JP2013011076A - Article or component containing cured body of self-curable powder - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a fireproof sash material, a fireproof sash frame, or a fireproof window, which maintains strength when heated to high temperature due to fire so as to prevent a glass pane from falling off, allows infilled material not to leak out resulting from erroneous boring or minimal damage, and has sufficient strength for normal use without metal reinforcement, with high productivity.SOLUTION: A fireproof material 16 is made from self-curable powder which is produced from a mixture of 100 pts.mass of an aggregate powder of inorganic hollow particles, 2 to 17 pts.mass of a binder composition of alkaline aqueous solution or dispersion liquid of water soluble phenol resin with a solid content of the water soluble phenol resin of 10 to 60 mass%, and a curing agent with the amount necessary for curing the water soluble phenol resin contained in the binder composition. The cavity part 11 of a sash material or a sash frame 4 is filled with the fireproof material 16, which is cured at normal temperature so that the cured body is used as a heat-resistant component and also as a reinforcement.

Description

The present invention relates to a self-curing powder that provides a cured product useful as a fire-resistant or fire-resistant heat insulating member, and further relates to an article or member containing the cured product. More specifically, the present invention relates to a fireproof sash material, a sash frame, and a fireproof window including the cured body as a heat resistant member.
In the present specification, “sash material” is a generic term for frame material, eaves material, and frame material, and “sash frame” refers to a sash frame as well as a so-called sash frame. Similarly, “frame” includes “框”.

  Conventionally, instead of an aluminum sash whose body is made of aluminum, a resin sash having excellent heat insulation and soundproofing properties has been widely used mainly in cold regions. Since this resin sash is excellent in heat insulation properties, it is difficult to condense and can improve the comfortability.

  However, since the resin sash has low fireproof performance, there is a problem that the resin sash cannot be used for fireproof doors or windows in fireproof areas or semi-fireproof areas, and methods for imparting fireproof properties have been studied. As a method for improving fire resistance, a method of filling a heat-resistant material in a hollow portion (hollow portion) of a resin sash is known (see Patent Document 1). For example, in the method described in Patent Document 1, a substantially U-shaped metal member is thermally expanded in a cavity of a synthetic resin shape member having a cavity along the longitudinal direction used as a general resin sash that is not fireproof. Fire resistance is imparted by inserting a sheet made of a heat-resistant refractory material into an L-shape and integrating them.

  By the way, in the fireproof window, it is of course important that the sash material itself is required to have fireproof property, but it is also important that the glass or the shoji integrated with the glass is not easily dropped during a fire. As a method for preventing the falling of glass and shoji, the metal stiffeners are provided on the upper and lower armpits of the resin shoji, and the left and right vertical scissors, respectively, and the vertical and horizontal metal stiffeners adjacent to each other at the corner portion are provided. Connected with corner metal fittings to connect the metal reinforcements for four rounds, attach the metal fittings to the metal reinforcements provided on the upper frame of the resin window frame, and support them on the metal reinforcements provided on the upper arm of the resin shoji There is known a method of attaching a metal fitting and suspending and supporting the resinous shoji with a support metal fitting and a receiving metal fitting when the resin shoji is closed and the heel of the resin shoji is softened or burned out. (See Patent Document 2).

  In addition, as a fire-proof resin sash that does not cause harmful deformation due to a load during heating, a resin composition sash filled with a cement composition having a specific composition (Patent Document 3), or heat-resistant inorganic particles A particulate or powder heat-resistant composition containing a high-temperature binder that functions as a binder for the heat-resistant inorganic particles when heated to a temperature of 100 ° C. to 800 ° C. What filled the part (patent document 4) is known.

Japanese Patent Laid-Open No. 2005-9304 Japanese Patent No. 4229286 Japanese Patent No. 2774897 JP 2010-270466 A

  The sash material described in Patent Document 1 not only functions as a fire sash, but is excellent in that it can be easily manufactured using a general resin sash material that is not fire proof. However, the heat-expandable refractory material used in the resin sash material has a strength enough to be self-supporting even after expansion, but its strength is not so high. In this case, when the area of the glass to be used is increased or the thickness is increased, the heated sash frame is deformed by the weight, and the glass may fall off. Such a phenomenon can be prevented to some extent by using a metal member having a function as a reinforcing material, but the effect is limited. That is, a gap is often provided between the metal member and the sash material from the viewpoint of ease of insertion of the metal member, and even if a thermally expandable refractory material is disposed in this gap, it is caused by the weight of the glass. The metal member may be tilted by force, and the glass may fall off. In addition, when there are a plurality of cavities in the sash material, it is difficult to insert metal members into all the cavities from the viewpoint of cost and labor, so when there is a cavity into which no metal member is inserted, The glass may fall off due to the deformation of the cavity.

  On the other hand, in the method described in Patent Document 2, not only processing of a resin shape is required to directly screw-fix various metal members (for example, reinforcing material, corner metal fitting, support metal fitting), Since the support bracket is exposed to the outside, there is a problem that there is a concern about failure due to corrosion or deformation due to external force.

  Moreover, although the fireproof resin sash material described in the said patent document 3 was excellent in performance itself, there was a problem in productivity. That is, the cement composition is in a liquid state before being hardened and is not only difficult to handle, but also takes a long time to harden, so when filling the cavity of a sash material, of course, until the cement composition hardens even after filling. There was a problem in terms of productivity because it was necessary to leave the product with care for a long time so as not to cause leakage or spillage.

  The fireproof resin sash material described in Patent Document 4 exhibits excellent performance during a fire. Further, since the powder composition is heated and cured in the event of a fire to give a high-strength cured body, there is no need for special metal reinforcement for imparting fire resistance, and the hollow sash body is not fireproof, for example. There is an advantage that a general resin hollow sash material can be used as it is. However, for example, “a powder composition comprising an aggregate of particles coated with a high-temperature binder made of a thermosetting resin in which inorganic hollow particles are combined with a novolak resin and a curing agent thereof (for example, hexamethylenetetramine)” is heat resistant. When used as a composition, since the powder composition does not cure at room temperature, the fireproof resin sash material is used to form a sash frame or window, and when it is installed in a building, a screw hole is accidentally formed. In the case where a slight breakage (for example, a small breakage that can be repaired by putty, etc.) that does not cause a practical problem as a sash material has occurred, etc., the filled powder composition Things sometimes leaked out. In addition, since the above powder composition does not exert a reinforcing effect during normal use (other than during a fire), in order to ensure the strength during normal use, the interior of the cavity is the same as a general resin hollow sash material. It was necessary to insert a metal reinforcement into the.

  Therefore, the present invention is not only characterized by having fireproof properties and maintaining strength when heated to a high temperature due to a fire or the like, and is not likely to drop out of the glass. Another object of the present invention is to provide a fireproof sash material, a fireproof sash frame, or a fireproof window that can prevent the filler from leaking out, reduce the number of metal reinforcing materials, and is excellent in productivity.

  Furthermore, the present invention provides a raw material for a heat-resistant member that can be suitably used for the fireproof sash material and the like, and also provides a method for efficiently producing the fireproof sash material and the like using the raw material. Objective.

  In the technique disclosed in Patent Document 4, the present inventor coated inorganic hollow particles with a resol resin disclosed as a high-temperature binder (more specifically, a thermosetting resin that is one embodiment thereof). When using the composition as a heat-resistant composition, paying attention to the fact that it can be cured at room temperature without heating to a predetermined temperature, and if the curing time can be sufficiently shortened within the range where the filling operation can be performed, I thought that the problem could be solved.

  In the field of mold production, a composition in which a water-soluble phenol resin is used as a binder and is cured with an organic ester is known as a binder composition used in an organic self-curing mold making method. (For example, refer to JP-A-5-192737). However, it is known that the molding sand using the composition has poor fluidity and filling property to a model and the like. It has been unclear whether or not those using inorganic hollow particles can be filled into a hollow portion having a complicated shape such as a resin hollow sash material. For example, when mold sand is filled into a casting frame by a pneumatic transportation method, it is necessary to use a special device called a sand magazine, and it is unclear whether general pneumatic transportation can be applied to the transportation of these powders. Met.

  As a result of various studies conducted by the present inventors under such a background, a basic aqueous solution containing a water-soluble phenol resin as a specific solid content concentration was used as a resol resin, and this was used as an inorganic hollow at a specific quantitative ratio. Powder obtained by adding to and mixing with particles can be filled into cavities by pumping, and after curing, self-cure at room temperature relatively quickly to give a cured product with excellent strength and heat insulation. As a result, the present invention has been completed.

  That is, this invention is shown to following [1]-[11].

  [1] A binder composition comprising 100 parts by mass of a powder composed of an aggregate of inorganic hollow particles and an aqueous alkaline solution or dispersion of a water-soluble phenol resin having a solid content concentration of 10 to 60% by mass of the water-soluble phenol resin. A self-curing powder obtained by mixing 2 to 17 parts by mass of a product and a necessary amount of a curing agent to cure the water-soluble phenol resin contained in the binder composition.

