JP2023150604A - Flat deck construction method - Google Patents

Abstract

To provide a flat deck construction method that reduces construction time and provides superior fire resistance by manufacturing the flat deck at the construction site that is evenly filled with filler in the length direction inside the rib.SOLUTION: A flat deck construction method of the present invention includes a process of preparing a flat deck comprising a flat part and a rib protruding from one surface of the flat part, a process of laying the flat deck on a building structure, a process of heating the rib of the flat deck placed on a building structure and a process of filling the inside of the heated rib with a filler through an injection port formed in the rib.SELECTED DRAWING: Figure 1

Description

The present invention relates to a method for constructing a flat deck in a building structure.

Conventionally, flat decks are sometimes used to construct floors or roof structures of building structures such as reinforced concrete and steel reinforced concrete. The flat deck extends along the longitudinal direction, and has a plurality of ribs each having a cavity inside formed on the lower surface of the flat portion, and has a flat upper surface (see, for example, Patent Document 1). Flat decks are used in floor or roof structures, for example, as formwork for pouring concrete onto the top surface of a flat section.

In a building structure, a fireproof partition structure is sometimes formed by a facing material such as gypsum board. In order to prevent flames from spreading in the event of a fire, the fireproof compartment structure must ensure that no gaps are formed between the floor structure and the roof structure in order to ensure sound insulation and heat insulation for compartments other than the fireproof compartment structure. There is. For example, when a flat deck is installed on a floor structure, when partitioning materials for forming compartments such as a fire protection compartment structure are butted against the bottom surface of the flat deck, a gap is created between the floor structure and the partitioning material due to the cavity inside the ribs. can. Therefore, it is necessary to remove the ribs by cutting the flat deck in the areas where the partition materials are butted against each other. The work to remove the ribs would be done on site, for example, after concrete has been poured. When ribs are removed at a construction site, the work is time-consuming and poses a safety problem.

To solve this problem, a flat deck with filler inside the ribs has been proposed. When filled inside the flat deck as a filler, the cavities inside the ribs prevent gaps from forming between the floor structure and the partitioning material, and the work of removing the ribs can be omitted.

JP 2017-110453 Publication

However, when using pre-manufactured flat decks with fillers filled inside the ribs, the filler is injected at the factory, which means that the delivery time to the construction site will be longer than before, and the flat decks will be flat. There was a problem in that the construction period for building structures using decks was long.
In addition, when manufacturing a flat deck with filler inside the ribs at the construction site, it is difficult to distribute the filler uniformly in the length direction inside the ribs, and the filler inside the ribs is not filled properly. This may result in a decrease in fire resistance.

Therefore, the present invention aims to shorten the construction period by manufacturing at the construction site a flat deck in which the filler is uniformly filled in the length direction inside the ribs, and provides a method for constructing a highly fire-resistant flat deck. That is the issue.

The gist of the present invention is as follows.
[1] A step of preparing a flat deck comprising a flat portion and a rib protruding from one surface of the flat portion, a step of laying the flat deck on a building structure, and a step of laying the flat deck on the building structure. A method for constructing a flat deck, the method comprising: heating the ribs of the flat deck; and filling the inside of the heated ribs with a filler through an injection port formed in the ribs.
[2] Construction of the flat deck according to [1], wherein in the filling step, the temperature of the rib at the position where the injection port is located and the temperature of the longitudinal end of the rib are 40°C or more and 80°C or less Method.
[3] In the filling step, the difference between the temperature of the rib at the position where the injection port is located and the temperature at the longitudinal end of the rib is within 20°C, according to [1] or [2]. How to construct a flat deck.
[4] The method for constructing a flat deck according to any one of [1] to [3], further comprising the step of pouring concrete into the flat portion of the flat deck installed on the building structure.
[5] The flat deck construction method according to [4], further comprising a step of forming an injection port in the rib after the step of placing the concrete.
[6] The method for constructing a flat deck according to [5], wherein the injection port is formed in the rib at a position where it abuts against a partition material forming a fireproof partition structure.
[7] The method for constructing a flat deck according to any one of [1] to [6], wherein the filler is a fireproof material.
[8] The method for constructing a flat deck according to any one of [1] to [7], wherein the filler is urethane foam.
[9] The method for constructing a flat deck according to any one of [1] to [8], wherein the injection port is formed at a bottom portion of the rib.
[10] A step of preparing a flat deck comprising a flat portion and a rib protruding from one surface of the flat portion, a step of laying the flat deck on a building structure, and a step of forming a rib formed on the rib. A method for constructing a flat deck, comprising the step of filling a filler from an injection port, the injection port being arranged at a position where it butts against a partition material forming a fireproof partition structure of the ribs.

According to the present invention, a flat deck uniformly filled with filler in the longitudinal direction of the ribs is manufactured at the construction site, thereby shortening the construction period and providing a method for constructing a highly fire-resistant flat deck. be able to.

1 is a flowchart showing a method for constructing a flat deck according to a first embodiment of the present invention. FIG. 2(a) is a plan view of the front side showing the flat deck according to the first embodiment of the present invention, and FIG. 2(b) is a sectional view taken along the line AA in FIG. 1(a). be. FIG. 1 is a perspective view showing a structure constructed by the flat deck construction method according to the first embodiment of the invention. It is a sectional view showing the construction state of the flat deck in the construction method of the flat deck concerning the 1st embodiment of the present invention. It is a sectional view showing the construction state of the flat deck in the construction method of the flat deck concerning the 1st embodiment of the present invention. FIG. 6(a) is a sectional view showing the construction state of the flat deck in the flat deck construction method according to the first embodiment of the present invention, and FIG. 6(b) is a cross-sectional view showing the back side of the flat deck in the same state. FIG. It is a flowchart which shows the construction method of the flat deck based on the 2nd Embodiment of this invention. FIG. 7 is a perspective view showing a structure constructed by a flat deck construction method according to a second embodiment of the invention.

(First embodiment)
As shown in FIG. 1, the flat deck construction method according to the first embodiment of the present invention includes the following steps S1 to S4.
S1: Step of preparing a flat deck comprising a flat portion and a rib protruding from one side of the flat portion S2: Step of laying the flat deck on a building structure S3: Flat deck laid on the building structure Step of heating the ribs S4: Step of filling the inside of the heated ribs with the filler through the injection port formed in the ribs

In step S1 of this construction method, as shown in FIGS. 2(a) and 2(b), a rib 12 (12 ₁ , 12 ₂ ) is prepared.

In the flat deck 1, the upper surface 11U of the flat portion 11 is a flat surface, or minute irregularities are formed on the flat surface, and the lower surface 11D of the flat portion 11 is provided with a plurality of ribs 12 ₁ and 12 ₂ protruding. The plurality of ribs 12 ₁ and 12 ₂ are arranged along the horizontal direction (Y-axis direction). Note that although FIG. 1 typically shows an example in which two ribs are provided, the number of ribs is not particularly limited. Each of the ribs 12 ₁ and 12 ₂ is a protrusion having a hollow inside and extends in the vertical direction (X-axis direction). Both ends 12A and 12B in the longitudinal direction of each rib 12 are configured to be closed, as shown in FIG. 3, and may be closed by being crushed or may be configured to use a closing member. Note that the flat deck 1 can be obtained, for example, by roll forming or press forming a metal plate such as a steel plate or other materials.

As shown in FIG. 2(b), the cross-sectional shape of the rib 12 of the flat deck 1 includes a hollow part 12a having a hollow inside, and a connecting part 12b connecting the lower surface 11D and the hollow part 12a. The cross-sectional shape of the cavity formed by the cavity portion 12a is not particularly limited, and can take various shapes such as a triangle, a square, and a circle, as long as a cavity is formed inside. The connecting portion 12b is narrowed in width from the hollow portion 12a and is arranged so that a pair of plate-like portions are brought together, and each plate-like portion connects the upper end of the hollow portion 12a to the lower surface 11D.

The flat deck 1 includes a claw portion 18C that connects with the rib 12 of the adjacent flat deck. The claw portion 18C is provided at the side end portion 18A of the flat portion 11. The claw portion 18C is formed by, for example, bending the flat portion 11. The claw portion 18C can be fitted into the connecting portion 12b of the rib 12 provided at the sidemost side end 18B of the flat deck 1 arranged adjacently. Note that the claw portion 18C is inserted between the pair of plate portions from the upper opening between the pair of plate portions forming the connecting portion 12b of the rib 12 provided on the side of the side end 18B of the flat deck 1. It is inserted into the gap and fitted.
Note that the flat deck 1 may not include the claw portion 14, and for example, a plurality of flat decks 1 may be arranged side by side without being connected.

