gas and black smoke. Since it has a porous structure, there is a concern that the binder component permeates into the underlying heat-foaming coating film layer when the colored coating film is formed, which adversely affects the heat-foaming property.

In view of the above-mentioned circumstances, the present invention provides a refractory structure having a refractory coating of an inorganic heat-foamable refractory paint containing an alkali silicate such as the above-mentioned refractory coating agent. It is an object of the present invention to provide a product having high designability, a good appearance, high fire resistance and heat insulation effect due to thermal foaming at the time of fire, and which can be easily manufactured and constructed at low cost.

[0009]

In order to achieve the above object, a refractory structure according to claim 1 of the present invention has a base material containing a water-soluble alkali silicate and an inorganic powder. A refractory base layer made of an inorganic material is formed,
On this fire-resistant base layer, a constitution is adopted in which a fire-resistant colored layer in which a chromatic inorganic aggregate is mixed with the heat-foamable inorganic material is formed.

The refractory structure having the above structure has a surface colored by the refractory colored layer, but since the underlying refractory base layer does not contain chromatic inorganic aggregate, the base layer is thermally foamed in case of fire. In addition to exhibiting the original excellent fire resistance and heat insulation effect, the fire resistant colored layer also contributes to fire resistance and heat insulation in the event of a fire because it has a certain degree of thermal foaming property, and the color layer becomes a fire resistant base layer. It also functions as a buffer layer for mitigating the thermal shock of the fire resistant base layer, so that the temperature of the fire resistant base layer in the case of fire is moderately increased and uniform thermal foaming occurs. On the other hand, since the coloring component of the refractory colored layer is composed of a chromatic inorganic aggregate having a large particle size, when the coating agent for forming the colored layer is prepared, it is easily dispersed uniformly by mixing with the thermally foamable inorganic material, The surface of the colored layer after processing becomes a beautiful ceramic-like colored surface with no color unevenness, and high designability is obtained. Further, the chromatic inorganic aggregate needs only a small amount to be used, as long as only the refractory colored layer can be toned to the desired shade. Furthermore, since the same heat-foamable inorganic material as that used for the refractory base layer is used for the refractory colored layer, both layers are firmly integrated with each other with high affinity, and interfacial peeling hardly occurs.

According to a second aspect of the present invention, in the refractory structure according to the first aspect, the refractory base layer has a thickness of 2 to 20 mm.
And the thickness of the refractory colored layer is set to 0.5 to 5 mm. In this case, it is possible to sufficiently secure the fire resistance / heat insulating property in the case of fire by the fire resistant base layer and surely obtain the high designability by the surface coloring.

According to a third aspect of the present invention, in the refractory structure according to the first or second aspect, the average particle size of the chromatic inorganic aggregate of the refractory colored layer is 0.05 to 1 mm.
In this case, the refractory colored layer has a clear color tone and excellent surface properties.

According to a fourth aspect of the present invention, in the refractory structure according to any one of the first to third aspects, the refractory colored layer contains porcelain sand as the chromatic inorganic aggregate. In this case, the surface of the refractory colored layer has a very beautiful ceramic tone with a transparent feeling like ceramics, and an extremely wide variety of shades can be expressed by selecting clay.

According to a fifth aspect of the present invention, in the refractory structure according to any one of the first to fourth aspects, the refractory base layer is formed of a coating film of an aqueous paste of the heat-foamable inorganic material, and the refractory coloring. It is assumed that the layer comprises a coating film of an aqueous paste containing 5 to 50% by weight of the chromatic inorganic aggregate with respect to the aqueous paste. With this configuration, thick coating of the fire-resistant base layer and the fire-resistant colored layer can be easily performed, and the fire resistance and color development of the color layer can be controlled by an appropriate mixing ratio of the chromatic inorganic aggregate in the fire-resistant colored layer. Can be secured together.

According to a sixth aspect of the present invention, in the refractory structure according to any one of the first to fifth aspects, the refractory colored layer contains a metal powder. In this case, the colored surface is given a luster due to the metal powder to exhibit a metallic color.

According to a seventh aspect of the present invention, in the refractory structure according to any one of the first to sixth aspects, an uneven pattern is formed on the surface of the refractory colored layer. in this case,
The unevenness of the colored surface further enhances the design.