  [2] 20 g of self-curing powder was put into a funnel having a sieve angle of 3600 times / minute, a sieve vibration width of 0.5 to 0.8 mm and a funnel angle of 60 ° and a narrow-bore diameter of 4.7 mm. The self-curing powder as described in [1] above, wherein the funnel passage speed is 0.1 g / min or more.

  [3] The self-curing powder according to [1] or [2], wherein the amount of the curing agent used is 10 to 200 parts by mass with respect to 100 parts by mass of the binder composition. .

  [4] The self-curable powder according to any one of [1] to [3], wherein the curing agent is an organic ester.

  [5] As the powder, the content ratio of particles having a particle diameter of 200 μm or less is 30% by mass or less, the content ratio of particles having a particle diameter in the range of 300 μm or more and 500 μm or less is 30% by mass or more, The self-hardening powder according to any one of [1] to [4], wherein a powder having a particle size distribution in which the content ratio of particles having a particle diameter of 600 μm or more is 20% by mass or less is used. body.

  [6] An article or member having a cavity inside, the article or member being filled with the cured product of the self-curable powder according to any one of [1] to [5] Element.

  [7] A sash body comprising a hollow sash body having a cavity along the longitudinal direction, and a heat-resistant member filled in the cavity, wherein the heat-resistant member is the above [ [1] A fireproof sash material comprising a cured product of the self-curable powder according to any one of [5].

  [8] A fireproof window in which a shoji having upper, lower, left, and right hooks is mounted in a frame having an upper frame, a lower frame, and left and right vertical frames each formed of a fireproof sash material, and at least the lower frame Is composed of the fire-resistant sash material according to [7] above.

  [9] The fireproof window according to [8] above, wherein at least the lower arm of the shoji is composed of the fireproof sash material according to [7].

  [10] The self-curing powder cured body according to any one of claims 1 to 5 is filled in the hollow portion of a sash frame having a hollow portion along the longitudinal direction. And sash frame.

  [11] The sash frame made of a sash frame having a cavity portion along the longitudinal direction communicates with the cavity portion on the inner peripheral surface of one end portion in the left-right direction of the upper frame or the inner peripheral surface of the upper end portion of the side frame. A filling port is provided, a first cylindrical jig is inserted into the filling port, and the self-curing powder according to any one of [1] to [5] is inserted through the first cylindrical jig. The cavity is communicated to the outside on the inner peripheral surface of the end portion of the lower frame or the inner peripheral surface of the lower end portion of the side frame, which is pumped into the hollow portion and positioned in a substantially diagonal relationship with respect to the filling port. An exhaust port is provided, a second cylindrical jig is inserted into the exhaust port, and the air in the cavity can be exhausted to the outside via the second cylindrical jig, and the self-exhaust in the cavity. A filling step of filling the curable powder, and a step of hardening the self-curing powder filled in the filling step. Method for producing a sash frame according to the above [10] to.

  The self-curing powder of the present invention shown in the above [1] to [5] is, for example, a mixer in which a predetermined amount of the binder composition and a curing agent are added to a powder composed of an aggregate of inorganic hollow particles. Can be prepared by kneading. The self-curing powder of the present invention thus obtained has a property of naturally curing at room temperature, but has a powder fluidity that can be pumped without being cured for a while after preparation. For this reason, it has the feature that it can be easily filled in "a member or article having a hollow inside" such as a hollow sash material, a frame body framed by the frame, and a shoji. Furthermore, since the self-curing powder of the present invention is self-curing at room temperature in a relatively short time after filling, even if a member or article to be filled is perforated or extremely lightly damaged, The filling will not leak out.

In addition, the cured product obtained by naturally curing the self-curing powder of the present invention has excellent strength and heat insulation, so that it not only functions as a fireproof material in the event of a fire, but also as a reinforcing material during normal use. Also works. Therefore, the article or member of the present invention shown in the above [6] has excellent fire resistance, and the use of a reinforcing material that has been conventionally required can be omitted.
For example, the fireproof sash material of the present invention shown in the above [7], which is an aspect of the member of the present invention, is compared with the conventional fireproof sash material described in Patent Document 4 as follows. Have the advantages. That is, in the above conventional fireproof sash material, when a general resin sash material is used as the sash material body, it is necessary to use a metal reinforcing member to ensure flameproofness and strength. On the other hand, in the sash material of the invention, the required strength can be ensured without using such a metal reinforcing member, and fire resistance performance equivalent to or higher than that of the conventional fireproof sash material can be realized. .
In addition, the cured body filled in the cavity of the fire-resistant sash material of the invention has water permeability, and organic components are hardly eluted even when contacted with water. Therefore, the sash material is used. In the fireproof window of the present invention shown in the above [8] and [9] and the sash frame of the present invention shown in the above [10], water inevitably infiltrated from a gap such as a screw part is discharged during a typhoon or the like. Therefore, it is possible to secure a flow path.

  Furthermore, according to the method of the present invention shown in [11], the first cylindrical jig is inserted into the filling port provided at a specific position, and the fireproof material is pumped into the cavity of the sash material. By discharging the air in the cavity through the second cylindrical jig from the exhaust port provided at a position having a specific relationship with the position where the first cylindrical jig is inserted, Since the self-curing powder of the present invention can be filled easily, the efficiency of the filling operation is improved, the filling is performed as uniformly as possible, and the filling rate can be greatly increased. As a result, the fireproof performance can be further improved. For this reason, the method of the present invention is suitable as a fireproof repair method in which a prefabricated window frame that is still attached to the opening of a building frame has a fireproof structure.

It is a perspective view which partially fractures and shows the fire prevention window after filling the self-hardening powder of this invention in the cavity part of a sash frame by the method of this invention, and carrying out fireproof repair. It is a principal part expanded horizontal sectional view of the II-II line in FIG. It is a figure which shows roughly one Embodiment in the case of filling the self-hardening powder of this invention in the cavity part of the sash material which comprises a sash frame using a filling apparatus. FIG. 4 is an enlarged vertical cross-sectional view of a main part of a circle A in FIG. 3. It is a perspective view of the 1st cylindrical jig. FIG. 6 is a cross-sectional view taken along line VI-VI in FIG. 5. It is a principal part expanded horizontal sectional view of the circle | round | yen B in FIG. It is a perspective view of the 2nd cylindrical jig. It is the IX-IX sectional view taken on the line of FIG. It is a perspective view of a sealing member. Similarly, it is a disassembled perspective view of a sealing member. It is a figure which shows schematically other embodiment at the time of filling the self-hardening powder of this invention in the cavity part of the sash material which comprises a sash frame by the method of this invention. It is a perspective view which shows other embodiment of a 1st cylindrical jig | tool. It is the XIV-XIV sectional view taken on the line of FIG. It is a schematic diagram of the test apparatus of funnel passage speed.

1. Self-hardening powder of the present invention The self-hardening powder of the present invention comprises 100 parts by weight of a powder composed of an aggregate of inorganic hollow particles and a water-soluble phenolic resin having a solid content concentration of 10 to 60% by weight. 2-17 parts by mass of a binder composition comprising an alkaline aqueous solution or dispersion of a water-soluble phenol resin and a curing agent in an amount necessary for curing the water-soluble phenol resin contained in the binder composition. It is characterized by being obtained. Hereinafter, a raw material and a manufacturing method are demonstrated about the self-hardening powder of this invention.

(Powder made of aggregate of inorganic hollow particles)
The inorganic hollow particles constituting the powder used as the raw material of the inorganic hollow particles are 800 ° C, preferably any hollow particles or powder made of an inorganic substance that does not soften or melt even when heated to 900 ° C. Examples thereof include glass balloons, shirasu balloons, coal ash balloons (fly ash balloons), ceramic balloons, and the like. Only one kind of these inorganic hollow particles may be used, or a plurality of different kinds may be used in combination. Self-curing powder uses inorganic hollow particles to reduce the weight of the powder and improve fluidity. Smoother supply to the cavity by pressure feeding than non-hollow particles makes it more reliable and uniform. Filling can be performed.

