JP2011156799A - Layered body - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a layered body having superior performances in refractory property, thermal insulation property, strength, etc. <P>SOLUTION: In the layered body, a refractory and thermal insulation layer made of a cured body of a composition comprising 4 to 40 pts.wt. of foamed organic resin particles, 5 to 300 pts.wt. of inorganic light-weight particles; and 5 to 800 pts.wt. of an endothermic substance based on 100 pts.wt. of cement is disposed on at least one side surface of a base material selected from an inorganic base material and an organic base material. <P>COPYRIGHT: (C)2011,JPO&INPIT

Description

  The present invention relates to a novel laminate. The laminate of the present invention has excellent performance in fire resistance, heat insulation and the like.

  Various materials having various performances such as fire resistance and heat insulation have been proposed as materials used for the wall surfaces of buildings. As an example of such a material, a material obtained by fixing rock wool with cement or the like is known. For example, Patent Document 1 (Japanese Patent Laid-Open No. 6-322856) describes a fireproof building material composed of a layer of rock wool granular cotton fixed on one side of a wood wool cement board with cement.

In Patent Document 1 and the like, in order to improve the heat insulation of the rock wool layer, it is necessary to set the ratio of rock wool to cement high. However, when the ratio of rock wool is increased, there is a problem that the strength is reduced.
In the rock wool layer having a reduced strength as described above, when an external force such as impact or vibration is applied, the layer is easily peeled off or dropped off. In other words, it is difficult to achieve both heat insulation and strength in the rock wool layer.

  Furthermore, the rock wool layer has a property of easily absorbing moisture. Due to such properties, in the rock wool layer, the strength of the layer itself is lowered, and the resistance to external forces such as impact and vibration may be insufficient. In addition, the adhesive strength at the interface between the rock wool layer and the base material is lowered, and there is a risk of causing the layer to fall off. In addition, heat insulation may be reduced due to moisture absorption. The problem caused by such moisture becomes more obvious as the ratio of rock wool to cement increases.

JP-A-6-322856

  The present invention has been made in view of the above-described problems, and an object of the present invention is to obtain a material having excellent performance in fire resistance, heat insulation, strength, and the like.

  In order to solve such a problem, the present inventors, as a result of intensive studies, have a laminate in which a fire-resistant heat insulating layer made of a cured body having a specific composition is laminated on a substrate selected from an inorganic substrate and an organic substrate. The present invention has been completed.

  That is, the present invention has the following characteristics.

1. On at least one surface of a substrate selected from an inorganic substrate and an organic substrate,
A refractory heat insulating layer made of a cured product of a composition containing 4 to 40 parts by weight of foamed organic resin particles, 5 to 300 parts by weight of inorganic light-weight particles, and 5 to 800 parts by weight of an endothermic substance is provided for 100 parts by weight of cement. A laminate characterized by being made.
2. On at least one surface of a substrate selected from an inorganic substrate and an organic substrate,
A refractory heat insulating layer comprising a cured product of a composition containing 4 to 40 parts by weight of foamed organic resin particles, 5 to 300 parts by weight of inorganic light-weight particles, and 5 to 800 parts by weight of an endothermic substance, relative to 100 parts by weight of cement;
An inorganic thin layer having a thickness of 0.05 to 1 mm,
The laminated body characterized by being provided in order.
3. On at least one surface of a substrate selected from an inorganic substrate and an organic substrate,
A composition containing 4 to 40 parts by weight of foamed organic resin particles, 5 to 300 parts by weight of inorganic light-weight particles, 5 to 800 parts by weight of an endothermic substance, and 200 to 1200 parts by weight of water is applied to 100 parts by weight of cement. A method for producing a laminate, characterized by being attached and cured.
4). On at least one surface of a substrate selected from an inorganic substrate and an organic substrate,
4 to 40 parts by weight of foamed organic resin particles, 5 to 300 parts by weight of inorganic light-weight particles, 5 to 800 parts by weight of endothermic material, 200 to 1200 parts by weight of water, and water-soluble metal salt with respect to 100 parts by weight of cement The manufacturing method of the laminated body characterized by apply | coating the composition containing 0.5-30 weight part and 0.5-30 weight part of water-soluble polymer compounds, and making it harden | cure.

  The laminate of the present invention can exhibit excellent performance in fire resistance, heat insulation, strength, and the like.

  Hereinafter, modes for carrying out the present invention will be described.

  The laminate of the present invention is a cured product of a composition comprising cement, foamed organic resin particles, inorganic light-weight particles, and an endothermic substance as essential components on at least one surface of a substrate selected from an inorganic substrate and an organic substrate. The fireproof heat insulation layer which consists of is provided.