According to an eighth aspect of the present invention, in the refractory structure according to any of the first to seventh aspects, a transparent coating film mainly composed of an inorganic binder is formed on the refractory colored layer. In this configuration, since the transparent coating imparts gloss to the colored surface, the design is further improved, and the transparent coating provides antifouling properties, sealing properties, and chemical resistance, so that the fire-resistant base layer and fire resistance are improved. The fire resistance of the colored layer and the good appearance of the colored surface can be kept stable for a long period of time. Since the transparent coating is a non-combustible inorganic substance, it does not generate toxic gas or black smoke at the time of fire, and even if the binder component penetrates into the substrate during formation of the film, the substrate is fire resistant. Since it is a colored layer, there is no fear of impairing the fire resistance of the fire resistant base layer.

A ninth aspect of the present invention is the refractory structure according to any one of the first to eighth aspects, wherein the thermally foamable inorganic material is a water-soluble alkali silicate, a holmite-based mineral powder, and other materials. It is assumed to contain a SiO ₂ imparting component. With this structure, the timing and speed of foaming due to the heat received by the foamable inorganic material during a fire are perfectly balanced, so the fire-resistant base layer is uniform and thick without cavities or cracks When converted into a layer, the heat-resistant foaming property of the refractory colored layer also becomes good, so that the excellent heat insulation property can be maintained for a long time.

According to a tenth aspect of the invention, in the refractory structure according to the ninth aspect, the formite-based mineral powder in the thermally foamable inorganic material is 5 to 5 with respect to the water-soluble alkali silicate.
While being blended in an amount of 0 wt%, SiO ₂ wherein SiO ₂ imparting component in the total amount of water-soluble alkali silicate
/ M ₂ O (M is an alkali metal) is mixed at a molar ratio of 3.7 to 8. in this case,
Since each component in the heat-foamable inorganic material has an appropriate ratio, the fire-resistant base layer and the fire-resistant colored layer have a better foaming state at the time of fire, and the foamed layer produced is less likely to sag. Will be things.

The invention of claim 11 is the same as claim 9 or 1 above.
In the refractory structure of 0, the SiO ₂ imparting component is
At least one selected from hydromica, calcium silicate, colloidal silica, natural glass, kaolins, and pearlites. In this case, the fire-resistant base layer and the fire-resistant colored layer will surely be converted into a foamed layer having excellent heat insulating properties in the event of a fire and hardly falling off.

[0021]

1 is a sectional view showing a structural example of a refractory structure according to the present invention. In the figure, reference numeral 1 is a base material, and a fire resistant base layer 2, a fire resistant colored layer 3 and a transparent coating 4 are sequentially laminated on the surface thereof.

The substrate 1 is, for example, various structural parts or article surfaces that require fireproof coating, such as inner and outer walls and ceilings of buildings and general houses, outdoor passage walls, tunnel inner walls, various building materials, fittings, equipment walls, etc. It includes everything that constitutes a part, and there are no restrictions in terms of its purpose or form. In addition, the material of the base material 1 is not particularly limited, and may be either an incombustible material or a combustible material. For example, various metals such as iron, slate, concrete, wood, plywood, cardboard, compressed paperboard, synthetic resin, A wide range of materials such as FRP are targeted.

The refractory base layer 2 is made of a heat-foamable inorganic material containing a water-soluble alkali silicate and an inorganic powder, and the refractory colored layer 3 is chromatic in the heat-foamable inorganic material of the refractory base layer 2. Composed of inorganic aggregate.
The transparent coating 4 is made of an inorganic coating mainly composed of an inorganic binder such as a silicone polymer.

In such a refractory structure, both the refractory base layer 2 and the refractory colored layer 3 are foamed by receiving heat during a fire to form an adiabatic foamed layer, and the heat insulating property of the base material causes Heat softening and heat deterioration when 1 is an incombustible material, the base material 1
When it is a combustible material, it has high fire resistance to fulfill the function of holding down burns and flames for a long time.
In addition to this, the surface of the refractory colored layer 3 forms a beautiful ceramic-colored surface with no color unevenness, and the glossiness of the transparent coating 4 provides a good appearance and high designability. Antifouling property, sealing property by the transparent film 4,
Fire resistant base layer 2 and fire resistant colored layer 3 due to chemical resistance
It has the characteristics of maintaining the fire resistance performance and good appearance of the colored surface stably over a long period of time. Therefore, this fire-resistant structure provides a very high-class feeling, for example, as a fire-resistant interior / exterior of a building.