The particle size distribution of the powder is not particularly limited, but when the self-curing powder of the present invention is used, the particle size distribution in the sash frame made of a sash material having a cavity along the longitudinal direction is used. It is preferable to control the particle size distribution in view of the filling property when filling into the container. For example, the method of the present invention is used to pump into the hollow portion of the sash frame made of a sash frame having a hollow portion along the longitudinal direction, such as an existing window frame that is still attached to the opening of the building frame. In the case of filling, it is preferable to have the following particle size distribution because it is easy to close-pack and hardly generate voids due to its own weight or vibration after filling.
That is, the content ratio of particles having a particle diameter of 200 μm or less is 30% by mass or less, the content ratio of particles having a particle diameter in the range of 300 μm or more and 500 μm or less is 30% by mass or more, and the particle diameter is 600 μm or more. It is preferable to have a particle size distribution in which the content ratio of certain particles is 20% by mass or less, the content ratio of particles having a particle size of 200 μm or less is 20% by mass or less, particularly 1 to 20% by mass, and the particle size is 300 μm. The content ratio of particles in the range of 500 μm or less is 40% by mass or more, particularly 40 to 90% by mass, and the content ratio of particles having a particle diameter of 600 μm or more is 10% by mass or less, particularly 5 to 10% by mass. It is particularly preferred that the remainder have a particle size distribution such that the particle size is greater than 500 μm and less than 600 μm. The particle size distribution is based on the result of particle size measurement by a dry screening test method (JIS K0069).
When the powder used as a raw material has such a particle size distribution, it can be mixed with a binder composition and a curing agent to achieve good filling properties even as the self-curable powder of the present invention. .

(Binder composition)
The binder composition is a composition in which the water-soluble phenol resin contained therein is polymerized by the action of a curing agent to bind the inorganic hollow particles to each other, from an aqueous alkali solution or dispersion of the water-soluble phenol resin. Become.
In the present invention, when the self-curing powder is prepared for use with the powder, the powder fluidity that can be pumped within a certain period of time immediately after the preparation is maintained, and is moderate at room temperature or room temperature. The binder composition in which the solid content concentration of the water-soluble phenol resin is 10 to 60% by mass with respect to 100 parts by mass of the powder is 2 for the reason that it cures in a short time and gives a cured product with high strength. It is necessary to use ~ 17 parts by mass. When satisfying such conditions, the powder fluidity can be pneumatically transported (pressed) into the elongated space, and the work grace time at room temperature (for example, 10 to 30 ° C.) is 3 minutes to It can be controlled within one hour. In order to obtain a self-curing powder having more preferable powder characteristics from the viewpoint of the strength of the cured product, the solid content concentration of the water-soluble phenol resin in the binder composition is 30 to 50% by mass. Preferably, the amount of the binder composition used is 4 to 10 parts by mass with respect to 100 parts by mass of the powder.
The solid content concentration of the water-soluble phenol resin is determined based on the sample mass before and after drying after measuring the mass after drying the sample weighed in advance in an air circulation furnace at 100 ° C. for 3 hours. Is.

  The water-soluble phenol resin contained in the binder composition means a resin obtained by reacting phenols with a stoichiometric excess of aldehydes in the presence of a basic catalyst. It is called resol type. In the present invention, the water-soluble phenol resin contains 0.1 to 1.2 equivalents of an alkali metal with respect to 1 equivalent of the phenolic hydroxyl group, from the viewpoint that it can easily undergo a self-curing reaction with a curing agent such as an organic ester. It is preferable to use an alkali phenol resin. When such an alkali phenol resin is used, the alkali phenol resin is neutralized by the acid derived from the curing agent and further polymerized, thereby further enhancing the action of bonding the inorganic hollow particles.

Phenols that can be used as raw materials for water-soluble phenol resins include phenol, cresol, resorcinol, 3,5-xylenol, bisphenol A, other substituted phenols, and mixtures thereof, but are water-soluble and relatively inexpensive. For this reason, it is preferable to use phenol.
As aldehydes, formaldehyde, acetaldehyde, furfural aldehyde and a mixture thereof can be used, but it is preferable to use formaldehyde. The amount of the aldehyde used may be an amount more than that required for the stoichiometric reaction with the phenol compound, but 1.2 to 2.5 mol may be used with respect to 1 mol of the phenol. preferable.
As the basic catalyst, alkali metal hydroxides such as sodium hydroxide, potassium hydroxide and lithium hydroxide can be used. The usage-amount of a basic catalyst is 0.1-1 mol normally with respect to 1 mol of phenols. When using organic ester as a hardening | curing agent, 0.4-1 mol is preferable.
The synthesis of the water-soluble phenol resin can be performed as follows. That is, first, a predetermined amount of phenols and aldehydes are mixed with water under heating to prepare a uniform mixed solution. Thereafter, after cooling, a predetermined amount of a basic catalyst is gradually added dropwise to the mixed solution in the form of an aqueous solution with stirring. After completion of the dropwise addition, the temperature of the mixed solution is gradually raised, and the reaction may be performed under reflux until the reaction solution reaches a predetermined viscosity.

  After completion of the reaction, an alkaline aqueous solution may be added as necessary to adjust the alkalinity of the water-soluble phenol, or water may be added to adjust the solid content concentration to obtain a binder composition. it can.

  In the binder composition, a strength-enhancing agent for a cured product composed of a formaldehyde supplement such as urea and / or a silane coupling agent such as γ-aminopropyltriethoxysilane is added to 100 parts by weight of the binder composition. On the other hand, it is preferable to add 0.5-5 mass parts and 0.05-1 mass parts, respectively.

(Curing agent)
The curing agent means a substance having a function of acting on a water-soluble phenol resin and naturally curing them at room temperature or room temperature (for example, 10 to 30 ° C.). For example, an acid or an organic ester can be used. Examples of the acid include sulfonic acids such as sulfuric acid, xylene sulfonic acid, and toluene sulfonic acid, and phosphoric acid. Examples of organic esters include methyl formate, ethyl formate, ethyl acetate, ethyl lactate, methyl sebacate, ethylene glycol diacetate, diacetin, triacetin, dimethyl succinate, dimethyl adipate, dimethyl glutarate, and a mixture of dibasic acid methyl esters. Or lactones such as γ-butyrolactone, γ-caprolactone, δ-valerolactone, δ-caprolactone, β-propiolactone, ε-caprolactone, or ethylene carbonate, propylene carbonate, 4-ethyldi Examples thereof include cyclic silalkylene carbonates (organic carbonates) such as oxolone, 4-butyldioxolone, 4,4-dimethyldioxolone, and 4,5-dimethyldioxolone. Among these curing agents, dibasic acid esters having a relatively slow hydrolysis rate are preferable from the viewpoint of workability.

  The use amount of the curing agent may be appropriately determined in consideration of the work grace time at room temperature, powder fluidity and strength, and more specifically, the viewpoint that the work grace time at room temperature can be controlled to 3 minutes to 1 hour. From 10 to 200 parts by weight, particularly 15 to 100 parts by weight, based on 100 parts by weight of the water-soluble phenol resin. 10 parts by mass or more is desirable for the reason of completely curing the water-soluble phenolic resin, and 200 parts by mass or less is desirable for the reason of causing inhibition of curing and reducing the strength. In particular, the content of the curing agent is such that the amount of the water-soluble phenol resin added in the range of 2 to 6 parts by mass with respect to 100 parts by mass of the inorganic hollow particles may include a larger amount of the curing agent. 10-200 mass parts is preferable with respect to a part. Moreover, when the addition amount of water-soluble phenol resin becomes more than 6 mass parts, it is better to suppress a hardening | curing agent to below the quantity of water-soluble phenol resin, and 10-100 mass parts is preferable with respect to 100 mass parts of water-soluble phenol resins. At this time, the total amount of the water-soluble phenol resin and the curing agent is desirably 2 to 30 parts by mass with respect to 100 parts by mass of the inorganic hollow particles.

2. Production method of self-curing powder of the present invention The self-curing powder of the present invention can be suitably produced by the following method. That is, while stirring the inorganic hollow particles with a stirrer such as a mixer, a binder composition to which a curing agent and, if necessary, a formaldehyde supplement and / or a strength enhancer are added in advance is easily put into a stirrer. Can be manufactured.

3. Use of self-curing powder of the present invention The self-curing powder of the present invention is naturally cured at room temperature to give a cured product having excellent strength and heat insulation. The cured body not only functions as a flame barrier during a fire, but also functions as a reinforcing material. Therefore, an article or member (the article or member of the present invention) in which the cured product of the self-curing powder of the present invention is filled in the cavity of the article or member having a cavity inside has excellent fire resistance. In addition, it is possible to omit the use of a reinforcing material that has been conventionally required.

  For example, it is a fireproof sash material comprising a sash body comprising a hollow shape member having a cavity along the longitudinal direction and a heat-resistant member filled in the cavity, which is an embodiment of the member of the present invention. "The fireproof sash material in which the heat-resistant member is made of a cured body of the self-curing powder of the present invention" (the fireproof sash material of the present invention) is described in Patent Document 4. Compared to such a conventional fireproof sash material, it has the following advantages. That is, in the above conventional fireproof sash material, when a general resin sash material is used as the sash material body, it is necessary to use a metal reinforcing member to ensure flameproofness and strength. On the other hand, the fireproof sash material of the invention can ensure the required strength without using such a metal reinforcing member, and can realize the fireproof performance equivalent to the conventional fireproof sash material. it can. At this time, the cured body filled in the cavity of the fireproof sash material of the present invention has water permeability, and even when it comes into contact with water, organic components are hardly eluted, so the sash material is used. In the fireproof window of the present invention configured as described above and the sash frame of the present invention, it is possible to secure a flow path for discharging water inevitably infiltrated from the sealing portion with glass during a typhoon or the like. Of course, these fireproof windows and sash frames of the present invention have the above-mentioned features of the fireproof sash material of the present invention.