In step S2 of this construction method, as shown in FIG. 3, the flat deck 1 is laid on a support material 14 that is a building structure.
As shown in FIG. 3, the flat deck 1 has, for example, both ends in the longitudinal direction placed on supporting members 14 such as beams, and is installed between the supporting members 14, thereby providing a floor structure, a ceiling structure, etc. Configure. The flat deck 1 is used when concrete is poured into a floor or ceiling slab of a building, and specifically, it is used as a part of a formwork in which concrete is poured into the upper surface 11U of the flat part 11.
The flat deck 1 is arranged adjacently by inserting and fitting the claw part 18C into the connecting part 12b of the rib 12 provided at the sidemost end 18B of the flat deck 1 arranged adjacently. It is possible to arrange the flat decks 1 connected to each other. Furthermore, the flat deck 1 may not include the claw portion 14, and for example, a plurality of flat decks 1 may be arranged side by side without being connected. Further, the number of flat decks 1 does not need to be plural, and if there is not a plurality, there is no need to connect them. By any means, as shown in FIG. 3, by arranging the flat deck 1 between the supporting members 14, a flat portion for pouring concrete can be formed.

In step S3 of this construction method, as shown in FIG. 4, the ribs 12 are heated using a heating device 40. The heating device 40 is not particularly limited as long as it is a device that can heat the ribs 12, and includes, for example, a contact type heater such as a contact type rubber heater, a far infrared heater, a gas heater, an oil heater, and the like.

As a method for heating the ribs 12 using the heating device 40, the ribs 12 may be heated while the heating device 40 is supported by the support material 14, for example. More specifically, as shown in FIG. 4, the heating device 40 is installed at the lower stage of the support member 14 on which the flat deck 1 is installed at the upper stage, and the entire length direction of one rib 12 of the flat deck 1 is installed. One example is a method of heating against. Further, in the above method, after heating one rib 12, the heating device 40 is repeatedly moved to the ribs 12 arranged side by side along the horizontal direction (Y-axis direction), and the adjacent ribs 12 are sequentially heated. good. The heating device 40 is preferably provided with wheels, pulleys, etc. (not shown) to facilitate movement on the installed support member 14. For example, the heating device 40 may be moved along the Y-axis direction by disposing wheels and pulleys on the support member 14. As described above, examples of the heating device supported by the support member 14 include a far-infrared heater, a gas heater, an oil heater, and the like. Further, a contact type heater such as a contact type rubber heater may be directly attached to the rib 12 to heat the rib 12.

In step S4 of this construction method, after step S3, the inside of the heated rib 12 is filled with a filler through the injection port 16 formed at the bottom of the cavity 12a of the rib 12.
When filling the inside of the rib 12 with the filler, it is not necessary to fill the entire rib 12 along the longitudinal direction. That is, the filler may be partially filled along the longitudinal direction of the rib 12.
Specifically, the filler is filled from the injection port 16 to the middle part between the rib ends 12A, 12B and the injection port 16, and the filler does not need to be filled at both rib ends 12A, 12B. . Further, as will be described later, when two or more injection ports 16 are provided, the portion between the injection ports 16 is typically filled with a filler, but it is not necessarily filled. Good too.
In addition, in the following description, the longitudinal end of the rib 12 means the end of the portion of the rib 12 filled with the filler. Therefore, when the entire inside of the rib 12 is filled with the filler, it means both ends 12A and 12B of the rib 12, but when the entire inside of the rib 12 is not filled with the filler, it means the lengthwise end. The portion is a portion inside the end portions 12A and 12B.

In step S4 of this construction method, it is preferable that the temperature of the rib 12 at the position where the injection port 16 is located and the temperature of the longitudinal end of the rib 12 are both 40° C. or more and 80° C. or less. Further, in step S4 of the present construction method, the difference between the temperature of the rib 12 at the position where the injection port 16 is located and the temperature at the longitudinal end of the rib 12 is preferably within 20°C. After step S5, when the temperature relationship between the portion of the heated rib 12 where the injection port 16 is located and the longitudinal end of the rib 12 falls within the above range, the filling material that has reacted uniformly inside the rib 12 is filled inside the rib 12. It becomes easier to fill, for example, it becomes easier to fill the entire cross section of the cavity 12a with the filler. From the viewpoint of filling the inside of the rib 12 with the filler that has reacted uniformly, the temperature of the rib at the position where the injection port 16 is located and the temperature at the longitudinal end of the rib 12 should be 45°C or more and 75°C or less. The temperature is preferably 50°C or more and 75°C or less, and even more preferably 55°C or more and 75°C or less. Further, from the same viewpoint, the difference between the temperature of the rib 12 at the position where the injection port 16 is located and the temperature at the longitudinal end of the rib 12 is preferably within 15°C, and preferably within 10°C. The temperature is more preferably within 5°C.

In this embodiment, as shown in FIG. 5, it is preferable to further include a step of pouring concrete 30 onto the upper surface 11U of the flat portion 11 of the flat deck 1 that has been laid. The process of placing concrete 30 is typically performed before filling the ribs 12 with the filling material, that is, before step S3, but may be performed after filling the ribs 12 with the filling material.

In this embodiment, it is preferable to further include a step of forming an injection port 16 in the rib 12, as shown in FIGS. 6(a) and (b), after the step of pouring concrete. Even if the injection port 16 is provided in the rib 12 after concrete is placed, it is possible to prevent the laid flat deck 1 from being deformed due to a decrease in the mechanical strength of the flat deck 1.
Through this step, an injection port 16 for injecting the filler is formed in the bottom portion of the rib 12, as shown in FIGS. 6(a) and 6(b). By forming the injection port 16 at the bottom of the rib 12, the filler can be injected from the bottom and spread throughout the cavity 12a in the cross section of the rib 12. Note that the bottom surface portion preferably refers to a surface constituting the bottom surface of the rib 12 when the cross-sectional shape of the hollow portion 12a of the rib 12 is triangular or square; however, when the cross-sectional shape of the hollow portion 12a of the rib 12 is circular For structures other than triangular and quadrangular, the part that can be seen from the bottom side is considered the bottom part.
The injection port 16 may be provided near the center of each rib 12 in the longitudinal direction, or may be provided near both ends 12A, 12B of each rib 12.
Moreover, one injection port 16 may be provided in each rib 12, or two or more injection ports 16 may be provided in each rib 12.

However, in this embodiment, the step of forming the injection port 16 in the rib 12 may be performed before the step S1, the step S2, and the step S3. Specifically, a flat deck 1 with injection ports 16 formed in the ribs 12 may be prepared, or injection ports 16 may be formed in the ribs 12 before the flat deck 1 is installed in a building structure. The injection holes 16 may be formed in the ribs 12 before concrete is placed.

According to the flat deck construction method of this embodiment, the flat deck with the filler filled inside the ribs can be constructed by uniformly filling the filler in the length direction inside the ribs without using a pre-manufactured one. It is possible to manufacture flat decks at the construction site, thereby shortening the construction period for building structures.
Furthermore, according to the flat deck construction method of this embodiment, it is possible to construct a highly fire-resistant flat deck in which the filler is uniformly filled in the length direction of the inside of the ribs, thereby creating a highly fire-resistant architectural structure. It can be a thing.

In this embodiment, a foam can be used as the filler. By using foam as a filler, the specific gravity is light and the overall weight of the building material can be reduced. The foam used for the filling is preferably an organic foam. The organic foam for the filler is preferably one selected from the group consisting of polyolefin foams such as urethane foam, phenol foam, styrene foam, PVC foam and polyethylene foam, among which urethane foam and phenol foam are preferred. It is more preferable to use either one, and urethane foam is even more preferable. Moreover, examples of foams (inorganic foams) other than organic foams include water glass, foamed concrete, and the like.

The filler is preferably made of a fire-resistant material from the viewpoint of improving fire protection. Fire-resistant materials refer to materials that exhibit performance equivalent to flame-retardant materials specified in the Building Standards Act and the Building Standards Act Enforcement Order (hereinafter referred to as "flame-retardant materials"). (hereinafter referred to as "semi-noncombustible material"), and more preferably a material that exhibits performance equivalent to that of a noncombustible material (hereinafter referred to as "noncombustible material"). Performance equivalent to flame retardant material is based on ISO5660-1, and in a heat generation test using a cone calorimeter tester, when heated at a radiant heat intensity of 50 kW/ ^m2 , the total calorific value after 5 minutes has elapsed. 8MJ/ ^m2 or less. Furthermore, the performance equivalent to a quasi-noncombustible material means that the total calorific value after 10 minutes is 8 MJ/m ² or less. Furthermore, the performance equivalent to that of a noncombustible material means that the total calorific value after 20 minutes is 8 MJ/m ² or less.