The use of the chromatic inorganic aggregate as the colorant for the refractory colored layer 3 has a large particle size, so that when the coating agent for forming the colored layer is prepared,
Easily uniformly dispersed by mixing with a paste of a heat-foamable inorganic material, and in addition to hardly causing color unevenness, the colored layer surface after coating becomes a beautiful ceramic-like colored surface,
This is because high designability is obtained. On the other hand, a fine-particle colorant such as an inorganic pigment cannot basically give a beautiful ceramic color tone to the colored layer 3 and is uniformly dispersed in the heat-foamable inorganic material when the coating agent is prepared. It is difficult to cause color unevenness on the surface of the colored layer after coating due to insufficient dispersion, and if stirring and mixing for a long time with a powerful mixer to prevent color unevenness, heat may be generated due to particle disintegration, etc. The expandable inorganic material is modified, and sufficient performance as a heat-foamable refractory layer cannot be imparted.

The chromatic inorganic aggregate used for the refractory colored layer 3 in the present invention is composed of chromatic colored inorganic particles such as glass, stone, and ceramic, and both artificial materials and natural materials are used. Although it can be used, powders of porcelain sand and chromatic natural stone are preferred, and porcelain sand is most suitable because it can easily express a beautiful ceramic tone having a transparent feeling. This porcelain sand is obtained by mixing powder of a metal oxide or the like, which is a coloring component, with porcelain clay, calcinated the calcinated product at a high temperature of around 1400 ° C., and crushing the calcinated product. It consists of blue, green, yellow, orange, red, depending on the type and combination and amount of the metal oxide etc. of the coloring component used.
Various colors such as pink and various colors from light to dark have been obtained.

The particle size of such a chromatic inorganic aggregate is preferably such that the average particle size of the aggregate is in the range of 0.05 to 1 mm. That is, if the particle size is too small, the surface of the fire-resistant colored layer 3 will appear whitish due to diffuse reflection, and if the particle size is too large, the surface property of the fire-resistant colored layer 3 will deteriorate. It becomes difficult to express a beautiful ceramic color tone together. Also,
The content of the chromatic inorganic aggregate is preferably in the range of 5 to 50% by weight with respect to the aqueous paste of the heat-foamable inorganic material, and when the content is too small, sufficient color development cannot be obtained, and conversely there is a large amount. If it is too much, the performance of the refractory colored layer 3 as the heat-foamable refractory layer will be deteriorated. In the refractory colored layer 3, by mixing metal powder such as stainless steel powder, tin powder, brass powder, and copper powder together with the above-mentioned chromatic inorganic aggregate, a metallic color to which luster of the metal powder is added. Can be expressed.

The heat-foamable inorganic material used for the refractory base layer 2 and the refractory colored layer 3 contains a water-soluble alkali silicate and an inorganic powder, which are melted by the heat received at the time of a fire and bubbles generated by evaporation of the water content. The fire-resistant coating agent according to the above-mentioned Japanese Patent Application No. 2001-354858 is suitable, but it is limited only to the coating agent. Not a thing.

Thus, the fire-resistant coating agent according to Japanese Patent Application No. 2001-354858 has a water-soluble alkali silicate as a basic component, a powder of holmite-based mineral, and a SiO ₂ addition component other than the former two components. It is an inorganic heat-foaming fire-resistant paint consisting of a water-based paste.When the paint film foams due to the heat received during a fire, the base material of the paint film becomes an ideal viscous molten state, and the foaming timing and speed are extremely high. A characteristic that it is perfectly balanced, and the entire coating expands uniformly with the stable growth of fine air bubbles that are generated evenly throughout the coating, producing a uniform and thick foam layer with optimal properties for heat insulation. Is equipped with.