  Furthermore, according to the method of the present invention described in detail below, the first cylindrical jig is inserted into the filling port provided at a specific position, and the fireproof material is pumped into the cavity of the sash material, By discharging the air in the cavity through the second cylindrical jig from the exhaust port provided at a position having a specific relationship with the position where the first cylindrical jig is inserted, fire prevention is provided in the cavity. Since the material can be easily filled, the efficiency of the filling operation is improved, the filling material is filled as uniformly as possible, and the filling rate can be greatly increased. As a result, the fireproof performance can be further improved. For this reason, the method of the present invention is a fireproof repair method (such a fireproof repair method using the method of the present invention) that makes an existing window frame that is still attached to the opening of a building frame to have a fireproof structure. Is referred to as “the present construction method”).

  Hereinafter, embodiments of the sash frame and the construction method of the present invention will be described in detail with reference to the drawings, but the present invention is not limited to these specific embodiments. For example, even if the article or member other than the sash material has a cavity inside, and the self-curable powder of the present invention is filled in the cavity and self-cured, the present invention As in the case of the sash material, it is possible to obtain performance improvement effects such as heat resistance, fire resistance, heat insulation, and reinforcement effect. Among the articles or members of the present invention, those excluding the fireproof sash material of the present invention, the fireproof window of the present invention and the sash frame of the present invention include doors, entrance doors, heat insulation boards, eaves materials, walls, etc. be able to.

4). Hereinafter, the sash frame of the present invention will be described with reference to the drawings.
FIG. 1 is a perspective view showing a partially broken fire-proof window after a fire-resistant material is filled in a cavity portion of a sash frame using a filling device, and after the fire-proof repair, and FIG. It is a principal part expanded horizontal sectional view of II line.
In the illustrated embodiment, in FIG. 2, the left side is described as “indoor side” and the right side is described as “outdoor side”.

As shown in FIGS. 1 and 2, a fireproof window after fireproof repair using a filling device to be described later, for example, a multi-layer glass window 1, is synthesized in an opening 3 provided in a building housing 2 such as a house or office. The resin sash frame 4 is assembled, and the multilayer glass W is fitted on the inner peripheral surface 4a of the sash frame 4 so as to be mounted in a killed state.
The sash frame 4 is constructed by assembling a synthetic resin sash material 5 made of a hollow shape material with a slightly rectangular cross section constituting the upper frame 4A, the lower frame 4B, and the left and right side frames 4C. Yes.
Moreover, as a hollow shape material which comprises the sash material 5, resin which mix | blended the cellulose fine powder prepared from the pulverized material of wood with vinyl chloride resin as disclosed by Unexamined-Japanese-Patent No. 9-137675, for example A member formed of the composition, a member whose surface is covered with a transparent or colored acrylic resin, as disclosed in JP-A No. 2000-303743, and the like are appropriately used.

In addition, although this construction method can be suitably used for the sash frame 4 made of a synthetic resin as described above, a sash frame using a sash material made of aluminum or an aluminum alloy made of a hollow material or an aluminum or aluminum alloy and a resin are used. The same applies to a so-called aluminum resin composite sash material used in combination.
On the inner peripheral surface 4 a of the sash frame 4, as shown in an enlarged view in FIG. 2, the sash member 5 and a protrusion protruded toward the inside of the indoor inner peripheral edge of the sash member 5. An inner circumferential groove portion 9 is formed that is surrounded by a portion 6 and a pressing member (pressing edge) 8 attached to an attachment concave portion 7 formed at an inner peripheral edge on the outdoor side of the sash member 5.
The inner peripheral groove 9 holds the outer peripheral end of the multilayer glass W in a fitted state.

The multilayer glass W is composed of, for example, a mesh glass W1 disposed on the indoor side and a float glass W2 disposed on the outdoor side.
The meshed glass W1 and the float glass W2 may be replaced with each other.

Even if the sash material 5 around the multilayer glass W is carbonized and falls off between the inner peripheral surface 4a of the sash frame 4 and the outer peripheral edge of the multilayer glass W, the flame is not lost. The refractory member 10 is disposed so as not to pass through the surroundings.
Examples of the refractory member 10 include non-flammable fibers such as ceramic fibers, for example, those obtained by coating the entire outer peripheral surface of a non-flammable fiber member with a sheet-like or film-like non-breathable member, vermiculite, kaolin, Thermally expandable inorganic materials such as mica, thermally expandable graphite, metal silicate, and borate, and combinations thereof can be suitably used.

  A sash member 5 constituting the upper frame 4A, the lower frame 4B, and the left and right side frames 4C of the sash frame 4 is formed with a cavity portion 11 along the longitudinal direction. The cavity portion 11 is formed of the upper frame 4A. The lower frame 4B and the left and right side frames 4C can communicate with each other over the entire circumference.

The cavity portion 11 has a partition wall 12 that also serves as a reinforcement, a relatively large main cavity portion 13 formed substantially at the center of the sash member 5, and an inner and outer 2 in the vertical direction adjacent to the outdoor side of the main cavity portion 13. It is divided into a plurality of relatively small small cavities 14A and 14B formed in steps.
The main cavity portion 13 further has a partition wall 12A and is divided into two large cavity portions 13A and 13B in the vertical direction, and the large cavity portions 13A and 13B are formed through holes 15 formed in the partition wall 12A. And communicated with each other.

  The main cavity 13 is filled with a fireproof material 16 across the inner and outer cavities 13A and 13B. By filling the fireproof material 16, the sash frame 4 has a fireproof performance having a desired fireproof performance. Can be repaired to the structure. The fireproof material 16 is made of the self-curing powder of the present invention before filling and immediately after filling, and after the self-curing powder curing time of the present invention has elapsed after filling, the self-curing powder of the present invention. It consists of a cured product of curable powder.

  1 and FIG. 2 have a substantially U-shaped cross section made of metal such as steel for the purpose of reinforcing a typical resin hollow sash material generally used conventionally, that is, a sash frame 4. An example in which a resin hollow sash material screwed by screws 18 is used as it is so that the long reinforcing material 17 is held inside the main cavities 13A and 13B of the sash material 5 is shown. Since the self-curing powder of the present invention is naturally cured after filling the cavity 13 to give a high-strength cured body, the use of the reinforcing material 17 can be omitted.

5. Next, the work process of this construction method for repairing the sash frame 4 of the existing multi-layer glass window 1 attached to the opening 3 of the building housing 2 to a fireproof structure will be described.
FIG. 3 is a diagram schematically showing an embodiment when a fireproof material made of the self-curing powder of the present invention is filled into a cavity of a sash material constituting a sash frame using a filling device. 4 is an enlarged longitudinal sectional view of the main part of the circle A in FIG. 3, FIG. 5 is a perspective view of the first cylindrical jig, FIG. 6 is a sectional view taken along the line VI-VI in FIG. FIG. 8 is a perspective view of the second cylindrical jig, FIG. 9 is a cross-sectional view taken along the line IX-IX of FIG. 8, and FIG. 10 is a perspective view of the sealing member. FIG. 11 is also an exploded perspective view of the sealing member.
FIG. 12 schematically shows another embodiment in which a fireproof material made of the self-hardening powder of the present invention is filled into a cavity of a sash material constituting a sash frame using a filling device. FIG. 13 is a perspective view showing another embodiment of the first cylindrical jig, and FIG. 14 is a sectional view taken along the line XIV-XIV in FIG.

  In the filling operation of the fireproof material 16 to the sash frame 4 by the filling device, first, the multi-layer glass W, the pressing member 8, the fireproof member 10, and other sealing members are removed from the sash frame 4 before filling.

Next, as shown in FIGS. 3 to 9, the filling port 19 (FIGS. 2 and 4) is formed by drilling the inner peripheral surface 4 a of one end portion of the upper frame 4 </ b> A in the left-right direction of the sash frame 4. Drill).
The filling port 19 is not necessarily provided in the upper frame 4A, and may be provided on the inner peripheral surface of the upper end portion of the side frame 4C, as shown in FIG. At this time, there is an advantage that it is difficult to be influenced by the shape of the frame (for example, the presence or absence of the frame 4D shown in FIG. 12).
On the other hand, inside the left and right ends of the lower frame 4B of the sash frame 4 positioned substantially diagonally to the filling port 19 or the lower end of the side frame 4C (in this embodiment, the lower end of the side frame 4C) By drilling the peripheral surface 4 a, the exhaust port 20 (see FIG. 7) is spaced apart so as to be positioned below the filling port 19.
The filling port 19 and the exhaust port 20 are drilled at positions facing the through holes 15 provided in the partition wall 12A that partitions the inside of the cavity portion 11 of the sash material 5 into main cavity portions 13A and 13B. Is preferred.
In the method of the present invention, by providing the filling port 19 and the exhaust port 20 in the positional relationship as described above, the fireproof material 16 is pumped into the cavity 11 of the sash material 5 by such air pressure. It can be uniformly filled at a high filling rate.