The organic foam such as urethane foam used as a filler only needs to have performance equivalent to at least one of a flame retardant material, a quasi-nonflammable material, and a noncombustible material, and must have performance equivalent to a noncombustible material. is preferred. When measuring organic foam according to the ISO-5660 test method, prepare a test sample by cutting the organic foam into 10 cm long, 10 cm wide, and 5 cm thick, and use the test sample to cut the organic foam into a cone. Perform a heat generation test using a calorimeter tester.

<Urethane foam>
The urethane foam constituting the filling will be explained in more detail. The urethane foam used in this embodiment is formed by curing and foaming a urethane resin composition. The urethane resin contained in the urethane foam is a reaction product obtained by mixing and reacting a polyisocyanate compound and a polyol compound. The urethane resin composition is in a liquid state immediately after being prepared by mixing various components so that it can be easily injected into the inside of the rib 12 and can fill the cavity 12a of the rib 12 without any gaps.
As a method for applying the urethane foam to fill and close the cavity 12a of the rib 12, discharge filling using a discharge device that discharges a liquid urethane resin composition is suitable. Note that, for example, when the urethane resin composition is a two-component curing type, the dispensing device includes a mixing section that mixes the first and second components, and a discharge device that dispenses the mixed urethane resin composition. Use one with an exit. As such a discharging device, a high-pressure foaming machine, a low-pressure foaming machine, other mixing/discharging systems, spray guns, caulking guns, etc. may be used.

The urethane resin composition that forms urethane foam generally contains a polyisocyanate compound and a polyol compound.
Examples of the polyisocyanate compound used in the urethane foam include aromatic polyisocyanates, alicyclic polyisocyanates, aliphatic polyisocyanates, and the like.
Examples of the aromatic polyisocyanate include phenylene diisocyanate, tolylene diisocyanate, xylylene diisocyanate, diphenylmethane diisocyanate, dimethyldiphenylmethane diisocyanate, triphenylmethane triisocyanate, naphthalene diisocyanate, and polymethylene polyphenyl polyisocyanate.

Examples of the alicyclic polyisocyanate include cyclohexylene diisocyanate, methylcyclohexylene diisocyanate, isophorone diisocyanate, dicyclohexylmethane diisocyanate, and dimethyldicyclohexylmethane diisocyanate.
Examples of the aliphatic polyisocyanate include methylene diisocyanate, ethylene diisocyanate, propylene diisocyanate, tetramethylene diisocyanate, hexamethylene diisocyanate, and the like.
The polyisocyanate compounds may be used alone or in combination of two or more.
As the polyisocyanate compound, diphenylmethane diisocyanate (MDI) is preferred because it is easy to use and easy to obtain.

Examples of the polyol compound include polylactone polyol, polycarbonate polyol, aromatic polyol, alicyclic polyol, aliphatic polyol, polyester polyol, polymer polyol, polyether polyol, and the like.
Examples of polylactone polyols include polypropiolactone glycol, polycaprolactone glycol, polyvalerolactone glycol, and the like.
Examples of polycarbonate polyols include polyols obtained by dealcoholization reaction of hydroxyl group-containing compounds such as ethylene glycol, propylene glycol, butanediol, pentanediol, hexanediol, octanediol, and nonanediol with diethylene carbonate, dipropylene carbonate, etc. etc.

Examples of aromatic polyols include bisphenol A, bisphenol F, phenol novolak, and cresol novolak.
Examples of the alicyclic polyol include cyclohexanediol, methylcyclohexanediol, isophoronediol, dicyclohexylmethanediol, and dimethyldicyclohexylmethanediol.
Examples of aliphatic polyols include ethylene glycol, propylene glycol, butanediol, pentanediol, and hexanediol.

Examples of polyester polyols include polymers obtained by dehydration condensation of polybasic acids and polyhydric alcohols, polymers obtained by ring-opening polymerization of lactones such as ε-caprolactone and α-methyl-ε-caprolactone, Examples include condensates of hydroxycarboxylic acids and the above-mentioned polyhydric alcohols.
Here, specific examples of the polybasic acid include adipic acid, azelaic acid, sebacic acid, terephthalic acid, isophthalic acid, and succinic acid. Specific examples of the polyhydric alcohol include bisphenol A, ethylene glycol, 1,2-propylene glycol, 1,4-butanediol, diethylene glycol, 1,6-hexane glycol, and neopentyl glycol. .
Further, specific examples of the hydroxycarboxylic acid include castor oil, a reaction product of castor oil and ethylene glycol, and the like.

Examples of polymer polyols include polymers obtained by graft polymerizing ethylenically unsaturated compounds such as acrylonitrile, styrene, methyl acrylate, and methacrylate to the above-mentioned aromatic polyols, alicyclic polyols, aliphatic polyols, polyester polyols, etc. , polybutadiene polyol, modified polyol of polyhydric alcohol, or hydrogenated products thereof.
Examples of modified polyols of polyhydric alcohols include those obtained by reacting polyhydric alcohols as raw materials with alkylene oxide to modify them.
Examples of the polyhydric alcohol used in the modified polyol include trihydric alcohols such as glycerin and trimethylolpropane, pentaerythritol, sorbitol, mannitol, sorbitan, diglycerin, dipentaerythritol, sucrose, glucose, mannose, fructose, Tetra- to octavalent alcohols such as methyl glucoside and its derivatives, phenol, phloroglucin, cresol, pyrogallol, catechol, hydroquinone, bisphenol A, bisphenol F, bisphenol S, 1-hydroxynaphthalene, 1,3,6,8-tetrahydroxy Phenols such as naphthalene, anthrol, 1,4,5,8-tetrahydroxyanthracene, and 1-hydroxypyrene, polybutadiene polyols, castor oil polyols, polymers or copolymers of hydroxyalkyl (meth)acrylates, and polyvinyl alcohols. Examples include functional (eg, functional group number 2 to 100) polyols and condensates of phenol and formaldehyde (novolak).

Although the method for modifying the polyhydric alcohol is not particularly limited, a method of adding alkylene oxide (hereinafter abbreviated as AO) is preferably used.
Examples of AO include AO having 2 to 6 carbon atoms, such as ethylene oxide (hereinafter abbreviated as EO), 1,2-propylene oxide (hereinafter abbreviated as PO), 1,3-propyleoxide, 1,2- Examples include butylene oxide and 1,4-butylene oxide.
Among these, from the viewpoint of properties and reactivity, PO, EO and 1,2-butylene oxide are preferred, and PO and EO are more preferred.
When two or more types of AO are used (for example, PO and EO), the addition method may be block addition, random addition, or a combination of these.

For example, the polyether polyol is prepared by ring-opening polymerization of at least one alkylene oxide such as ethylene oxide, propylene oxide, and tetrahydrofuran in the presence of at least one low molecular weight active hydrogen compound having two or more active hydrogens. Examples include the resulting polymers.
Examples of low molecular weight active hydrogen compounds having two or more active hydrogens used in polyether polyols include diols such as bisphenol A, ethylene glycol, propylene glycol, butylene glycol, and 1,6-hexanediol, glycerin, and trimethylol. Examples include triols such as propane, and amines such as ethylene diamine and butylene diamine.

As the polyol used in the urethane foam, it is preferable to use a polyester polyol or a polyether polyol, and a polyester polyol is more preferable, since it has a large effect of reducing the total calorific value when burned. Among these, it is preferable to use polyester polyols with a molecular weight of 200 to 800, and it is more preferable to use polyester polyols with a molecular weight of 300 to 500.

The isocyanate index of the urethane resin is preferably in the range of 120 to 1,000, more preferably in the range of 200 to 800, and even more preferably in the range of 300 to 600. When the isocyanate index is 120 or more, the isocyanate groups will be in excess of the hydroxyl groups and will be more likely to be trimerized, making it easier to impart nonflammability. Moreover, when it is 1,000 or less, the balance between nonflammability and manufacturing cost becomes good.