The water-soluble alkali silicate in this refractory coating agent is a basic component for providing the film with thermal foaming property, and is made into a molten state by receiving heat at the time of fire to vaporize the contained water content. It is allowed to remain in the coating film, thereby enabling conversion of the coating film into a foam layer. Further, also in the coating agent, the aqueous solution thereof serves as a liquid medium in which other compounding ingredients are dispersed or dissolved as a paint base. Therefore, it is preferable that the water-soluble alkali silicate accounts for 30% by weight or more of the components excluding water in the coating agent, and if this ratio is too small, sufficient thermal foamability cannot be obtained.

Examples of such water-soluble alkali silicates include sodium silicate, potassium silicate, lithium silicate, and the like, and commercially available products in the form of an aqueous solution as water glass can be preferably used. This water-soluble alkali silicate is represented by the structural formula of M ₂ O · nSiO ₂ (M is an alkali metal), and the molar ratio of M ₂ O and SiO ₂ varies depending on the type of compound and the grade of water glass. There is.

The holmite-based mineral used in the fire-resistant coating agent is a mineral having a fibrous structure,
It enables the coating film to maintain an appropriate water content necessary for foaming continuously, and controls the foaming of the coating film due to the heat received at the time of fire, and the exquisite balance of the timing and speed of foaming described above. And contributes to the formation of a uniform foam layer with excellent heat insulation, and the reinforcing action of the fibrous structure effectively prevents the generation of cracks during drying and solidification of the coating film as well as aging cracks. Perform a function. Such holmite-based mineral is not particularly limited, but a typical example thereof is magnesium inosilicate mineral sepiolite, which has an appropriate fiber length and can be obtained at low cost. There is an advantage.

The amount of the powder of the holmite-based mineral is preferably in the range of 5 to 50% by weight, more preferably 5 to 30% by weight, based on the water-soluble alkali silicate. That is, even if this blending amount is too small or too much,
The balance of the timing and speed of foaming due to heat reception of the coating film as described above is easily disrupted, and it becomes difficult to form a foam layer with excellent heat insulation properties, and cracking of the coating film is prevented especially when the blending amount is too small. In terms of, it is difficult to obtain a sufficient effect.

The SiO ₂ imparting components other than the former two used in the above-mentioned refractory coating agent have a function of increasing the pour point of the coating film after foaming and allowing the foam layer to have an excellent heat-shielding effect for a long time. . That is, the higher the ratio of SiO _{2 in} the above molar ratio, the higher the pour point (flow temperature) of the coating film after foaming, and the more time it takes for heat to fall from the heat received during a fire. The excellent heat insulation effect of the foam layer lasts for a long time. For example, JIS-
As the same molar ratio of No. 3 water glass is about 3.2, since the ratio of SiO ₂ cannot be set high only by the water-soluble alkali silicate, this SiO ₂ addition component is added to the SiO ₂ mixture.
Increase the ratio of.

Examples of the SiO ₂ imparting component include hydromica such as vermiculite, calcium silicate,
Examples include colloidal silica, natural glass, pearlites such as perlite, clay minerals mainly composed of SiO _{2 such} as kaolins and sillimanite, and calcined products thereof, hollow aluminosilicate particles, and the like. You may. Therefore, the compounding amount of the SiO ₂ imparting component is such that the total amount of SiO ₂ / M ₂ O and the water-soluble alkali silicate is large.
It is preferable to set the molar ratio of (M is an alkali metal) to be 3.7 to 8. That is, if this molar ratio is too low, the pour point after the foaming becomes low, and it becomes difficult to maintain a high heat insulating property for a long time due to the dropping of the foamed layer. On the contrary, if the molar ratio is too high, the relative ratio of the water-soluble alkali silicate in the coating agent may decrease, which may easily cause insufficient foaming. However, if the molar ratio exceeds 8, it is prepared as a coating agent. Have difficulty.

Further, the above refractory coating agent includes
Water-soluble alkali silicate, holmite-based mineral powder,
In addition to the SiO ₂ imparting component, various additives can be blended if necessary. Suitable additives include glass fibers that prevent cracking of the coating film and improve strength, titanium oxide powder that functions as a fungicide for the coating film and as a dripping stop in the molten state, and polymethylhydrogensiloxane for preventing elution by rainwater. Such silicone-based water repellents are listed.