  Of the components constituting the fireproof heat insulating layer, cement acts as a binder. Examples of cement include ordinary Portland cement, early-strength Portland cement, ultra-early-strength Portland cement, moderately hot Portland cement, sulfate-resistant Portland cement, white Portland cement, and other portland cements, as well as alumina cement, ultrafast cement, and expanded Cement, acid phosphate cement, silica cement, blast furnace cement, fly ash cement, keens cement and the like can be mentioned. These can be used alone or in combination of two or more. Among these, Portland cement is preferable. More specifically, at least one of ordinary Portland cement, early-strength Portland cement, ultra-early strong Portland cement, moderately hot Portland cement, sulfate-resistant Portland cement and white Portland cement is preferable.

As the foamed organic resin particles, those obtained by foaming an organic resin in a granular form, or those obtained by foaming an organic resin and then crushed into a granular form can be used. These have only to have pores in individual particles.
Examples of the foamed organic resin particles include known foamed organic resins such as foamed polystyrene, foamed polyurethane, foamed phenol, foamed polyethylene, foamed polypropylene, and foamed polyvinyl chloride, and one or more of these can be used. In the present invention, expanded polystyrene particles are particularly suitable.
The average particle diameter of the foamed organic resin particles is usually about 1 to 10 mm. Further, the bulk density of the foamed organic resin granular material is usually 0.08 g / cm ³ or less, preferably 0.03 g / cm ³ or less, more preferably 0.015 g / cm ³ or less.

  In the present invention, sufficient physical properties in fire resistance can be obtained by using the above-mentioned foamed organic resin particles that have been subjected to a flame-retarding treatment. As a method of such a flame retardant treatment, there are (1) a method of flame retardant treatment during the production of foamed organic resin particles, and (2) a method of flame retardant treatment after production of the foamed organic resin particles.

  Examples of the method for flame retardant treatment during the production of the foamed organic resin particles (1) include a method of adding a flame retardant. In this case, the flame retardant is added as a method of adding an organic resin during polymerization, for example, at the initial stage of suspension polymerization, or when a certain degree of polymerization conversion is reached. Examples include a method of adding a flame retardant, a method of adding a flame retardant at the time of extrusion, and the like.

Moreover, in said (1), the organic resin composition excellent in a flame retardance can be used, and an expanded organic resin particle can also be manufactured. For example, polyol, 4,4-diphenylmethane diisocyanate (MDI), and isocyanurate foam using a catalyst that nucleates the isocyanate moiety, and modified phenol foam using a resin in which a flame-retardant phenol resin is bound to the polyol. And foams using an organic resin obtained by polymerizing a monomer containing halogen. As the polyol, it is particularly preferable to use one selected from aromatic polyester polyols and aromatic polyether polyols (Mannich-modified polyether polyols and the like).
In the case of using such an organic resin excellent in flame retardancy, a flame retardant can be further added.

  Examples of the flame retardant include tricresyl phosphate, diphenyl cresyl phosphate, diphenyl octyl phosphate, tri (β-chloroethyl) phosphate, tributyl phosphate, tri (dichloropropyl) phosphate, triphenyl phosphate, triphenyl phosphate Organic phosphorus such as (dibromopropyl) phosphate, chlorophosphonate, bromophosphonate, diethyl-N, N-bis (2-hydroxyethyl) aminomethyl phosphate, di (polyoxyethylene) hydroxymethyl phosphonate Compounds: Chlorinated polyphenyl, chlorinated polyethylene, diphenyl chloride, triphenyl chloride, pentachloride fatty acid ester, perchloropentacyclodecane, chlorinated naphthalene, tetrachlorophthalic anhydride, etc. Bromine compounds such as tetrabromobisphenol A, decabromodiphenyl oxide, hexabromocyclododecane, tribromophenol, ethylenebistetrabromophthalimide, ethylenebispentabromodiphenyl: antimony compounds such as antimony trioxide and antimony pentachloride; Examples include phosphorus compounds such as phosphorus trichloride, phosphorus pentachloride, ammonium phosphate, and ammonium polyphosphate; inorganic compounds such as zinc borate, sodium borate, and aluminum hydroxide.

  Examples of the method for flame-retardant treatment after the production of the foamed organic resin particles (2) include flame retardants, alkoxysilane compounds, silicate compounds and the like (collectively referred to as “flame retardants”). Examples include a method of coating or adsorbing particles. Moreover, these flame retardant agents can be used alone or in combination of two or more.