  As shown in FIGS. 3, 4, and 12, the filling device includes the sash material from a filling port 19 that is opened on an inner peripheral surface 4 a of one end of the upper frame 4 </ b> A in the left-right direction of the sash frame 4. 5 includes a first cylindrical jig 21 or a first cylindrical jig 21 ′ that is inserted toward the inside of the cavity 11.

As shown in FIGS. 5 and 6, the first cylindrical jig 21 is composed of a bottomed cylindrical body 22 such as a metal, for example. At the time of insertion, a contact plate 23 made of metal or the like having a rectangular shape in a plan view extending so as to contact the inner peripheral surface 4a of the upper frame 4A from the outside is fixed by welding or the like.
The upper end surface 21b of the cylindrical body 22 serving as the insertion end portion 21a in the upper part from the contact plate 23 of the first cylindrical jig 21 to be inserted into the filling port 19 is closed, and the insertion end portion 21a. Two discharge ports 24 are opened on the peripheral side surface.
The two discharge ports 24 are formed in the partition wall 12A that partitions the interior of the main cavity 13 in the cavity 11 of the sash member 5 when the first cylindrical jig 21 is inserted into the filling port 19. It arrange | positions so that it can communicate across the large cavity parts 13A and 13B through the hole 15. FIG.

The first cylindrical jig 21 ′ may be one having an insertion end 21 a made of a tubular body different from the first cylindrical jig 21 as shown in FIGS. 13 and 14. Is possible.
The first cylindrical jig 21 ′ has an opening at the end surface of the upper end surface 21 b of the closed insertion end 21 a in the first cylindrical jig 21 shown in FIGS. It will be.
When the first cylindrical jig 21 ′ having such a tubular body is used, the insertion end 21 a of the first cylindrical jig 21 ′ enters the large cavity portion 13 A at the filling port 19. If so, the fireproof material 16 can be filled without any problem through the through hole 15 in the large cavity 13A as well as in the large cavity 13B.

  In addition to the first cylindrical jig 21 or the first cylindrical jig 21 ′, the filling device includes a first cylindrical jig 21 or a first cylindrical jig as shown in FIGS. 3, 7, and 12. A second cylindrical jig 25 to be inserted into the exhaust port 20 opened on the inner peripheral surface 4a of the lower end portion of the side frame 4C located substantially diagonally to the filling port 19 into which 21 'is inserted; ing.

As shown in FIGS. 8 and 9, the second cylindrical jig 25 is formed of a cylindrical body 26 made of metal, for example, in the same manner as the first cylindrical jig 21. On the outer periphery of the intermediate portion, a metal contact plate 27 having a rectangular shape in a plan view extending so as to contact the inner peripheral surface 4a of the side frame 4C from the outside when being inserted into the exhaust port 20 is fixed by welding or the like. ing.
One end portion of the cylindrical body 26 serves as an insertion end portion 25a of the second cylindrical jig 25 inserted into the exhaust port 20, and the fireproof material 16 is formed in the insertion end portion 25a. The exhaust port portion is formed by mounting the bottomed cylindrical air filter member 28 made of a wire mesh or the like having a particle diameter of the self-curing powder or a hole having a diameter smaller than the powder diameter.

When the second cylindrical jig 25 is inserted into the exhaust port 20, the air filter member 28 has a large cavity portion through a through hole 15 provided in the partition wall 12 </ b> A that partitions the inside of the main cavity portion 13 of the sash material 5. It is preferable that they are arranged so as to communicate across 13A and 13B.
The shape of the air filter member is limited to a bottomed cylindrical shape as long as it has a function of preventing the fireproof material 16 from being discharged to the outside through the exhaust port 20 and discharging only air. For example, it may be a film-like object that covers the opening at the end of the second cylindrical jig 25.

  As shown in FIGS. 4 and 7, the filling member 19 and the exhaust port 20 are in contact with a sealing member 29 provided on the inner peripheral surface 4 a of the sash frame 4 and the outer periphery of the first cylindrical jig 21. It is attached so as to be interposed between the plate 23 and the contact plate 27 provided on the outer periphery of the second cylindrical jig 25.

As shown in FIGS. 10 and 11, the sealing member 29 is, for example, a thin plate disposed between a substrate 30 made of hard vinyl chloride, a backup sheet 31 made of natural sponge rubber, and the substrate 30 and the backup sheet 31. The elastic film 32 is made of a rubber sheet and is elastically stretchable.
The elastic film 32 is disposed on the back surface of the substrate 30 and is integrated by being sandwiched between the substrate 30 and the backup sheet 31.
The substrate 30, the backup sheet 31, and the elastic film 32 have substantially the same rectangular shape in plan view as the contact plates 23 and 27 of the first and second cylindrical jigs 21.

Through holes 33 and 34 are formed in the central portions of the substrate 30 and the backup sheet 31 at positions aligned with each other.
The elastic film 32 sandwiched and integrated between the substrate 30 and the backup sheet 31 is positioned so as to be aligned with the through holes 33 and 34, and the diameters of the through holes 33 and 34 are determined. A slit-like opening 35 having substantially the same length is provided.

  The sealing member 29 including the through holes 33 and 34 and the slit-shaped opening 35 is arranged so that the positions of the through-holes 33 and 34 and the slit-shaped opening 35 are aligned with the filling port 19 or the exhaust port 20. The slit-shaped opening 35 of the elastic film 32 is elastically attached to the exhaust port 20 in accordance with the insertion or extraction operation of the first cylindrical jig 21 and the second cylindrical jig 25, respectively. An expanded state or a contracted state is set.

That is, an air filter member that forms the insertion end portion 21a in which the discharge port 24 of the first cylindrical jig 21 or the first cylindrical jig 21 'is formed or the insertion end portion 25a of the second cylindrical jig 25. When 28 is inserted from the through hole 33 of the substrate 30 constituting the sealing member 29 toward the through hole 34 of the backup sheet 31, the slit-shaped opening 35 of the elastic film 32 is forcibly extended in the expanding direction. It will be in an expanded state.
As a result, the filling port 19 or the exhaust port 20 is opened, and the first cylindrical jig 21, the first cylindrical jig 21 ′, or the second cylindrical jig 25 is inserted into the filling port 19 via the sealing member 29. Alternatively, it can be inserted from the exhaust port 20 into the cavity 11 of the sash 5 constituting the sash frame 4.

On the other hand, when the first cylindrical jig 21 or the first cylindrical jig 21 ′ or the second cylindrical jig 25 is inserted, the first or second cylindrical jigs 21, 21 ′, 25 are attached to the sash. When pulled out from the cavity 11 of the material 5 through the sealing member 29, the slit-like opening 35 of the elastic film 32 is contracted so that it can elastically return from the expanded state to the contracted state. Is preferred.
Thus, even when the first cylindrical jig 21, the first cylindrical jig 21 ′, or the second cylindrical jig 25 is pulled out from the filling port 19 or the exhaust port 20, the filling member 19 19 and the exhaust port 20 can be closed.
Therefore, the first cylindrical jig 21 or the first cylindrical jig 21 ′ and the second cylindrical jig 25 can be reused (reused).

After removing the first cylindrical jig 21 or the first cylindrical jig 21 ′ and the second cylindrical jig 25, the sealing member 29 is removed, and the filling port 19 and the exhaust are held with parts such as waterproof tape and a cap. It is preferable to close the mouth 20.
By doing so, not only can water be prevented from entering the frame even when used for a long period of time, but also the sealing member 29 can be reused.

As shown in FIGS. 3 and 12, the filling device is disposed upstream of the hopper 36 for storing the fireproof material 16, and is used for pumping the fireproof material 16 in the hopper 36. An air compressor 37 for supplying pressurized air, a fireproof material transfer pipe connecting the hopper 36 and the first cylindrical jig 21 or the first cylindrical jig 21 ′, specifically a supply hose ( It is preferable to include a material pressure feeding means composed of a fireproof material transfer pipe) 38, an air hose 39 for supplying pressurized air from the air compressor 37 into the hopper 36, and the air hose 39.
That is, the first cylindrical jig 21 or the first cylindrical jig 21 'is connected to a supply hose 38 at a supply port 36a of a hopper 36 in which the fireproof material 16 is stored, as shown in FIGS. It is preferable to be connected via

  In the hopper 36, the air whose pressure is adjusted by the pressure regulating valve 40 disposed between the air compressor 37 and the hopper 36 through the air hose 39 connected to the air compressor 37 passes through the valve 41. The hopper 36 and the air compressor 37 constitute a material pressure feeding means.