To form the fire-resistant base layer 2 and the fire-resistant colored layer 3 of the fire-resistant structure, an aqueous paste of a heat-foamable inorganic material such as the above-mentioned fire-resistant coating agent is prepared, and these are used as the base material 1. May be sequentially coated on the surface. The prepared aqueous paste is generally in the form of cream or putty, but as it is, various coating means such as spray coating with a spray gun, roller coating, iron coating, brush coating, cast coating from slits, etc. Can be applied with. Of course, if necessary, water may be added to dilute the solution so that the viscosity becomes appropriate depending on the coating method applied. Also,
It is also possible to carry out overcoating while setting the refractory base layer 2 and the refractory colored layer 3 to a required thickness. Since the refractory base layer 2 and the refractory colored layer 3 are made of the same heat-foamable inorganic material, the layers 2 and 3 are firmly integrated with each other with high affinity, and the interfacial peeling hardly occurs. Becomes

The refractory base layer 2 has a thickness of 2 to 20 mm.
If it is too thin, sufficient fire resistance cannot be obtained, and if it is too thick, the weight of the refractory structure becomes large and dripping easily occurs due to its own weight during foaming.
The thickness after foaming is usually about 3 to 4 times that before foaming. The thickness of the refractory colored layer 3 is 0.5 to 5 mm.
If it is too thin, the color of the underlying fire-resistant base layer 2 will show through and the coloring effect will be poor, whereas if it is too thick, the fire-resistant performance of the underlying fire-resistant base layer 2 will be impaired.

The transparent coating 4 is not essential for the refractory structure of the present invention, but as described above, it has the effect of imparting luster to the surface to further enhance the design, and the antifouling property of the surface. Also, it has an advantage that it functions as a protective layer that enhances the sealing property and the chemical resistance, and thus keeps the fire resistance of the fire resistant base layer 2 and the fire resistant colored layer 3 and the good appearance of the colored surface stably for a long period of time. In order to form such a transparent coating 4, a commercially available inorganic transparent coating agent can be used, and the surface of the fire-resistant colored layer 3 can be coated by spray coating or brush coating on the surface of several tens to several hundreds of μm. It may be applied so as to cover it with a uniform thickness.

In the refractory structure of the present invention,
Since the fire-resistant base layer 2 and the fire-resistant colored layer 3 are relatively thick, it is easy to form an uneven pattern on the surface, and this uneven pattern can further enhance the design. Such a concavo-convex pattern may be formed by concavo-convex the surface of the refractory base layer 2 as shown in FIG. 1 so that the concavities and convexities appear on the surface of the refractory colored layer 3 or the transparent coating 4. The base layer 2 may be flat, and the surface of the refractory colored layer 3 thereon may be uneven. Then,
There are no restrictions on the types of uneven patterns, and various settings such as geometric patterns, cast patterns, and irregular patterns can be set.A tile-like appearance is created with joint-like lattice grooves, or rough irregular irregularities. The appearance of can also be given. Further, the patterning may be performed by a brush operation during coating, a trowel operation, a roller operation, or the like, or by using a marking roller or an appropriate patterning jig when the coating film is not dried after coating. May be.

[0041]

EXAMPLES The present invention will be specifically described below with reference to examples. In the following, "parts" means "parts by weight". The details of each component used in the examples are as follows. JIS No. 3 water glass ・ ・ ・ Osaka Soda Co., Ltd. (concentration 38%, SiO ₂ / M ₂ O molar ratio 3.2) Sepiolite powder ・ ・ ・ Milcon MS-2-2 calcium silicate powder Showa Mining ・ ・ ・HYKRON India Limited Hikon S-3 Colloidal Silica ・ ・ ・ Nissei Kyodo Co., Ltd. Zeocyl 77 (hydrous amorphous SiO ₂ 98%) Perlite powder ・ ・ ・ Tomoe perlite natural glass powder ・ ・ ・ Kyushu Permis Parmis Kp-F aluminosilicate particles manufactured by Nihon Philite Phyllite 5e (hollow particles) vermiculite powder (unbaked product ... particle size 1.2 to 2.2 mm) Australian vermiculite・ Titanium oxide powder manufactured by Industry Co., Ltd. FR-41 (rutile type) manufactured by Furukawa Co., Ltd.