As the flame retardant, those similar to the above (1) can be used.
The alkoxysilane compound is not limited. For example, tetramethoxysilane, tetraethoxysilane, methyltrimethoxysilane, methyltriethoxysilane, ethyltrimethoxysilane, ethyltriethoxysilane, dimethyldimethoxysilane, dimethyldiethoxysilane, diethyl Dimethoxysilane, diethyldiethoxysilane, etc. can be used.

  Moreover, as said silicate compound, commercially available water glass etc. can also be used besides sodium silicate, potassium silicate, lithium silicate, ammonium silicate, etc., for example.

  The flame retardant treatment agent may be dissolved or dispersed in water or other suitable solvent as necessary, and the solution or dispersion may be treated on the foamed organic resin by a method such as coating or adsorption. A binder such as an acrylic resin can be appropriately blended in the solution or dispersion. After the treatment with the above solution or dispersion, it may be dried or heat treated if necessary. The usage-amount of a flame-retardant processing agent can be suitably determined according to a desired flame retardance, the kind of the said foaming organic resin, etc.

  The ratio of the foamed organic resin particles is usually 4 to 40 parts by weight, preferably 5 to 35 parts by weight with respect to 100 parts by weight of cement. When there are too few foamed organic resin particles, heat insulation etc. become inadequate. When there are too many foamed organic resin particles, it becomes difficult to obtain sufficient physical properties in terms of fire resistance, strength, and the like.

  Inorganic light-weight particles are inorganic materials having pores in individual particles. Examples of such inorganic light-weight particles include perlite, expanded shale, vermiculite, expanded vermiculite, pumice, and shirasu balloon, and one or more of these can be used. The average particle diameter of the inorganic lightweight particles is usually about 0.1 to 5 mm.

  The ratio of the inorganic lightweight particles is usually 5 to 300 parts by weight, preferably 10 to 250 parts by weight with respect to 100 parts by weight of cement. When there are too few inorganic light-weight particles, it becomes difficult to obtain sufficient physical properties in fire resistance, heat insulation and the like. When there are too many inorganic lightweight particles, it becomes disadvantageous in terms of strength and the like.

The endothermic substance is a metal compound that releases water when heated. Such an endothermic substance generates water vapor during heating, and contributes to improvement of fire resistance performance by its endothermic action.
Examples of such endothermic substances include:
Metal hydroxides such as aluminum hydroxide, magnesium hydroxide, calcium hydroxide, barium hydroxide, strontium hydroxide, scandium hydroxide;
Metal borates such as borax (sodium tetraborate), disodium octaborate, zinc borate;
Zeolite, halloysite, allophane, ettringite and the like can be mentioned, and one or more of these can be used. As the endothermic substance, a metal hydroxide is particularly suitable.

  The ratio of the endothermic substance is usually 5 to 800 parts by weight, preferably 10 to 600 parts by weight, and more preferably 20 to 300 parts by weight with respect to 100 parts by weight of cement. When there is too little endothermic substance, fire resistance etc. become inadequate. When there are too many endothermic substances, it becomes difficult to obtain sufficient physical properties in terms of heat insulation and strength.

In the present invention, it is preferable to contain a water-soluble metal salt in addition to the above components. The water-soluble metal salt is preferably one that dissolves in water to produce a metal ion, and more preferably one that produces a divalent or higher polyvalent metal ion. Such a water-soluble metal salt facilitates the formation of an inorganic thin layer by interaction with a water-soluble polymer compound described later.
As such a water-soluble metal salt, for example,
Metal sulfates such as ammonium aluminum sulfate, sodium aluminum sulfate, aluminum sulfate, potassium aluminum sulfate, iron sulfate, potassium iron sulfate, magnesium sulfate, nickel sulfate, zinc sulfate, beryllium sulfate, zirconium sulfate;
Metal phosphates such as aluminum phosphate, cobalt phosphate, magnesium phosphate, magnesium ammonium phosphate, magnesium hydrogen phosphate, zinc phosphate, zinc dihydrogen phosphate;
Metal nitrates such as aluminum nitrate, zinc nitrate, calcium nitrate, cobalt nitrate, bismuth nitrate, zirconium nitrate, cerium nitrate, iron nitrate, iron nitrate, nickel nitrate, magnesium nitrate;
Metal acetates such as zinc acetate and cobalt acetate;
Metal chloride salts such as calcium chloride, aluminum chloride, cobalt chloride, iron chloride,
And one or more of these can be used.

  As said water-soluble metal salt, what dissolve | melts in water especially and produces | generates an aluminum salt is preferable, and aluminum sulfate is especially preferable.