  The fireproof material 16 in the hopper 36 to which the air has been pumped passes through the first cylindrical jig 21 or the first cylindrical jig 21 ′ connected to the supply hose 38 and the filling port of the sash frame 4 together with the air. From 19, it is forcibly pumped into the cavity 11 of the sash material 5.

A baffle plate 42 is disposed in the hopper 36 near the upper portion of the supply port 36a.
Between the outer peripheral surface of the baffle plate 42 and the inner peripheral wall surface of the hopper 36, a flow gap 43 of a fireproof material is formed.
The baffle plate 42 prevents the supply port 36a of the hopper 36 from being blocked by a load due to the weight of the fireproof material 16, and the fireproof material 16 flows out smoothly from the flow gap 43 of the hopper 36 toward the supply port 36a. It is for making it happen.

In the filling apparatus having the material pressure feeding means, the first cylindrical jig 21 or the first cylindrical jig 21 ′ is connected to the inner peripheral surface or the side frame at one end in the left-right direction of the upper frame 4 </ b> A of the sash frame 4. The second cylindrical jig 25 is inserted into the inner peripheral surface of the end portion of the lower frame 4B or the inner peripheral surface of the lower end portion of the side frame 4C. The fireproof material 16 is inserted into the provided exhaust port 20 and is pumped by pressurized air into the cavity 11 via the first cylindrical jig 21 or the first cylindrical jig 21 ′. The active material 16 can be uniformly filled into the cavity 11 of the sash material 5 at a high filling rate. At this time, in the filling device, in order to more stably fill the fireproof material 16 into the cavity 11 of the sash material 5, as shown in FIG. Therefore, it is preferable to include suction / exhaust means for sucking the air in the cavity 11 and exhausting it outside.
By doing so, by optimally balancing the pressure-feeding force of the air into the cavity 11 by the material-pumping means and the suction-exhausting force of the air in the cavity 11 by the suction-exhaust means, The filling rate of the fireproof material 16 can be improved.

That is, in the embodiment shown in FIG. 3, the second cylindrical jig 25 is connected to a suction fan 44 as a suction exhaust means via a suction hose 45.
The suction fan 44 is an air filter that forms the insertion end portion 25a of the second cylindrical jig 25 from the hopper 36 and the fireproof material 16 that is pressure-fed together with air into the cavity 11 of the sash member 5 in the sash frame 4. The member 28 prevents the air from leaking to the outside, forcibly sucks only air and exhausts it to the outside.
Thereby, the fireproof material 16 can be filled with the cavity 11 of the sash material 5 in the sash frame 4 densely.

  Further, in the filling device, the fireproof material 16 is more stably supplied toward the cavity 11 of the sash material 5, and more reliably and efficiently filled at a high filling rate to obtain high fireproof performance. As shown in FIG. 12, pressurized air is supplied from the air compressor 37 to the first cylindrical jig 21 or the first cylindrical jig 21 ′ side of the supply hose 38 as a fireproof material transfer pipe in the material pressure feeding means. Is preferably supplied.

That is, in the embodiment shown in FIG. 12, the air hose 39 is branched into two on the downstream side of the pressure regulating valve 40, one is connected to the hopper 36 side via the valve 41 as the main pipe 39a, and the other is connected to the branch pipe. By connecting to the supply hose 38 through the valve 46 as 39b, the pressurized air supplied from the air compressor 37 is separately supplied from the middle of the supply hose 38 when the fireproof material 16 is pressure-fed. Assists in the pumping.
This makes it possible to perform pumping continuously and stably, and eliminates the need to use auxiliary means such as giving vibration to the frame to eliminate temporary clogging during pumping. Thus, the cavity portion 11 of the sash material 5 in the sash frame 4 can be more reliably and reliably filled with the fireproof material 16.

  The position where the branch pipe 39b is connected to the supply hose 38 is preferably 5 to 20 cm, particularly 10 to 15 cm upstream from the first cylindrical jig 21 or the first cylindrical jig 21 '.

The fireproof material 16 (the self-curing powder of the present invention) is easily densely packed when being fed into the cavity 11 of the sash material 5, and it is difficult to generate voids due to its own weight or vibration after filling. The following particle size distribution is preferable.
That is, the inorganic hollow particles contained in the self-curing powder of the present invention are particles having a particle size of 200 μm or less in a state where the liquid component is not attached to the surface, and the content ratio of the particles is 30% by mass or less. It is particularly preferable to have a particle size distribution in which the content ratio of particles having a diameter of 300 μm or more and 500 μm or less is 30% by mass or more and the content ratio of particles having a particle diameter of 600 μm or more is 20% by mass or less.
The particle size distribution is based on the result of particle size measurement by a dry sieving test method (JIS K 0069).
For example, an air filter is placed at one end of a hollow sash material cut to a length of 1 m, and fire-resistant materials with different particle size distributions are pumped and tightly packed, and then the sash material is vibrated by hitting the side with a hammer. When the volume of the gap generated when the fireproof material is forced and compacted is measured, the gap generated when using the fireproof material having a particle size distribution deviating from the particle size distribution A is the entire filling space. The gaps generated when using fireproof materials having particle size distributions A and B were 5 to 9% and 5 to 7%, respectively, while they were about 10 to 15% with respect to the product.

The fireproof material 16 (the self-curing powder of the present invention) filled in the cavity 13 is cured relatively quickly and exhibits excellent fireproofing properties. For this reason, even if each sash material 5 constituting the upper frames 4A, 4B, 4C, and 4D of the sash frame 4 loses its strength due to heat, the multilayer glass W is formed by the cured body formed in the cavity 11. Since it can continue to support, it is possible to prevent the multilayer glass W from falling off.
In addition, since the fireproof material 16 uses inorganic hollow particles, the cured body has high heat insulation performance, so that damage due to heat of the non-heated surface of the sash material 5 is greatly reduced even in a fire. And more excellent fire resistance can be exhibited. Furthermore, even if the heating surface of the sash material 5 is lost due to carbonization deterioration or melting, the cured body does not collapse, so that the effect that the multilayer glass W can be supported can be obtained.

Further, when the sash frame 4 is filled with the fireproof material 16 (self-curing powder of the present invention), the optimum range of the pressure and flow rate of the air for pumping the fireproof material 16 is as shown in FIGS. 3 and 12. In addition, for example, it is preferable that the difference (differential pressure) between the pressure at the filling port 19 and the pressure at the exhaust port 20 is 0.15 to 0.20 MPa.
5. The fireproof sash material and the fireproof window of the present invention have been described in detail above, taking the case of fireproof repair as an example, but when the sash frame of the present invention is newly manufactured, according to the above method at the production factory, What is necessary is just to fill self-hardening powder. In addition, when the fireproof sash material of the present invention is newly produced, it is not particularly necessary to pump the self-curing powder of the present invention, and various filling methods can be applied. For example, the lower end of the communicating cavity is temporarily sealed, the self-curing powder of the present invention is dropped and filled from above, the upper end is temporarily sealed as necessary, and the self-curing powder of the present invention is left standing for a predetermined time. The body may be cured. It can also be heated to promote curing.

  Furthermore, the cross-sectional profile of the fire-resistant sash material of the present invention can be changed according to various requirements. The fireproof sash material of the present invention may be a firewood material or a cubic material. In particular, when the fireproof sash material of the present invention is a saddle material, the embodiment shown in FIGS. 1 and 2 is shown in FIG. 1 only by slight modification so as not to have a function of fixing to the building frame opening. The fireproof window can be fireproof shoji, and the frame material shown in FIG. Furthermore, with respect to these details, except for the description of the case attachment portions 115a and 115b, the accessory fixtures 180, and the screws 190, the fireproof window can be read as fireproof shoji, and the frame material can be read as saddle. The “description of the embodiment shown in the figure” described can be applied almost as it is.

  In addition, the fireproof window of the present invention is not limited to a so-called “fitted window”, and “a shoji having the flame retardant panel having upper, lower, left and right fences on an opening frame body installed in an opening of a building housing. As a window that can be freely opened and closed within the frame. At this time, at least the lower frame among the upper frame, the lower frame, and the left and right vertical frames constituting the opening frame body needs to be a frame material made of the fireproof sash material of the present invention, It is necessary to be a firewood made of the fireproof sash material of the present invention.

  Examples The present invention will be described in more detail with reference to examples. However, the present invention is not limited to these examples.

(Inorganic hollow particles)
A fly ash balloon was used as the inorganic hollow particles, and particles having a particle size distribution shown in Table 1 were used. In addition, each opening is shown by the mass ratio of the particle | grains of the particle size which passes a 1 step large opening but does not pass the said opening. For example, the opening 425 indicates a mass ratio of particles having a particle size that passes through the opening 300 but does not pass through the opening 425.