[0042]   Example 1     JIS No. 3 water glass: 72.0 parts     Sepiolite powder ... 7.0 parts     Calcium silicate powder ... 6.0 parts     Colloidal silica: 13.5 parts     Titanium oxide powder ... 1.5 parts

A refractory coating agent (SiO ₂ / Na ₂ O molar ratio of 4.51) was prepared by stirring and mixing the above composition, and the refractory coating agent was spray-coated on the surface of a slate plate having a thickness of 4 mm. After leaving and drying twice, a fire-resistant base layer having a thickness of about 5 mm was formed, and before the fire-resistant base layer was cured, the surface of the layer was textured by a marking roller. Then, on this refractory base layer, 100 g by weight of the refractory coating agent was used to produce green-colored porcelain sand (ceramic sand made by Meshu Kosan Co., Ltd., particle size 0.1 to 0.5
mm) 30 parts by weight is added and mixed to obtain a coating for a colored layer, which is spray-coated to form a fire-resistant colored layer having a thickness of about 1.5 mm, and the surface of the colored layer after drying is silicone-based. A coating agent (Star Bright Top S manufactured by Kabeichi Co., Ltd.) was applied by brushing to form a transparent film, and a fire resistant structure sample was prepared.

[0044]   Example 2       JIS No. 3 water glass ・ ・ ・ 83.4 parts       Sepiolite powder ... 7.3 parts       Natural glass powder ... 6.3 parts       Aluminosilicate particles ... 1.3 parts       Titanium oxide powder ... 1.7 parts

A fire-resistant coating agent (SiO ₂ / Na ₂ O molar ratio of 3.86) was prepared by mixing the above compositions with stirring, and a slate plate was prepared in the same manner as in Example 1 using this fire-resistant coating agent. A refractory base layer having a thickness of about 5 mm was formed on the surface of and the surface was patterned. Then, on this fire-resistant base layer, 20 parts by weight of blue-colored porcelain sand (Cerasand made by Meshu Kosan Co., Ltd., particle size: 0.05 to 0.15 mm) and stainless steel powder with respect to 100 parts by weight of the fire-resistant coating agent (Average particle size of 0.05 mm) 5 parts by weight is added and mixed to obtain a coating agent for a coloring layer, which is spray-coated to form a fire-resistant coloring layer having a thickness of about 1.0 mm, and the coloring layer is dried. A transparent coating was formed on the subsequent surface in the same manner as in Example 1 to prepare a fire resistant structure sample.

[0046]   Example 3       JIS No. 3 water glass ・ ・ ・ 56.7 parts       Sepiolite powder ... 3.6 parts       Calcium silicate powder ・ ・ ・ 18.8 parts       Colloidal silica: 3.8 parts       Titanium oxide powder ... 1.0 part       Water repellent (methyl sodium siliconate) ... 3.2 parts       Water: 12.9 copies

The above composition was stirred and mixed to prepare a refractory coating agent (SiO ₂ / Na ₂ O molar ratio 5.55). This refractory coating agent was treated in the same manner as in Example 1 to prepare the surface of the slate plate. A refractory base layer having a thickness of about 5 mm was formed on. Then, on this refractory base layer, 7 parts by weight of red-colored porcelain sand (Cerasand manufactured by Bishu Kosan Co., Ltd., particle size 0.5 to 1.0 mm) was added and mixed with 100 parts by weight of the refractory coating agent. The coating agent for a colored layer thus obtained is coated with a roller, and patterning is performed by operating this roller to form a fire-resistant colored layer having an average thickness of about 2.0 mm and a wavy uneven pattern. An inorganic coating agent (described above) was spray-coated on the dried surface of the colored layer to form a transparent film, and a fireproof structure sample was produced.

[0048]   Example 4       JIS No. 3 water glass: 62.5 parts       Sepiolite powder ... 2.3 parts       Colloidal silica: 4.8 parts       Vermiculite powder ・ ・ ・ 14.9 parts       Perlite powder ... 6.0 parts       Titanium oxide powder ... 1.0 part       Water repellent (methyl sodium siliconate) ... 2.4 parts       Water ... 6.3 parts

A refractory coating agent (SiO ₂ / Na ₂ O molar ratio of 5.63) was prepared by stirring and mixing the above compositions, and the refractory coating agent was spray-coated on the surface of a slate plate having a thickness of 4 mm. After leaving and drying twice, a fire-resistant base layer having a thickness of about 5 mm was formed, and before the fire-resistant base layer was cured, the surface of the layer was textured by a marking roller. Then, on this fire-resistant base layer, 100 g by weight of the fire-resistant coating agent was mixed with pink porcelain sand (Cerasand made by Meshu Kosan Co., Ltd., particle size 0.15 to 0.5).
mm) 25 parts by weight is added and mixed to obtain a coating material for a coloring layer, which is spray-coated to form a fire-resistant coloring layer having a thickness of about 1.5 mm. A transparent coating was formed in the same manner as in 1 to prepare a fire resistant structure sample.