  The ratio of the water-soluble metal salt is usually 0.5 to 30 parts by weight, preferably 1 to 25 parts by weight, and more preferably 2 to 20 parts by weight with respect to 100 parts by weight of cement. If it is this range, an inorganic thin layer will be efficiently formed by interaction with the below-mentioned water-soluble polymer compound, and fireproofness can be improved.

In the present invention, it is preferable to contain a water-soluble polymer compound in addition to the above components. By including the water-soluble polymer compound, an inorganic thin layer is easily formed.
As such a water-soluble polymer compound, for example,
Examples include polyvinyl alcohol, poly (meth) acrylic acid, polyalkylene oxide, biogum, galactomannan derivatives, alginic acid and derivatives thereof, gelatin, casein and albumen, derivatives thereof, and cellulose derivatives. The water-soluble polymer compound is more preferably a high-viscosity product. Specifically, the viscosity of a 1% aqueous solution of the water-soluble polymer compound (value measured at 20 ° C. using a B-type viscometer is shown below). ) Is usually 8000 mPa · s or more, preferably 10,000 mPa · s or more, more preferably 12000 mPa · s or more.

  The ratio of the water-soluble polymer compound is usually 0.5 to 30 parts by weight, preferably 0.8 to 15 parts by weight, and more preferably 1 to 10 parts by weight with respect to 100 parts by weight of cement. If it is this range, an inorganic thin layer will be efficiently formed by interaction with water-soluble metal salt, and fireproofness can be improved.

  In the present invention, by using a water-soluble metal salt and a water-soluble polymer compound in combination, an inorganic thin layer can be efficiently formed on the refractory heat-insulating layer when the composition of the present invention is cured. Can improve fire resistance. The action mechanism is not clear, but it is presumed that the water retention improvement effect by both components contributes.

  The inorganic thin layer is derived from the cement component and includes at least a Ca component and a Si component. The inorganic thin layer is formed by solidifying the cement component dispersed or dissolved in water in the surface layer of the refractory heat insulating layer in the curing stage of the refractory heat insulating layer. The thickness of the inorganic thin layer is preferably 0.05 to 1 mm, more preferably 0.08 to 0.5 mm, and still more preferably 0.1 to 0.4 mm.

  In the laminate of the present invention, a fireproof heat insulating layer made of a cured product of a composition containing the above components as essential components is provided on at least one surface of a substrate. This refractory heat insulating layer can be obtained by curing a composition containing each of the above components, which is appropriately kneaded by adding water or the like. Under the present circumstances, the said composition may contain a thickener, surfactant, a flame retardant, a water reducing agent, an antifoamer, resin, a fiber, etc. as needed.

  The ratio of water is usually 200 to 1200 parts by weight, more preferably 400 to 1000 parts by weight, and still more preferably 500 to 800 parts by weight with respect to 100 parts by weight of cement. By adding water in this range, an inorganic thin layer can be efficiently formed on the fireproof heat insulating layer.

The base material should just be what can fix the said fireproof heat insulation layer. As the substrate, an inorganic substrate and / or an organic substrate can be used.
Examples of the inorganic base material include mortar, concrete, calcium silicate board, gypsum board, calcium carbonate foam board, incombustible volcanic glassy multilayer board, fiber reinforced cement board, lightweight cement board and the like. In addition, examples of the inorganic base material include a fibrous sheet containing inorganic fibers. Examples of the inorganic fiber include rock wool, glass fiber, silica fiber, silica-alumina fiber, carbon fiber, and silicon carbide fiber. In addition, a metal plate is not included in the inorganic base material in this invention.
Examples of the organic base material include plastic, rubber, paper, etc., an organic resin foam, a fibrous sheet containing organic fibers, and the like. Among these, as the organic resin foam, for example, polystyrene foam, polyethylene foam, polypropylene foam, vinyl chloride foam, viscose sponge, rubber foam, EVA foam, ABS foam, polyamide foam, acrylic foam, urethane foam, phenol foam, Examples include urea foam, silicon foam, and epoxy foam.

The fireproof heat insulating layer can be formed by spraying the composition on at least one surface of the substrate and applying the composition by various means such as troweling and curing. The application and curing of the composition may be performed before or after the base material is installed in the building.
Moreover, a fireproof heat insulation layer can also be provided through various undercoat layers.