Note that the isocyanate index can be calculated by the following method.
Isocyanate index = number of equivalents of polyisocyanate ÷ (number of equivalents of polyol + number of equivalents of water) x 100
Here, each equivalent number can be calculated as follows.
- Number of equivalents of polyisocyanate = amount of polyisocyanate used (g) x NCO content (mass%) / molecular weight of NCO (mol) x 100
・Number of equivalents of polyol = OHV x amount of polyol used (g) ÷ molecular weight of KOH (mmol)
OHV is the hydroxyl value (mgKOH/g) of the polyol.
- Number of equivalents of water = amount of water used (g) / molecular weight of water (mol) x number of OH groups in water In each of the above formulas, the molecular weight of NCO is 42 (mol), the molecular weight of KOH is 56100 (mmol), The molecular weight of water is 18 (mol), and the number of OH groups in water is 2.

"Flame retardants"
In order to impart a flame retardant effect to the urethane foam, it is preferable to contain a flame retardant, and examples include the use of liquid flame retardants such as phosphate esters. As the flame retardant, in order to improve flame retardancy, it is also preferable to use a solid flame retardant, and it is also preferable to use a solid flame retardant and a liquid flame retardant in combination.
Liquid flame retardants are flame retardants that become liquid at room temperature (23°C) and normal pressure (1 atm), and solid flame retardants are flame retardants that become solid at room temperature (23°C) and normal pressure (1 atm). be. Specific examples of liquid flame retardants include phosphoric acid esters.
Examples of the solid flame retardant include at least one selected from red phosphorus, phosphate-containing flame retardants, bromine-containing flame retardants, boron-containing flame retardants, antimony-containing flame retardants, and metal hydroxides.
It is more preferable that the flame retardant used in the urethane foam contains red phosphorus and phosphoric acid ester from the viewpoint of nonflammability, ease of handling, and the like. Further, the flame retardant is composed of red phosphorus, phosphate ester, and at least one selected from phosphate-containing flame retardants, bromine-containing flame retardants, boron-containing flame retardants, antimony-containing flame retardants, and metal hydroxides. is also preferable.

<Phosphate ester>
As the phosphoric acid ester, monophosphoric acid ester, condensed phosphoric acid ester, etc. can be used. A monophosphoric acid ester is a phosphoric acid ester having one phosphorus atom in the molecule. Monophosphoric acid esters are not limited as long as they are liquid at room temperature and pressure, but examples include trialkyl phosphates such as trimethyl phosphate, triethyl phosphate, tributyl phosphate, tri(2-ethylhexyl) phosphate, and tris(β-chloro). halogen-containing phosphate esters such as propyl) phosphate, trialkoxy phosphates such as tributoxyethyl phosphate, tricresyl phosphate, tricylenyl phosphate, tris(isopropylphenyl) phosphate, cresyl diphenyl phosphate, diphenyl (2-ethylhexyl) phosphate Acidic phosphoric esters such as aromatic ring-containing phosphoric acid esters such as monoisodecyl phosphate and diisodecyl phosphate are included.

Examples of the condensed phosphoric acid ester include aromatic condensed phosphoric acid esters such as trialkyl polyphosphate, resorcinol polyphenyl phosphate, bisphenol A polycresyl phosphate, and bisphenol A polyphenyl phosphate.
Commercially available condensed phosphate esters include, for example, resorcinol polyphenyl phosphate (trade name CR-733S), bisphenol A polycresyl phosphate (trade name CR-741), aromatic condensed phosphate ester (trade name CR747), and resorcinol. Examples include polyphenyl phosphate (manufactured by ADEKA, trade name ADEKA STAB PFR), bisphenol A polycresyl phosphate (trade names FP-600, FP-700), and the like.

Among the above, it is preferable to use monophosphoric acid ester because it has a high effect of reducing the viscosity in the composition before curing and the effect of reducing the initial calorific value, and it is preferable to use tris (β-chloropropyl) phosphate. is more preferable. The phosphoric acid esters may be used alone or in combination of two or more.

The amount of phosphoric acid ester blended is preferably in the range of 1.5 to 52 parts by weight, more preferably in the range of 1.5 to 20 parts by weight, based on 100 parts by weight of the urethane resin.2. The range is more preferably from 0 to 15 parts by weight, and most preferably from 2.0 to 10 parts by weight.
By setting the amount of phosphoric acid ester to be at least the above lower limit, it is possible to prevent the dense residue formed from the urethane foam from cracking in the event of a fire. Further, by setting the amount of the phosphoric acid ester to be less than or equal to the above upper limit value, foaming of the urethane resin composition is not inhibited. Moreover, by setting it within the above range, it becomes easy to impart nonflammability.

<Red phosphorus>
The red phosphorus used in the present invention is not limited, and commercially available products can be appropriately selected and used. Red phosphorus does not need to be blended alone, and may be surface-treated as appropriate.
The amount of red phosphorus blended in the urethane foam is preferably in the range of 3.0 to 18 parts by weight, more preferably 4.0 to 12 parts by weight, based on 100 parts by weight of the urethane resin. By setting the amount of red phosphorus to be equal to or higher than the above lower limit, the self-extinguishing property of the urethane foam is maintained, and it becomes easier to impart nonflammability to the urethane foam. Furthermore, by setting the amount of red phosphorus to be less than or equal to the above upper limit, foaming of the urethane resin composition is not inhibited. As mentioned above, the urethane resin is a reaction product of a polyisocyanate compound and a polyol compound, and 100 parts by mass of the urethane resin means a total of 100 parts by mass of the polyisocyanate compound and the polyol compound in the urethane resin composition. do.

<Phosphate-containing flame retardant>
Phosphate-containing flame retardants include, for example, phosphoric acid salts of various phosphoric acids and at least one metal or compound selected from metals of Groups IA to IVB of the Periodic Table, ammonia, aliphatic amines, and aromatic amines. Mention may be made of acid salts.
The phosphoric acid is not particularly limited, but various phosphoric acids such as monophosphoric acid, pyrophosphoric acid, and polyphosphoric acid can be mentioned.
Examples of metals in Groups IA to IVB of the periodic table include lithium, sodium, calcium, barium, iron (II), iron (III), aluminum, and the like. Examples of aliphatic amines include methylamine, ethylamine, diethylamine, triethylamine, ethylenediamine, piperazine, and the like. Further, examples of aromatic amines include pyridine, triazine, melamine, ammonium, and the like.
In addition, the above-mentioned phosphate-containing flame retardant may be subjected to known water resistance improvement treatments such as silane coupling agent treatment and coating with melamine resin.

Specific examples of phosphate-containing flame retardants include monophosphates, pyrophosphates, polyphosphates, and the like.
Monophosphates are not particularly limited, but include, for example, ammonium salts such as ammonium phosphate, ammonium dihydrogen phosphate, and ammonium hydrogen phosphate, monosodium phosphate, disodium phosphate, trisodium phosphate, and phosphorous acid. Sodium salts such as monosodium, disodium phosphite, sodium hypophosphite, monopotassium phosphate, dipotassium phosphate, tripotassium phosphate, monopotassium phosphite, dipotassium phosphite, hypophosphorous acid Potassium salts such as potassium, monolithium phosphate, dilithium phosphate, trilithium phosphate, monolithium phosphite, dilithium phosphite, lithium hypophosphite, etc., barium dihydrogen phosphate, phosphorus Barium salts such as barium oxyhydrogen, tribarium phosphate, barium hypophosphite, magnesium salts such as monohydrogen phosphate, magnesium hydrogen phosphate, trimagnesium phosphate, magnesium hypophosphite, calcium dihydrogen phosphate , calcium salts such as calcium hydrogen phosphate, tricalcium phosphate, and calcium hypophosphite; zinc salts such as zinc phosphate, zinc phosphite, and zinc hypophosphite.

Further, the polyphosphate is not particularly limited, but examples thereof include ammonium polyphosphate, piperazine polyphosphate, melamine polyphosphate, ammonium amide polyphosphate, aluminum polyphosphate, and the like.
Among these, monophosphates are preferably used, and ammonium dihydrogen phosphate is more preferably used, since the self-extinguishing properties of phosphate-containing flame retardants are improved.
The phosphate-containing flame retardants may be used alone or in combination of two or more.