(Preparation of binder composition)
Add 825.6 parts by mass of 92% paraformaldehyde and 1073.3 parts by mass of water to 1190 parts by mass of phenol, and heat to reflux on a hot water bath until the mixture becomes homogeneous. Warm to completely dissolve the phenol and paraformaldehyde. Thereafter, the aqueous solution was once cooled, and a mixed solution of 131.9 parts by mass of 48% by mass NaOH aqueous solution and 184.6 parts by mass of 48% by mass KOH aqueous solution was gradually added dropwise thereto as an alkali catalyst. After gradually raising the temperature to 80 ° C., the temperature was maintained and the reaction was conducted under reflux. And when the viscosity of the reaction liquid became 150 mPa * s / 50 degreeC, it cooled, and the synthesis | combination of water-soluble phenol resin was complete | finished. Thereafter, 290.1 parts by mass of a 48% NaOH aqueous solution and 406.2 parts by mass of a 48% KOH aqueous solution were further added as regulators to the solution containing the water-soluble phenol resin. Water was added so that was 45%. Further, a binder composition is prepared by adding urea to a ratio of 1% and γ-aminopropyltriethoxysilane at a ratio of 0.2% with respect to the total mass of the mixed solution. did.

(Measurement of physical properties of self-curing powder of the present invention)
Self-curing powder was produced from the obtained inorganic hollow particles and binder composition, and the following measurements were performed.

(1) Funnel passing speed The fluidity of the self-curing fluid is measured using the apparatus shown in FIG. This apparatus comprises, in order from the top, a sieve mesh 51, a vibrating means 52 for vibrating the sieve mesh, a funnel 53 for charging powder, a weigh scale 54, and a support base 55 for supporting the vibrating means 52 and the funnel 53. The vibration means 52 includes a vibration table for fixing the funnel 53 and a vibration motor. In addition, the apparatus used in this test is a table for measuring the angle of repose in which the powder falling through the funnel 53 of the apparatus for measuring the angle of repose (POWDER TESTER <TYPE PT-E> manufactured by Hosokawa Micron Corporation) is deposited. Instead, a weight scale 54 is used. The funnel 53 used in this test is made of glass. The inclination angle θ is 60 °, the tube length a of the tube portion 56 is 35 mm, and the inner diameter is 4.7 mm. In the measurement method, first, a binder composition and a curing agent are mixed with inorganic hollow particles at an appropriate ratio to obtain a self-curing powder. Next, 20 g of self-curing powder is put into the funnel 53 and set. Then, the vibration is started by adjusting the scale of the rheostat (vibration level knob) to 5 (vibration width 0.5 mm). After vibrating for 1 minute, the weight of the self-curing powder that has passed through the funnel 53 is measured. If there is a passage of 0.1 g or more (0.1 g / min or more) after 1 minute, the range is such that the self-hardening powder can be filled by pumping. Moreover, when all 20g of self-hardening powder passes a funnel within 1 minute, it describes with 20g / min or more.

(2) Angle of repose A binder composition and a curing agent are mixed with inorganic hollow particles at an appropriate ratio to obtain a self-curing powder, which is manufactured by Hosokawa Micron Co., Ltd. in accordance with the principle of JIS R 9301-2-2. Measure the angle of repose with POWDER TESTER <TYPE PT-E>. The self-hardening powder of the present invention is preferably a powder having a low angle of repose and good fluidity for filling the cavity with the self-hardening powder, and the self-hardening powder is pumped into the cavity by applying a constant pressure. For refilling, the angle of repose is more preferably 65 degrees or less.

(3) Compressive strength A binder composition and a curing agent are mixed with inorganic hollow particles at an appropriate ratio to obtain a self-curing powder, which is made into a wooden pattern of φ50 mm × h50 mm in accordance with JACT test method HM-1. After leaving the self-hardening powder poured and hardened for 7 days in an atmosphere of temperature 25 ° C x humidity 60%, it is removed from the wooden mold and the compressive strength is measured with the Takachiho Seiki anti-pressure tester (H3000D). .

Example 1
While stirring the inorganic hollow particles with a stirrer such as a mixer, first, 0.3 part by weight of dimethyl glutarate as a curing agent is added to 100 parts by weight of the inorganic hollow particles and stirred for 30 seconds. 2 parts by mass of the product was added and further stirred for 30 seconds to obtain a self-curing powder. Table 2 shows the physical properties measured with this self-curing powder.

Example 2
Self-curing powder was obtained in the same manner as in Example 1 except that the curing agent (dimethyl glutarate) in Example 1 was changed to 2.2 parts by mass. Table 2 shows the physical properties measured with this self-curing powder.

Example 3
Self-curing powder was obtained in the same manner as in Example 1 except that the curing agent (dimethyl glutarate) in Example 1 was changed to 4 parts by mass. Table 2 shows the physical properties measured with this self-curing powder.

Example 4
Self-curing powder was obtained in the same manner as in Example 1 except that the curing agent (dimethyl glutarate) in Example 1 was changed to 0.8 parts by mass and the binder composition was changed to 3 parts by mass. Table 2 shows the physical properties measured with this self-curing powder.

Example 5
Self-curing powder was obtained in the same manner as in Example 1 except that the curing agent (dimethyl glutarate) in Example 1 was changed to 0.8 parts by mass and the binder composition was changed to 5 parts by mass. Table 2 shows the physical properties measured with this self-curing powder.

Example 6
Self-curing powder was obtained in the same manner as in Example 1 except that the curing agent (dimethyl glutarate) in Example 1 was changed to 1.0 part by mass and the binder composition was changed to 5 parts by mass. Table 2 shows the physical properties measured with this self-curing powder.

Example 7
Self-curing powder was obtained in the same manner as in Example 1 except that the curing agent (dimethyl glutarate) in Example 1 was changed to 1.8 parts by mass and the binder composition was changed to 7 parts by mass. Table 2 shows the physical properties measured with this self-curing powder.

Example 8
Self-curing powder was obtained in the same manner as in Example 1 except that the curing agent (dimethyl glutarate) in Example 1 was changed to 1.2 parts by mass and the binder composition was changed to 8 parts by mass. Table 2 shows the physical properties measured with this self-curing powder.

Example 9
Self-curing powder was obtained in the same manner as in Example 1 except that the curing agent (dimethyl glutarate) in Example 1 was changed to 1.5 parts by mass and the binder composition was changed to 10 parts by mass. Table 2 shows the physical properties measured with this self-curing powder.

Example 10
Self-curing powder was obtained in the same manner as in Example 1 except that the curing agent (dimethyl glutarate) in Example 1 was changed to 1.8 parts by mass and the binder composition was changed to 12 parts by mass. Table 2 shows the physical properties measured with this self-curing powder.

Example 11
Self-curing powder was obtained in the same manner as in Example 1 except that the curing agent (dimethyl glutarate) in Example 1 was changed to 2.3 parts by mass and the binder composition was changed to 15 parts by mass. Table 2 shows the physical properties measured with this self-curing powder.

Example 12
Self-curing powder was obtained in the same manner as in Example 1 except that the curing agent (dimethyl glutarate) in Example 1 was changed to 2.4 parts by mass and the binder composition was changed to 16 parts by mass. Table 2 shows the physical properties measured with this self-curing powder.

Example 13
Self-curing powder was obtained in the same manner as in Example 1 except that the curing agent (dimethyl glutarate) in Example 1 was changed to 2.6 parts by mass and the binder composition was changed to 17 parts by mass. Table 2 shows the physical properties measured with this self-curing powder.

Example 14
A self-curing powder was obtained in the same manner as in Example 1 except that the curing agent in Example 1 was changed to 0.8 parts by mass of ethylene glycol diacetate and the binder composition was changed to 5 parts by mass. Table 2 shows the physical properties measured with this self-curing powder.

Example 15
A self-curing powder was obtained in the same manner as in Example 1 except that the curing agent in Example 1 was changed to 0.8 parts by mass of triacetin and the binder composition was changed to 5 parts by mass. Table 2 shows the physical properties measured with this self-curing powder.

Example 16
In the preparation of the binder composition, after the synthesis of the water-soluble phenol resin is completed, 48% NaOH aqueous solution and 48% KOH aqueous solution are added as preparation agents, and then water is added so that the solid content becomes 10%. The binder composition was prepared by adding. Self-curing powder was obtained in the same manner as in Example 1 except that the curing agent (dimethyl glutarate) in Example 1 was changed to 0.8 parts by mass and the binder composition was changed to 5 parts by mass. Table 2 shows the physical properties measured with this self-curing powder.

Example 17
In the preparation of the binder composition, after the synthesis of the water-soluble phenol resin is completed, 48% NaOH aqueous solution and 48% KOH aqueous solution are added as preparation agents, and then water is added so that the solid content becomes 60%. The binder composition was prepared by adding. Self-curing powder was obtained in the same manner as in Example 1 except that the curing agent (dimethyl glutarate) in Example 1 was changed to 0.8 parts by mass and the binder composition was changed to 5 parts by mass. Table 2 shows the physical properties measured with this self-curing powder.