The fire-resistant structure samples prepared in Examples 1 to 4 all have a beautiful color with a shade corresponding to the clay used in the fire-resistant colored layer, no color unevenness, and a sense of transparency and luster. It had a ceramic-like colored surface with an uneven pattern and had a high design value. Then,
The colored surface of the refractory structure sample produced in Example 2 was
It had a brilliant metallic color. When the colored surfaces of these samples were pressed with a hammer, neither peeling of the fire resistant base layer from the slate plate of the base material nor peeling of the interface between the fire resistant base layer and the fire resistant colored layer occurred.

On the other hand, these samples were set in a heating test furnace with the plate surface direction vertical, and the surface of the refractory colored layer side was heated by a direct burner (1400 ° C.) with a gas burner and the slate plate side surface was also heated. When the temperature and the temperature inside the furnace were measured via a thermocouple, melting foaming occurred in the refractory base layer and the refractory colored layer when the temperature inside the furnace reached about 300 ° C about 5 minutes after the start of heating. Both layers gradually expanded and were converted into a thick heat-insulating foam layer, but the temperature on the slate plate side remained around 200 ° C. even when the temperature inside the furnace reached 840 ° C. 30 minutes after the start of heating.

[0052]

According to the invention of claim 1, as a refractory structure, a chromatic color is contained in the heat-foamable inorganic material on the fire-resistant base layer made of the heat-foamable inorganic material provided on the substrate. A fire-resistant colored layer containing an inorganic aggregate is formed, so the surface has a beautiful ceramic-like colored surface with no color unevenness, has a high designability, has a good appearance, and is fire-resistant in the event of a fire. Provided is a base layer and a refractory colored layer that exhibit high fire resistance and heat insulation by thermal foaming, and can be easily manufactured and constructed at low cost.

According to the second aspect of the present invention, in the above refractory structure, since the refractory base layer and the refractory colored layer have specific thicknesses, the refractory base layer provides fire and heat insulation during a fire. Is sufficiently secured, and high designability due to surface coloring is surely obtained.

According to the invention of claim 3, in the above refractory structure, since the chromatic inorganic aggregate of the refractory colored layer has a specific particle size, the refractory colored layer has a clear color. It has excellent surface properties.

According to the invention of claim 4, in the above refractory structure, since porcelain sand is used as the chromatic inorganic aggregate of the refractory colored layer, the surface of the colored layer has a transparent feeling like a ceramic. With a very beautiful ceramic tone,
There is an advantage that a very wide variety of shades can be expressed by selecting the clay.

According to the invention of claim 5, in the above refractory structure, an aqueous paste is used for forming the refractory base layer and the refractory colored layer, and the chromatic inorganic aggregate is blended in the refractory colored layer. By setting the ratio to a specific range,
The thick coating of both layers is easy, and the fire resistance and color development of the colored layer can be sufficiently ensured.

According to the invention of claim 6, in the above refractory structure, since the refractory colored layer contains the metal powder, there is an advantage that the colored surface exhibits a metallic color.

According to the invention of claim 7, in the above refractory structure, since the refractory colored layer has an uneven pattern on the surface, there is an advantage that the designability is further enhanced.

According to the invention of claim 8, in the above refractory structure, since the refractory colored layer has a transparent coating mainly composed of an inorganic binder, gloss is imparted to the colored surface and designability is improved. Further, due to the stain resistance, sealing property and chemical resistance of the transparent film, the fire resistance of the fire resistant base layer and the fire resistant colored layer and the good appearance of the colored surface can be stably maintained for a long period of time. There is an advantage.

According to the invention of claim 9, in the above refractory structure, since the thermally foamable inorganic material having a specific composition is used, the heat insulating foam layer generated at the time of fire is uniform and thick. It has the advantage that it does not drip easily and cracks and better fire resistance can be obtained.