The blending amount of the phosphate-containing flame retardant is preferably in the range of 1.5 to 52 parts by mass, more preferably in the range of 1.5 to 20 parts by mass, based on 100 parts by mass of the urethane resin. , more preferably in the range of 2.0 to 15 parts by weight, and most preferably in the range of 2.0 to 10 parts by weight.
When the amount of the phosphate-containing flame retardant is at least the above lower limit, the self-extinguishing properties of the urethane foam are maintained and fire resistance is easily imparted. Further, when the amount of the phosphate-containing flame retardant is equal to or less than the above upper limit, foaming of the urethane resin composition is not inhibited.

<Bromine-containing flame retardant>
The bromine-containing flame retardant is not particularly limited as long as it is a compound containing bromine in its molecular structure, and examples thereof include aromatic brominated compounds.
Specific examples of aromatic brominated compounds include hexabromobenzene, pentabromotoluene, hexabromo biphenyl, decabromo biphenyl, hexabromocyclodecane, decabromodiphenyl ether, octabromodiphenyl ether, hexabromodiphenyl ether, bis(pentabromo Examples include monomeric organic bromine compounds such as phenoxy)ethane, ethylene-bis(tetrabromophthalimide), and tetrabromobisphenol A.
In addition, polycarbonate oligomers produced using brominated bisphenol A as a raw material, brominated polycarbonates such as copolymers of polycarbonate oligomers and bisphenol A, diepoxy compounds produced by the reaction of brominated bisphenol A and epichlorohydrin, and brominated phenols. brominated epoxy compounds such as monoepoxy compounds obtained by the reaction of brominated epoxy compounds with epichlorohydrin, poly(brominated benzyl acrylate), brominated polyphenylene ether, brominated bisphenol A, condensates of cyanuric chloride and brominated phenol, brominated ( Brominated polystyrene such as polystyrene), poly(brominated styrene), crosslinked brominated polystyrene, and halogenated bromine compound polymers such as crosslinked or non-crosslinked brominated poly(-methylstyrene).
From the viewpoint of controlling the calorific value at the initial stage of combustion, brominated polystyrene, hexabromobenzene, etc. are preferable, and hexabromobenzene is more preferable.
Bromine-containing flame retardants may be used alone or in combination of two or more.

The amount of the bromine-containing flame retardant used in the present invention is preferably in the range of 1.5 to 50 parts by mass, and preferably in the range of 1.5 to 20 parts by mass, based on 100 parts by mass of the urethane resin. It is more preferably in the range of 2.0 to 15 parts by weight, and most preferably in the range of 2.0 to 10 parts by weight.
When the amount of the bromine-containing flame retardant is greater than or equal to the above lower limit, the self-extinguishing properties of the urethane foam are maintained and fire resistance is easily imparted. Further, when the amount of the bromine-containing flame retardant is equal to or less than the above upper limit, foaming of the urethane resin composition is not inhibited.

<Boron-containing flame retardant>
Examples of boron-containing flame retardants include borax, boron oxide, boric acid, and borates.
Examples of boron oxide include diboron trioxide, boron trioxide, diboron dioxide, tetraboron trioxide, and tetraboron pentoxide.
Examples of borates include borates of alkali metals, alkaline earth metals, elements of Group 4, Group 12, and Group 13 of the periodic table, and ammonium.
Specifically, alkali metal borates such as lithium borate, sodium borate, potassium borate, and cesium borate; alkaline earth metal borates such as magnesium borate, calcium borate, and barium borate; Examples include zirconium acid, zinc borate, aluminum borate, ammonium borate, and the like.
The boron-containing flame retardant is preferably a borate, more preferably zinc borate.
Boron-containing flame retardants may be used alone or in combination of two or more.

The blending amount of the boron-containing flame retardant is preferably in the range of 1.5 to 50 parts by mass, more preferably in the range of 1.5 to 20 parts by mass, based on 100 parts by mass of the urethane resin. The range is more preferably from .0 to 15 parts by weight, and most preferably from 2.0 to 10 parts by weight.
When the amount of the boron-containing flame retardant is at least the above lower limit, the self-extinguishing properties of the urethane foam are maintained and fire resistance is easily imparted. Further, when the amount of the boron-containing flame retardant is equal to or less than the above upper limit, foaming of the urethane resin composition is not inhibited.

<Antimony-containing flame retardant>
Examples of the antimony-containing flame retardant used in the present invention include antimony oxide, antimonate salts, and pyroantimonate salts.
Examples of antimony oxide include antimony trioxide and antimony pentoxide. Examples of antimonate salts include sodium antimonate, potassium antimonate, and the like. Examples of the pyroantimonate include sodium pyroantimonate, potassium pyroantimonate, and the like.
Preferably, the antimony-containing flame retardant is antimony oxide.
Antimony-containing flame retardants may be used alone or in combination of two or more.

The blending amount of the antimony-containing flame retardant is preferably in the range of 1.5 to 50 parts by mass, more preferably in the range of 1.5 to 20 parts by mass, based on 100 parts by mass of the urethane resin. The range is more preferably from .0 to 15 parts by weight, and most preferably from 2.0 to 10 parts by weight. When the amount of the antimony-containing flame retardant is at least the above lower limit, the self-extinguishing properties of the urethane foam are maintained and fire resistance is easily imparted. Further, when the amount of the antimony-containing flame retardant is equal to or less than the above upper limit, foaming of the urethane resin composition is not inhibited.

<Metal hydroxide>
Examples of metal hydroxides include magnesium hydroxide, calcium hydroxide, aluminum hydroxide, iron hydroxide, nickel hydroxide, zirconium hydroxide, titanium hydroxide, zinc hydroxide, copper hydroxide, vanadium hydroxide, and water. Examples include tin oxide. The metal hydroxides may be used alone or in combination of two or more.

The blending amount of the metal hydroxide is preferably in the range of 1.5 to 50 parts by mass, more preferably in the range of 1.5 to 20 parts by mass, based on 100 parts by mass of the urethane resin. The range is more preferably from .0 to 15 parts by weight, and most preferably from 2.0 to 10 parts by weight. When the amount of the metal hydroxide is at least the above lower limit, the self-extinguishing properties of the urethane foam are maintained and fire resistance is easily imparted. Further, since the amount of metal hydroxide is below the above upper limit, foaming of the urethane resin composition is not inhibited.

Preferred combinations of the above flame retardants include, for example, any of the following (a) to (n), among which combinations containing at least red phosphorus and phosphoric acid ester are preferred.
(a) Red phosphorus and phosphate esters (b) Flame retardants containing red phosphorus and phosphates (c) Flame retardants containing red phosphorus and bromine (d) Flame retardants containing red phosphorus and boron (e) Flame retardants containing red phosphorus and antimony Flame retardants (f) Red phosphorus and metal hydroxides (g) Flame retardants containing red phosphorus, phosphate esters and phosphates (h) Flame retardants containing red phosphorus, phosphate esters and bromine (i) Red phosphorus, phosphate esters and boron-containing flame retardants (j) red phosphorus, phosphate-containing flame retardants and bromine-containing flame retardants (k) red phosphorus, phosphate-containing flame retardants and boron-containing flame retardants (l) red phosphorus, bromine-containing flame retardants and Boron-containing flame retardants (m) Red phosphorus, phosphate esters, phosphate-containing flame retardants and bromine-containing flame retardants (n) Red phosphorus, phosphate esters, phosphate-containing flame retardants, bromine-containing flame retardants and boron-containing flame retardants fuel

The total blending amount of the solid flame retardant is preferably in the range of 4.5 to 70 parts by mass, more preferably in the range of 4.5 to 40 parts by mass, based on 100 parts by mass of the urethane resin. The range is more preferably from .5 to 30 parts by weight, and most preferably from 4.5 to 20 parts by weight.
When the amount of the solid flame retardant is greater than or equal to the above lower limit, it becomes easier to impart nonflammability to the urethane foam. Furthermore, it is possible to prevent the dense residue formed from urethane foam from cracking in the event of a fire. When the amount of the solid flame retardant is below the above upper limit, foaming of the urethane resin composition is not inhibited by the flame retardant.

As described above, the urethane foam of the present invention is formed by curing and foaming a urethane resin composition. The urethane resin composition contains the above-mentioned polyol compound, isocyanate compound, and flame retardant, and generally further contains a catalyst, a blowing agent, and a foam stabilizer.

"catalyst"
The urethane resin composition may contain, for example, a resinization catalyst, a trimerization catalyst, or both, as a catalyst, and preferably contains both. The resinization catalyst is a catalyst that promotes the reaction between a polyol compound and a polyisocyanate.