Comparative Example 1
Self-curing powder was obtained in the same manner as in Example 1 except that the curing agent (dimethyl glutarate) in Example 1 was changed to 2.7 parts by mass and the binder composition was changed to 18 parts by mass. Table 2 shows the physical properties measured with this self-curing powder.

Comparative Example 2
Self-curing powder was obtained in the same manner as in Example 1 except that the curing agent (dimethyl glutarate) in Example 1 was changed to 3.0 parts by mass and the binder composition was changed to 20 parts by mass. Table 2 shows the physical properties measured with this self-curing powder.

Comparative Example 3
Self-curing powder was obtained in the same manner as in Example 1 except that the curing agent (dimethyl glutarate) in Example 1 was changed to 0.3 parts by mass and the binder composition was changed to 1 part by mass. Table 2 shows the physical properties measured with this self-curing powder.

Comparative Example 4
Self-curing powder was obtained in the same manner as in Example 1 except that the inorganic hollow particles in Example 1 were changed to cinnabar. Table 2 shows the physical properties measured with this self-curing powder.

  From Table 2, from the relationship between the blending amounts of the binder compositions of Examples 1 to 13 and Comparative Examples 1 to 3 and the funnel passage speed, the binder composition was 2 to 17 with respect to 100 parts by mass of the inorganic hollow particles. If it is the range of a mass part, the fluidity | liquidity of self-hardening powder can be obtained, and it becomes possible to fill a cavity with self-hardening powder by pumping, and to obtain compressive strength. In Examples 1 to 9 in which the angle of repose is 65 degrees or less, higher fluidity can be obtained, and self-hardening powder can be filled to every corner even in a cavity having a complicated structure. In Examples 5 to 9 in which the binder composition was 4 to 10 parts by mass, the flow strength was improved and the compressive strength was lowered. When the compressive strength was raised, the flowability was deteriorated. A good self-hardening fluid can be obtained. In addition, the amount of the curing agent greatly affects the compressive strength from Examples 1 to 3, and the content of the curing agent is preferably 10 to 200 parts by mass with respect to 100 parts by mass of the binder composition. Moreover, when dredged sand is used for the particles in comparison with Example 1 and Comparative Example 4, it is difficult to obtain fluidity due to the weight of the particles, whereas good fluidity is obtained by using inorganic hollow particles. be able to. From Examples 16 to 17, it is desirable that the solid content concentration be in the range of 10 to 60% by mass. Within this range, a good self-curing powder can be obtained.

(Example of sash using self-curing powder of the present invention)
The self-curing powder produced in Examples 6 and 7 is filled with 2.1 kg, which is almost full by the above-mentioned filling method, in the W1000H2120 size fitting window frame composed of a PVC resin frame by this method. did. After filling, the windows were stored at room temperature for 7 days or more and then subjected to a heating test for 20 minutes from the outdoor side along the standard temperature curve of ISO834. There was no damage such as cracks through which the flame passed, and there was no gap. After completion of the test, the polyvinyl chloride on the heated surface side was burned away, but the filled self-curing powder remained, and it was confirmed that it was effective in terms of flame barrier properties.
Separately from this, JIS A 4710 is prepared by filling a self-curing powder into a vertical window made of polyvinyl chloride resin containing a LOW-E glass having a size of W1690H1370 and a multi-layer glass of meshed glass, and fitting into a window. In each case, the thermal insulation performance was improved by about 0.1 W / m ² · K compared to the continuous window not filled with the self-curing powder. Furthermore, when the discharge property of the water inevitably infiltrated at the time of the watertight test was confirmed, the flow path was secured, and the discharged water contained almost no organic component. Incidentally, about the hardened | cured material obtained by hardening the self-hardening powder manufactured in Example 1, the elution amount of the phenol resin after hardening 12th is 10 ppm or less, and PH is 7-8.

DESCRIPTION OF SYMBOLS 1 Multi-layer glass window 2 Building frame 3 Opening part 4 Sash frame 4A Upper frame 4B Lower frame 4C Side frame 4D Side wall 4a Inner peripheral surface 5 Sash material 6 Protrusion part 7 Mounting recessed part 8 Holding member (holding edge)
DESCRIPTION OF SYMBOLS 9 Inner peripheral groove part 10 Refractory member 11 Cavity part 12 Partition 12A Partition 13 Main cavity part 13A, 13B Large cavity part 14A, 14B Small cavity part 15 Through-hole 16 Fireproof material (self-hardening powder of this invention or its hardened body )
17 Reinforcing material 18 Screw 19 Filling port 20 Exhaust port 21, 21 'First cylindrical jig 21a Insertion end 21b Upper end surface 22 Cylindrical body 23 Contact plate 24 Discharge port 25 Second cylindrical jig 25a Insertion end 26 Cylindrical body 27 Contact plate 28 Air filter member (suction port)
29 Sealing member 30 Substrate 31 Backup sheet 32 Elastic film 33, 34 Through hole (opening)
35 Slit-shaped opening (opening)
36 Hopper (material pumping means)
36a Supply port 37 Air compressor (material pressure feeding means)
38 Supply hose (fireproof material transfer pipe)
39 Air hose 39a Main pipe 39b Branch pipe 40 Pressure regulating valve 41 Valve 42 Baffle plate 43 Flow gap 44 Suction fan (suction exhaust means)
45 Suction hose 46 Valve 51 Sieve net 52 Vibrating means 53 Funnel 54 Weighing scale 55 Support base 56 Tube part W Multi-layer glass W1 Netted glass W2 Float glass

Claims (11)

100 parts by weight of a powder composed of an aggregate of inorganic hollow particles, and a binder composition 2 composed of an aqueous alkali solution or dispersion of a water-soluble phenol resin having a solid content concentration of 10 to 60% by weight of the water-soluble phenol resin. A self-curing powder obtained by mixing 17 parts by mass and a curing agent in an amount necessary to cure the water-soluble phenol resin contained in the binder composition. A funnel when 20 g of self-curing powder is put into a funnel having a sieve angle of 3600 times / minute, a sieve vibration width of 0.5 to 0.8 mm and a funnel angle of 60 ° and a narrow aperture of 4.7 mm. The self-curing powder according to claim 1, wherein the passing speed is 0.1 g / min or more. The self-curing powder according to claim 1 or 2, wherein the amount of the curing agent used is 10 to 200 parts by mass with respect to 100 parts by mass of the binder composition. The self-curable powder according to any one of claims 1 to 3, wherein the curing agent comprises an organic ester. As the powder, the content ratio of particles having a particle diameter of 200 μm or less is 30% by mass or less, the content ratio of particles having a particle diameter in the range of 300 μm or more and 500 μm or less is 30% by mass or more, and the particle diameter is The self-curable powder according to any one of claims 1 to 4, wherein a powder having a particle size distribution in which the content ratio of particles having a particle size of 600 µm or more is 20 mass% or less is used. An article or member comprising the article or member having a cavity therein and filled with the cured body of the self-curing powder according to any one of claims 1 to 5. A fireproof sash material comprising a sash body made of a hollow material having a cavity along the longitudinal direction, and a heat-resistant member filled in the cavity, wherein the heat-resistant member is a heat-resistant member. A fireproof sash material comprising a cured product of the self-curable powder according to any one of the above. A fireproof window in which a shoji with upper, lower, left, and right hooks is mounted in a frame having an upper frame, a lower frame, and left and right vertical frames each formed of a fireproof sash material, wherein at least the lower frame is claimed. A fireproof window comprising the fireproof sash material according to 7. The fireproof window according to claim 8, wherein at least the lower arm of the shoji is made of the fireproof sash material according to claim 7. A sash comprising a sash frame made of a sash material having a cavity along the longitudinal direction and filled with a cured body of the self-curing powder according to any one of claims 1 to 5. frame. A filling port that communicates with the cavity portion is provided on the inner peripheral surface of one end portion in the left-right direction of the upper frame of the upper frame of the sash frame having a hollow portion along the longitudinal direction or the inner peripheral surface of the upper end portion of the side frame. And a first cylindrical jig is inserted into the filling port, and the self-hardening powder according to any one of claims 1 to 5 is pumped into the cavity through the first cylindrical jig. An exhaust port is provided on the inner peripheral surface of the end portion of the lower frame or the inner peripheral surface of the lower end portion of the side frame, which is positioned in a diagonal relationship with respect to the filling port, and the cavity portion communicates with the outside. A second cylindrical jig is inserted into the exhaust port, and the air is exhausted to the outside through the second cylindrical jig, and the self-curing powder is filled into the cavity. And a step of curing the self-hardening powder filled in the filling step. Method for producing a sash frame according to.

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