According to the tenth aspect of the present invention, in the refractory structure using the heat-foamable inorganic material having the above-mentioned specific composition, the components of the heat-foamable inorganic material are set to a specific blending ratio, so that the fire-resistant structure is set. The foamed base layer and the fire-resistant colored layer have better foaming conditions at the time of a fire, and the foamed layer produced is less likely to droop down, and thus the fire resistance is further improved.

According to the invention of claim 11, in the refractory structure using the heat-foamable inorganic material of the above-mentioned specific composition, since a specific one is used as the SiO ₂ imparting component of the material, the refractory base is used. There is an advantage that the layer and the refractory colored layer have an excellent heat insulating property in the case of a fire and can be surely converted into a foamed layer which does not easily drop.

[Brief description of drawings]

FIG. 1 is a cross-sectional view showing a structural example of a refractory structure according to the present invention.

[Explanation of symbols]

1 base material 2 Fire-resistant base layer 3 Fireproof colored layer 4 Transparent coating

   ─────────────────────────────────────────────────── ─── Continued front page    (72) Inventor Fujio Kondo             2-5-2 Ohamacho, Amagasaki City, Hyogo Osaka             Yushi Kogyo Co., Ltd. (72) Inventor Goro Wakisaka             2-chome, Nagao Furniture Town, Hirakata City, Osaka Prefecture             Ceremony company Kabeichi F-term (reference) 4F100 AA01B AA01C AA03C AA18B                       AA18C AA20B AA20C AA40C                       AB01B AR00D AT00A BA03                       BA04 BA07 BA10B BA10D                       BA25 CA24B DE01B DE01C                       EJ02B EJ02C GB07 GB90                       HB00B HB21B JJ02 JJ07                       JJ07B JL10B JN01D YY00B                       YY00C                 4G012 PA02 PA13                 4H028 AA02 AA05 AB03 BA03 BA04

Claims (11)

[Claims] 1. A refractory base layer made of a heat-foamable inorganic material containing a water-soluble alkali silicate and an inorganic powder is formed on a substrate, and the heat-foamable inorganic material is formed on the fire-resistant base layer. A fire resistant structure having a fire resistant colored layer formed by mixing chromatic inorganic aggregate therein. 2. The refractory structure according to claim 1, wherein the refractory base layer has a thickness of 2 to 20 mm and the refractory colored layer has a thickness of 0.5 to 5 mm. 3. The average particle size of the chromatic inorganic aggregate of the refractory colored layer is 0.05 to 1.0 mm.
Refractory structure described in. 4. The fire resistant structure according to claim 1, wherein the fire resistant colored layer contains porcelain sand as the chromatic inorganic aggregate. 5. The refractory base layer comprises a coating film of an aqueous paste of the heat-foamable inorganic material, and the refractory colored layer contains 5 to 50% by weight of the chromatic inorganic aggregate with respect to the aqueous paste. A coating film of an aqueous paste prepared by
The fire resistant structure according to any one of 4 above. 6. The refractory structure according to claim 1, wherein the refractory colored layer contains a metal powder. 7. The refractory structure according to claim 1, wherein an uneven pattern is formed on the surface of the refractory colored layer. 8. The refractory structure according to claim 1, wherein a transparent coating film mainly composed of an inorganic binder is formed on the refractory colored layer. 9. The fire resistant material according to claim 1, wherein the thermally foamable inorganic material contains a water-soluble alkali silicate, a holmite-based mineral powder, and a SiO ₂ imparting component other than these. Structure. 10. The formite-based mineral powder in the thermally foamable inorganic material is 5 to 50 relative to the water-soluble alkali silicate.
It is mixed in a ratio of wt%, and the above-mentioned SiO ₂ imparting component is contained in a total amount of SiO ₂ / water-soluble alkali silicate.
The refractory structure according to claim 9, wherein the refractory structure is mixed in a molar ratio of M ₂ O (M is an alkali metal) of 3.7 to 8. 11. The SiO ₂ imparting component is hydromica, calcium silicate, colloidal silica, natural glass,
The refractory structure according to claim 9 or 10, which is at least one selected from kaolins and pearlites.