The resinization catalyst is a catalyst that promotes the reaction between a polyol compound and a polyisocyanate. Examples of the resinization catalyst include amine catalysts such as imidazole compounds and piperazine compounds, and metal catalysts.
Examples of imidazole compounds include tertiary amines in which the secondary amine at position 1 of the imidazole ring is substituted with an alkyl group, an alkenyl group, or the like. Specifically, N-methylimidazole, 1,2-dimethylimidazole, 1-ethyl-2-methylimidazole, 1-methyl-2-ethylimidazole, 1,2-diethylimidazole, and 1-isobutyl-2-methyl Examples include imidazole. Alternatively, an imidazole compound in which the secondary amine in the imidazole ring is substituted with a cyanoethyl group may also be used.
Examples of the piperazine compound include tertiary amines such as N-methyl-N'N'-dimethylaminoethylpiperazine and trimethylaminoethylpiperazine.
In addition to imidazole compounds and piperazine compounds, examples of resin conversion catalysts include pentamethyldiethylenetriamine, triethylamine, N-methylmorpholine bis(2-dimethylaminoethyl)ether, N,N,N',N",N"- Pentamethyldiethylenetriamine, N,N,N'-trimethylaminoethyl-ethanolamine, bis(2-dimethylaminoethyl)ether, N,N-dimethylcyclohexylamine, diazabicycloundecene, triethylenediamine, tetramethylhexamethylenediamine , various tertiary amines such as tripropylamine, and the like.
Examples of the metal catalyst include metal salts selected from bismuth and tin, with bismuth salts being preferred.
The blending amount of the resin conversion catalyst is preferably in the range of 0.02 to 5 parts by mass, more preferably in the range of 0.04 to 3 parts by mass, and 0.02 to 5 parts by mass, more preferably 0.04 to 3 parts by mass, based on 100 parts by mass of the urethane resin. The range is more preferably from 0.04 to 2 parts by weight, and most preferably from 0.06 to 1 part by weight.
By setting the blending amount of the resin-forming catalyst to the above lower limit value or more, the formation of urethane bonds is promoted and the curability becomes good. Further, by setting the amount of the resinization catalyst to be less than or equal to the above upper limit value, an appropriate foaming rate can be maintained and it is easy to handle.

The trimerization catalyst is a catalyst that causes the isocyanate groups contained in the polyisocyanate compound to react and trimerize, thereby promoting the production of isocyanurate rings. By using a trimerization catalyst, it becomes easier to improve nonflammability.
Trimerization catalysts include nitrogen-containing aromatic compounds such as tris(dimethylaminomethyl)phenol, 2,4-bis(dimethylaminomethyl)phenol, and 2,4,6-tris(dialkylaminoalkyl)hexahydro-S-triazine. , alkali metal carboxylates such as potassium acetate, potassium 2-ethylhexanoate, potassium octylate, tertiary ammonium salts such as trimethylammonium salt, triethylammonium salt, triphenylammonium salt, tetramethylammonium salt, tetraethylammonium, tetra Quaternary ammonium salts such as phenylammonium salts can be used.

The blending amount of the trimerization catalyst is preferably in the range of 0.6 to 10 parts by mass, more preferably in the range of 0.6 to 8 parts by mass, and 0.6 to 10 parts by mass, more preferably 0.6 to 8 parts by mass, based on 100 parts by mass of the urethane resin. It is more preferably in the range of 6 to 6 parts by weight, and most preferably in the range of 0.6 to 3.0 parts by weight.
When the amount of the trimerization catalyst is greater than or equal to the above lower limit, the problem of inhibiting trimerization of isocyanate will not occur. Further, when the amount of the trimerization catalyst is equal to or less than the above-mentioned upper limit, an appropriate foaming rate can be maintained and it is easy to handle.

《Foaming agent》
The foaming agent contained in the urethane resin composition promotes foaming of the urethane resin. Specific examples of blowing agents include water, low-boiling hydrocarbons such as propane, butane, pentane, hexane, heptane, cyclopropane, cyclobutane, cyclopentane, cyclohexane, and cycloheptane, dichloroethane, propyl chloride, isopropyl chloride, Chlorinated aliphatic hydrocarbon compounds such as butyl chloride, isobutyl chloride, pentyl chloride, isopentyl chloride, fluorine compounds such as trichloromonofluoromethane, trichlorotrifluoroethane, hydrocarbons such as CHF ₃ , CH ₂ F ₂ , CH ₃ F, etc. Fluorocarbon, dichloromonofluoroethane, (e.g. HCFC141b (1,1-dichloro-1-fluoroethane), HCFC22 (chlorodifluoromethane), HCFC142b (1-chloro-1,1-difluoroethane)), HFC-245fa (1 , 1,1,3,3-pentafluoropropane), HFC-365mfc (1,1,1,3,3-pentafluorobutane), HFO-1233zd(E) (trans-1- chloro-3,3,3-trifluoropropene), HFO-1234yf (2,3,3,3-tetrafluoro-1-propene), HFO-1336mzz(Z) (cis-1,1,1,4, 4,4,-hexafluorobut-2-ene), hydroolefin compounds such as HFO-1224yd (Z), ether compounds such as diisopropyl ether, or organic physical blowing agents such as mixtures of these compounds, nitrogen gas, Examples include inorganic physical blowing agents such as oxygen gas, argon gas, and carbon dioxide gas.

The amount of the blowing agent used in the urethane resin composition is preferably in the range of 0.1 to 30 parts by weight based on 100 parts by weight of the urethane resin. Further, the blowing agent is more preferably in the range of 0.1 to 18 parts by mass, even more preferably in the range of 0.5 to 18 parts by mass, and even more preferably 1 to 10 parts by mass, based on 100 parts by mass of the urethane resin. Parts by weight are most preferred.
When the content of the foaming agent is greater than or equal to the above lower limit, foaming is promoted and the density of the resulting urethane foam can be reduced. When the content of the foaming agent is equal to or less than the above upper limit value, it is possible to prevent the foam from breaking and forming the foam.

《Foam stabilizer》
The foam stabilizer contained in the urethane resin composition improves the foamability of the urethane resin composition.
Examples of the foam stabilizer include surfactants such as polyoxyalkylene foam stabilizers such as polyoxyalkylene alkyl ether, and silicone foam stabilizers such as organopolysiloxane.
The amount of foam stabilizer added to the urethane resin is preferably in the range of 0.1 to 10 parts by mass, for example, per 100 parts by mass of the urethane resin.
Each of the resinization catalyst, trimerization catalyst, blowing agent, and foam stabilizer may be used alone or in combination of two or more.

The urethane resin composition may further contain an inorganic filler. Examples of inorganic fillers include, but are not limited to, silica, diatomaceous earth, alumina, titanium oxide, calcium oxide, magnesium oxide, iron oxide, tin oxide, antimony oxide, ferrites, basic magnesium carbonate, calcium carbonate, and magnesium carbonate. , zinc carbonate, barium carbonate, dawsonite, hydrotalcite, calcium sulfate, barium sulfate, gypsum fiber, potassium salts such as calcium silicate, talc, clay, mica, montmorillonite, bentonite, activated clay, seviolite, imogolite, sericite, Glass fiber, glass beads, silica balloons, aluminum nitride, boron nitride, silicon nitride, carbon black, graphite, carbon fiber, carbon balloons, charcoal powder, various metal powders, potassium titanate, magnesium sulfate, lead zirconate titanate, aluminum borate , molybdenum sulfide, silicon carbide, stainless steel fibers, various magnetic powders, slag fibers, fly ash, silica alumina fibers, alumina fibers, silica fibers, zirconia fibers, and the like.
The inorganic fillers may be used alone or in combination of two or more.

Furthermore, the urethane resin composition may contain antioxidants such as phenolic, amine, and sulfur-based antioxidants, heat stabilizers, metal damage inhibitors, antistatic agents, stabilizers, etc., as necessary, within a range that does not impair the purpose of the present invention. It may contain additives such as agents, crosslinking agents, lubricants, softeners, pigments, tackifier resins, and tackifiers such as polybutene and petroleum resins.

Furthermore, the urethane resin composition may contain antioxidants such as phenol-based, amine-based, and sulfur-based antioxidants, sedimentation inhibitors, heat stabilizers, metal damage inhibitors, antistatic agents, etc., as necessary, within a range that does not impair the purpose of the present invention. Additives such as inhibitors, stabilizers, crosslinking agents, lubricants, softeners, tackifying resins, etc. can be included.