The laminate of the present invention can be produced by the following method.
(1) On at least one surface of the substrate,
A composition containing 4 to 40 parts by weight of foamed organic resin particles, 5 to 300 parts by weight of inorganic light-weight particles, 5 to 800 parts by weight of an endothermic substance, and 200 to 1200 parts by weight of water is applied to 100 parts by weight of cement. Apply and cure.
(2) On at least one surface of the substrate,
4 to 40 parts by weight of foamed organic resin particles, 5 to 300 parts by weight of inorganic light-weight particles, 5 to 800 parts by weight of endothermic material, 200 to 1200 parts by weight of water, and water-soluble metal salt with respect to 100 parts by weight of cement A composition containing 0.5 to 30 parts by weight and 0.5 to 30 parts by weight of a water-soluble polymer compound is applied and cured.
In the present invention, the method (2) is particularly preferable. According to such a method, a laminate is obtained in which a refractory heat insulating layer having a thickness of 5 to 100 mm is provided on a base material, and an inorganic thin layer having a thickness of 0.05 to 1 mm is further formed thereon. Cheap. The thickness of the refractory heat insulating layer is usually 5 to 100 mm, preferably 10 to 50 mm. If it is this range, it has the outstanding performance in fire resistance, heat insulation, etc.

  Examples are given below to clarify the features of the present invention.

The following were used as raw materials.
・ Cement: Portland cement, bulk specific gravity 1.2
-Foamed organic resin particles A: Styrofoam particles, average particle diameter 3 mm, bulk specific gravity 0.014
-Foamed organic resin particles B: a mixture of a lithium silicate solution and an acrylic styrene emulsion with respect to 100 parts by weight of the foamed organic resin particles A (lithium silicate solution (solid content 23 wt%): acrylic styrene emulsion (solid content 50 wt%) = 9: 1 (weight ratio)) 60 parts by weight added and mixed, then dried at 50 ° C. for 24 hours. Inorganic lightweight particles: granite, average particle diameter of 1 mm, bulk specific gravity of 0.12.
Endothermic substance: Aluminum hydroxide, bulk specific gravity 1.2
Water-soluble metal salt: Aluminum sulfate Water-soluble polymer compound: Methyl cellulose (1% aqueous solution has a viscosity of 15000 mPa · s)

Example 1
610 parts by weight of water was added to a composition in which 21 parts by weight of foamed organic resin particles A, 140 parts by weight of inorganic light-weight particles, 9 parts by weight of an endothermic substance, and 5 parts by weight of a water-soluble polymer compound were uniformly mixed with 100 parts by weight of cement. In addition, kneading.
The kneaded material was cured at room temperature, cut into a length of 8 cm, a width of 14 cm, and a thickness of 4 cm, and the density and thermal conductivity of the cured product were measured. The thermal conductivity was measured using a thermal conductivity meter “Kemthrm QTM-D3” (manufactured by Kyoto Electronics Industry).

Further, the kneaded product was applied to one surface of a fiber reinforced cement board so that the dry thickness was 35 mm, to prepare a test body, and the following tests were performed.
(Heating test A)
A heater at 600 ° C. was installed on the fiber reinforced cement plate side of the test body and heated for 10 minutes, and then the temperature on the cured body side of the test body was measured. The test results are shown in Table 1. The evaluation was performed in five stages, with “A” being the lowest temperature region and “E” being the highest temperature region.

(Examples 2-16, Comparative Examples 1-2)
A cured body and a test body were prepared in the same manner as in Example 1 with the formulations shown in Tables 1 and 2, and the same test was performed. The results are shown in Tables 1-2.

Furthermore, the heating test B was done about Examples 3-5 and 7-9.
(Heating test B)
The total calorific value after irradiating 50 kW / m < ² > of radiant heat for 20 minutes was measured with the radiant electric heater with respect to the hardening body side of the test body. The results are shown in Table 3.

Claims (2)

On at least one surface of a substrate selected from an inorganic substrate and an organic substrate,
A refractory heat insulating layer made of a cured product of a composition containing 4 to 40 parts by weight of foamed organic resin particles, 5 to 300 parts by weight of inorganic light-weight particles, and 5 to 800 parts by weight of an endothermic substance is provided for 100 parts by weight of cement. A laminate characterized by being made. On at least one surface of a substrate selected from an inorganic substrate and an organic substrate,
A refractory heat insulating layer comprising a cured product of a composition containing 4 to 40 parts by weight of foamed organic resin particles, 5 to 300 parts by weight of inorganic light-weight particles, and 5 to 800 parts by weight of an endothermic substance, relative to 100 parts by weight of cement;
An inorganic thin layer having a thickness of 0.05 to 1 mm,
The laminated body characterized by being provided in order.