Since the urethane resin composition reacts and cures, it is advisable to divide it into two liquids before molding the urethane foam. Specifically, it is preferable to divide the liquid into a polyol liquid containing a polyol compound and an isocyanate liquid containing a polyisocyanate compound. At this time, components other than the polyol compound and the polyisocyanate compound may be appropriately blended into the polyol solution or isocyanate solution, but are preferably blended into the polyol solution. This is because polyol compounds have low reactivity and are unlikely to cause side reactions even when mixed with components other than the polyol compound and polyisocyanate compound.

The urethane resin composition can be made into urethane foam by injecting it into the cavity 12a of the rib 12, and hardening and foaming in the cavity 12a. The method of injecting the urethane resin composition into the cavity 12a of the rib 12 is not particularly limited, but the polyol liquid and the isocyanate liquid are mixed before being injected into the cavity 12a of the rib 12 to obtain a mixture. The mixture may be injected into the cavity 12a of the rib 12, or the polyol solution and the isocyanate solution may be separately injected into the cavity 12a of the rib 12 and mixed in the cavity 12a.
Specifically, but not particularly limited to, an isocyanate liquid and a polyol liquid are separately stored in two containers, mixed with a caulking gun, etc., and the mixture is discharged from the caulking gun into the inside of the rib. It is best to inject it.
In a urethane resin composition, a reaction starts when the components are mixed, and the viscosity increases over time, hardening and foaming progress, and fluidity is lost to form polyurethane foam. The urethane resin composition is usually cured and foamed by being left at room temperature (for example, about 10 to 40°C), but it may be heated if necessary.

(Second embodiment)
The flat deck construction method according to the second embodiment of the present invention includes steps S1, S2, and S4, as shown in FIG.
Hereinafter, differences between the second embodiment and the first embodiment will be explained. Further, parts whose description is omitted are the same as those in the first embodiment. Furthermore, in the following description, members having the same configuration as those in the first embodiment are given the same reference numerals.

In step S4 of this construction method, as shown in FIG. 8, the injection port 16 is formed so as to be disposed at a position abutted against the partition material 20 forming the fireproof partition structure of the rib 12.
The partitioning material 20 is placed against one surface 11D side of the flat portion 11 of the flat deck 1. Specifically, the partitioning material 20 is arranged so that the upper end surface is butted against the bottom surface of the rib 12. Therefore, in step S4 of this construction method, the injection port 16 is placed at a position where it butts against the partition material 20 forming the fire protection partition structure, so that The filling material can be reliably injected into the inside of the rib 12. This is because the position where the injection port 16 is arranged and its vicinity are likely to be reliably filled with the filler in the cross section. Therefore, a gap is not created inside the rib 12 at the position where it abuts against the partition material 20 forming the fireproof partition structure, and a highly fire-resistant flat deck can be constructed.

The surface material constituting the partitioning material 20 is a member for forming partitions in an architectural structure. Examples of surface materials include gypsum board, extruded cement board, lightweight aerated concrete (ALC) board, precast concrete (PC) board, glass fiber reinforced concrete (GRC) board, lightweight wood wool cement board, wood chip cement board, and metal. Examples include sandwich panels, calcium silicate plates, slate plates, concrete, brick, glass and metal plates (eg, aluminum, iron). Among these, from the viewpoint of fire resistance and workability, one type selected from the group consisting of gypsum board, extruded cement board, lightweight cellular concrete, precast concrete board, and glass fiber reinforced concrete board is preferable, and gypsum board is preferred. More preferred.
In this embodiment, as shown in FIG. 8, a partitioning material 20 made of a face material 21 is shown. The facing material 21 can constitute a wall 25 in an architectural structure. The wall 25 is provided with a support frame 26 that is mounted on the building structure. The support frame 26 is, for example, a frame-shaped member consisting of horizontal bars extending in the horizontal direction and vertical bars extending in the vertical direction. It is fixed by a member.
Depending on the type of partition material 20, the support frame 26 may be omitted as appropriate, or another support may be used instead. Further, the partitioning member 20 may be fixed to the bottom surface 12D of the rib 12 without being fixed to the support frame 26, or may be fixed only to the bottom surface 12D of the rib 12 without the support frame 26 being fixed. good.

In the fireproof compartment structure according to the present embodiment, a noncombustible material (not shown) may be provided between the compartment material 20 and the lower surface 11D of the flat deck 1, if necessary.
As the noncombustible material, known noncombustible materials that can fill gaps can be used, such as rock wool and glass wool.

As described above, in this embodiment, it is possible to reliably fill the inside of the rib 12 at the position where it abuts against the partitioning material 20 forming the fireproof partition structure, resulting in good fire protection, sound insulation, and It is possible to form a compartment having heat insulation properties and the like.

Further, in the second embodiment, the present invention may further include a step S3 of heating the rib 12 before step S4 of the present construction method.
By injecting the filling material through the injection port 16 of the heated rib 12, the vicinity of the injection port 16 can be filled with the uniformly reacted filling material, so that the area forming the fireproof compartment structure where the injection port 16 is placed can be filled with the filling material that has reacted uniformly. It is possible to reliably fill the inside of the rib 12 at the position where it abuts against the drawing material 20. Further, it becomes easier to uniformly fill parts other than the injection port 16 and its vicinity with the filler. Therefore, a gap is not created inside the rib 12 at the position where it abuts against the partition material 20 forming the fireproof partition structure, and a highly fire-resistant flat deck can be constructed.

Note that the second embodiment may be applied in the case where the filler is completely filled along the longitudinal direction of the rib 12, as in the first embodiment, or when the filler is filled entirely along the longitudinal direction of the rib 12. Although it may be applied when the ribs 12 are not completely filled, it is effective to apply when the ribs 12 are not completely filled along the longitudinal direction. If the ribs 12 are not completely filled along the longitudinal direction, there will be hollow portions 12a inside the ribs 12 that remain hollow, and if the partitioning material is butted against this portion, the fire resistance will decrease. On the other hand, the filling port 16 and its vicinity are likely to be filled with filler over the entire cross section of the cavity 12a, so by butting the partitioning material against the filling port 16, good fire resistance can be easily maintained.

(Other embodiments)
Although the embodiment in which the injection port 16 is provided in the bottom portion of the rib 12 has been described above, the injection port 16 may be provided in a portion other than the bottom portion of the rib 12. For example, the injection port 16 may be provided on the side surface of the rib 12 constituting the cavity 12a.
Further, in the second embodiment, the portion where the partitioning materials are butted is the portion where the injection port 16 is provided, but is not necessarily limited to the portion where the injection port 16 is provided. For example, even if the inlet 16 is not provided, if the partitioning material is butted against the part filled with filler over the entire cross section of the rib cavity 12a, a highly fire-resistant flat deck will be constructed. be able to.

The present invention will be explained in more detail below using Examples, but the present invention is not limited to these Examples.
In addition, the measurement method and evaluation method of each physical property in this invention are as follows.

[Temperature measurement]
In Examples and Comparative Examples, the liquid temperature of the filling material injected into the ribs of the flat deck was measured. The results are shown in Table 2.
In Examples and Comparative Examples, the temperatures at the right end of the rib, the center of the rib, and the left end of the rib were measured when injecting into the rib of a flat deck. The results are shown in Table 2.
In Examples and Comparative Examples, the temperature difference between the center of the rib and the right edge or left edge of the rib when injecting into the rib of the flat deck was calculated, and the one with the largest difference was adopted. The results are shown in Table 2.

[Construction period]
When the shipping date of the flat deck was set as day 0, the period required to start on-site construction was evaluated based on the following criteria. The results are shown in Table 2.
A: Within 1 week until the start of construction B: More than 1 week but less than 2 weeks until the start of construction C: More than 2 weeks until the start of construction

[Fillability (fire resistance)]
A flat deck was cut at both ends in the longitudinal direction of the rib and at a distance of 0.3 m from both ends, and the cut surface was evaluated according to the following criteria. The results are shown in Table 2.
A: The filler was fully filled up to both ends in the longitudinal direction of the rib. B: The filler was fully filled at the cut surface of 0.3 m from both ends, but the filler was completely filled at both ends in the longitudinal direction of the rib. There are areas that are not filled. C: There are areas that are not filled with filler at both ends of the rib in the longitudinal direction and at a cut surface of 0.3 m from both ends.

According to the formulation shown in Table 1, in order to obtain urethane foams related to Examples and Comparative Examples, two components were prepared: (1) a polyol-containing composition and (2) a polyisocyanate. The details of the components in Table 1 are as follows.

(1) Polyol-containing composition [polyol]
・P-phthalic acid polyester polyol (manufactured by Kawasaki Chemical Industries, Ltd., product name: Maximol RLK-087, hydroxyl value = 200 mgKOH/g)
〔catalyst〕
・Trimerization catalyst: 2-ethylhexanoic acid potassium salt (manufactured by Air Products, product name: DABCO K-15), concentration 70-80% by mass
・Resinization catalyst (amine type): 1,2-dimethylimidazole (manufactured by Tosoh Corporation, product name: TOYOCAT-DM70) concentration 65-75% by mass
[Foam stabilizer]
・Silicone foam stabilizer (manufactured by Dow Corning Toray, product name: SH-193)
[Foaming agent]
・HFO-1233zd(E) (manufactured by Central Glass Co., Ltd., product name: Solstice LBA)
・Water [sedimentation inhibitor]
・Fumed silica (manufactured by Nippon Aerosil Co., Ltd., product name: Aerosil R976S)
[Liquid flame retardant]
・Tris (β-chloropropyl) phosphate (manufactured by Daihachi Chemical Co., Ltd., product name: TMCPP)
[Solid flame retardant]
・Red phosphorus flame retardant (manufactured by Rin Kagaku Kogyo Co., Ltd., product name: Nova Excel 140, metal hydroxide coating, red phosphorus content of 94% by mass or more)
・Zinc borate (manufactured by Hayakawa Shoji Co., Ltd., product name: Firebrake ZB)
・Ethylene bis(pentabromophenyl) (manufactured by Albemarle, product name: SAYTEX 8010)

(2) Polyisocyanate/Polyisocyanate (MDI, manufactured by Sumitomo Chemical Co., Ltd., product name: Sumidur 44V20)

[Example 1]
A flat deck was prepared in which the length of the ribs in the longitudinal direction (X-axis direction) (the length between both ends of the ribs) was 3 m. The prepared flat deck was laid on a supporting material, which is a building structure, and concrete was poured on the top surface of the flat part of the laid flat deck. Then, an injection port was formed in the center of the bottom of the rib of the flat deck. Thereafter, a 3 m long contact type rubber heater was used as a heating device, and the temperature control setting of the rubber heater was set so that the rib temperature was around 60° C. for heating. Separately, a polyol-containing composition and a polyisocyanate having the formulations shown in Table 1 for forming urethane foam were prepared, and each was stored in a closed container. At the construction site, a urethane resin composition prepared by mixing the polyol-containing composition and polyisocyanate discharged from each closed container with a liquid temperature of 35°C was poured into the ribs through the injection port using Graco's spray equipment H-25. 0.19 kg was injected into the interior (volume 3,200 ml). The urethane resin composition injected into the inside of the rib was reacted and foamed to form urethane foam as a filler filling the inside of the rib.

[Example 2]
Divide the 3m long rubber heater into 1m long rubber heaters and adjust the temperature settings for each so that the temperature of the rib at the position where the injection port is located and the temperature at the longitudinal end of the rib will be a predetermined difference. The procedure was carried out in the same manner as in Example 1 except that the procedure was changed to .

[Example 3]
The same procedure as in Example 1 was carried out except that the temperature control setting of the 3 m long rubber heater was changed so that the rib temperature was around 45°C.

[Example 4]
Divide the 3m long rubber heater into 1m long and 2m long rubber heaters, adjust the temperature settings for each, and make a predetermined difference between the temperature of the rib at the position where the injection port is located and the temperature at the longitudinal end of the rib. The same procedure as in Example 1 was carried out except for the following changes.

[Example 5]
The same procedure as in Example 1 was carried out except that the temperature control setting of the 3 m long rubber heater was changed so that the rib temperature was around 75°C.

[Example 6]
Divide the 3m long rubber heater into 1m long and 2m long rubber heaters, adjust the temperature settings for each, and make a predetermined difference between the temperature of the rib at the position where the injection port is located and the temperature at the longitudinal end of the rib. The same procedure as in Example 1 was carried out except for the following changes.

[Example 7]
The same procedure as in Example 1 was carried out except that the liquid temperature was changed from 35°C to 40°C and the heater temperature adjustment setting was changed to a rib temperature of around 50°C.

[Example 8]
The same procedure as in Example 1 was carried out except that the liquid temperature was changed from 35°C to 25°C and the heater temperature adjustment setting was changed to a rib temperature of around 75°C.

[Reference example 1]
A flat deck was prepared in which the length of the ribs in the longitudinal direction (X-axis direction) (the length between both ends of the ribs) was 3 m. Then, an injection port was formed in the center of the bottom of the rib of the flat deck. Thereafter, the ribs were heated using a 3 m long contact type rubber heater as a heating device, and the temperature control setting of the rubber heater was set so that the rib temperature was around 60°C. Separately, a polyol-containing composition and a polyisocyanate having the formulations shown in Table 1 for forming urethane foam were prepared, and each was stored in a closed container. A urethane resin composition prepared by mixing the polyol-containing composition and polyisocyanate discharged from each sealed container with a liquid temperature of 35°C using a spraying device H-25 manufactured by Graco Co., Ltd. at a separate factory other than the construction site. 0.19 kg was injected into the inside of the rib (volume (volume 3,200 ml) from the injection port. The urethane resin composition injected into the inside of the rib was reacted and foamed to form urethane foam as a filler to fill the inside of the rib. Formed.
A flat deck with filler filled inside the ribs manufactured at the separate factory mentioned above was laid on a supporting material that is a building structure, and concrete was poured on the top surface of the flat part of the laid flat deck.

[Reference example 2]
Divide the 3m long rubber heater into 1m long and 2m long rubber heaters, adjust the temperature settings for each, and make a predetermined difference between the temperature of the rib at the position where the injection port is located and the temperature at the longitudinal end of the rib. The same procedure as in Example 1 was carried out except for the following changes.

[Reference example 3]
Divide the 3m long rubber heater into 1m long and 2m long rubber heaters, adjust the temperature settings for each, and make a predetermined difference between the temperature of the rib at the position where the injection port is located and the temperature at the longitudinal end of the rib. The same procedure as in Example 1 was carried out except for the following changes.

As shown in Table 2, each example aims to shorten the construction period by manufacturing at the construction site a flat deck in which the filler is uniformly filled in the length direction of the inside of the rib, and the filling property (fire resistance) is improved. I was able to get a high flat deck.

1 Flat deck 11 Flat part 11D Bottom surface 11U Top surface 12 Rib 12a Cavity part 12b Connection part 14 Support material 16 Inlet 18A, 18B Side end part 18C Claw part 20 Partition material 21 Face material 25 Wall 26 Support frame body 30 Concrete 40 Heating device

Claims (10)

preparing a flat deck comprising a flat part and a rib protruding from one side of the flat part;
a step of laying the flat deck on a building structure;
heating the ribs of the flat deck installed on the building structure;
A method for constructing a flat deck, comprising the step of filling the inside of the heated rib with a filler through an injection port formed in the rib. 2. The flat deck construction method according to claim 1, wherein in the filling step, the temperature of the rib at the position where the injection port is located and the temperature of the longitudinal end of the rib are 40° C. or more and 80° C. or less. The method for constructing a flat deck according to claim 1 or 2, wherein in the filling step, the difference between the temperature of the rib at the position where the injection port is located and the temperature at the longitudinal end of the rib is within 20°C. . The method for constructing a flat deck according to any one of claims 1 to 3, further comprising the step of pouring concrete into the flat portion of the flat deck installed on the building structure. The method for constructing a flat deck according to claim 4, further comprising the step of forming an injection port in the rib after the step of pouring the concrete. 6. The method for constructing a flat deck according to claim 5, wherein the injection port is formed in the rib at a position where it abuts against a partition material forming a fireproof partition structure. The method for constructing a flat deck according to any one of claims 1 to 6, wherein the filler is a refractory material. The method for constructing a flat deck according to any one of claims 1 to 7, wherein the filler is urethane foam. The flat deck construction method according to any one of claims 1 to 8, wherein the injection port is formed in a bottom portion of the rib. preparing a flat deck comprising a flat part and a rib protruding from one side of the flat part;
a step of laying the flat deck on a building structure;
filling the filler from an injection port formed in the rib,
A method of constructing a flat deck, wherein the injection port is arranged at a position where it butts against a partition material forming a fireproof partition structure of the ribs.