JP4975551B2 - Fireproof insulation sheet and fireproof treatment method - Google Patents

Description

The present invention relates to a fireproof heat insulating sheet.

Conventionally, in order to enhance the fire resistance performance of buildings in the building field, fire resistant heat insulating sheets for applying a heat insulating coating to building materials have been used. The fireproof heat insulating sheet is affixed in a gap between the outer wall and the internal structure, is affixed to the surface of the building structure, or is used for a joint portion of the outer wall of the building. As characteristics required for such a fireproof heat insulating sheet, not only flame retardancy, heat insulating properties, and flameproofness but also ease of construction, ease of handling, and the like have been demanded.

As such a refractory heat insulating sheet, there is one disclosed in Patent Document 1. In Patent Document 1, a fireproof insulation sheet in which a fireproof coating material made of a resin composition containing thermally expandable graphite is impregnated in a mat made of a nonflammable fiber material, or a base material layer is provided on one or both sides of the fireproof coating material A fireproof insulation sheet is disclosed.
JP 2003-293482 A

The mat and base material layer used for the fireproof insulation sheet disclosed in the above patent document enhances the handleability and workability of the fireproof insulation sheet, and the fireproof insulation sheet expands in the surface direction when the fireproof coating material expands. It is provided for the purpose of reliably forming a fireproof heat insulating layer by preventing the expanded fireproof coating material from scattering.

However, since the conventional fireproof heat insulating sheet has a structure in which the base material layer is exposed to the outside, it is basically necessary to use a nonflammable material for the base material layer. If a non-combustible material is not used for the base material layer, the base material layer will be easily burned off when the flame wraps around the base material layer side. There was a possibility that the fireproof heat insulating layer was not formed. Incombustible fiber materials that can be used for the base material layer are expensive and have poor handleability, and there is a need for a technology that can expand the range of materials that can be used for the base material layer. It was.

In addition, it is desirable to use a bulky mat as a base material layer for impregnation, even if it is a fireproof insulation sheet in which a mat or the like is impregnated with a fireproof coating material. In some cases, the restraining force in the surface direction of the base material layer is insufficient. In that case, when the heat-expandable material expands, the fireproof insulation sheet extends in the surface direction, creating a gap with the structure to be protected, and if flame or air wraps around the gap, There was a possibility that the heat insulating sheet could not perform its function sufficiently.

An object of this invention is to provide the fireproof sheet which can prevent the expansion of the fireproof heat insulation sheet accompanying expansion | swelling of a thermally expansible material reliably, and can expand the selection range of the material which can be used for a base material layer.

As a result of intensive studies, the inventor has found that the above object can be achieved by sandwiching a base material layer made of a fiber material with a fireproof layer made of a fireproof resin composition, and has completed the present invention.

The present invention is a fireproof heat insulating sheet in which both sides of a base material layer made of a sheet-like material made of a fiber material are sandwiched between fireproof layers made of a fireproof resin composition, and the base material layer has a combustible fiber The softening point, melting point and decomposition temperature of the combustible fiber material are made higher than the expansion start temperature of the expansion material , and one fireproof layer is made into a thermally expandable fireproof layer containing the expansion material, and the other It is a fireproof heat insulation sheet which made the fireproof layer the carbonization fireproof layer which does not contain an expansion material .

It is preferable that a thermoplastic resin is mixed in the refractory resin composition constituting the carbonized refractory layer (claim 2). Furthermore, it is preferable that the melting point of the thermoplastic resin contained in the refractory resin composition constituting the carbonized refractory layer is lower than the softening point, melting point and decomposition temperature of the combustible fiber material constituting the base material layer. (Claim 3). Moreover, this invention is a fireproof processing method which performs a fireproofing process to a building using the fireproof heat insulation sheet in any one of Claim 1 thru | or 3, Comprising: A carbonization fireproof layer is on the structure surface of a building. This is a fireproofing method for fixing a fireproof heat insulating sheet to a structure so that the side of the thermally expandable fireproof layer faces the structure.

According to the present invention, since the fireproof heat insulating sheet has a structure in which the base material layer is sandwiched between the fireproof layers, the temperature rise of the base material layer becomes slow even when the fireproof heat insulating sheet is exposed to the flame, and the base material Since the supply of oxygen to the layer is also blocked, a flammable fiber material can be used for the base layer. That is, there is an effect that the range of materials that can be used for the base material layer is widened while reliably preventing the expansion of the refractory heat insulating sheet accompanying the expansion of the thermally expandable material. In addition, since at least one of the refractory layers is a thermally expandable refractory layer, when exposed to a flame, the thermally expandable refractory layer expands to form a refractory heat insulating layer excellent in fire resistance and heat insulation. Can be formed. And since a combustible fiber material is contained in a base material layer, a fireproof heat insulation sheet can be made cheaper and excellent in handleability. In addition, since the melting point, softening point, and decomposition temperature of the fiber material contained in the base material layer are set higher than the expansion start temperature of the expansion material, the base material layer extends in the sheet surface direction while the expansion material is expanding. Can be reliably prevented, and the expansion ratio in the direction perpendicular to the sheet surface can be increased. In addition, since the other refractory layer is a carbonized refractory layer that does not contain an expansion material, the refractory heat insulating layer formed in the event of a fire can be made stronger, and the refractory heat insulating layer can be peeled off or dropped from the structure. It can be prevented beforehand.

Further, when the thermoplastic resin is mixed with the refractory resin composition constituting the carbonized refractory layer, when heated, a part of the carbonized refractory layer 3 is melted and heated. Thus, it is possible to effectively prevent the gap between the fireproof heat insulating sheet and the surface of the structure or the gap from being enlarged.
Furthermore, when the melting point of the thermoplastic resin contained in the refractory resin composition constituting the carbonized refractory layer is lower than the softening point, melting point and decomposition temperature of the combustible fiber material constituting the base material layer. The thermoplastic resin in the carbonized refractory material melts faster than the base material layer loses its reinforcing function, and the refractory heat insulating sheet can be adhered to the building structure.
Moreover, the fireproof thermal insulation sheet according to any one of claims 1 to 3 is arranged such that the carbonized fireproof layer faces the structure surface of the building, and the side of the thermally expandable fireproof layer is opposite to the structure. If the fireproof thermal insulation sheet is fixed to the structure, the carbonized refractory layer remains as a relatively strong carbonized layer when exposed to flames or hot air, preventing the expanded refractory thermal insulation layer from scattering and falling off. And it can be reliably held on the surface of the structure.

Hereinafter, embodiments of the present invention will be described with reference to the drawings. Drawing 1 is a mimetic diagram showing the section of the embodiment of the fireproof heat insulation sheet of the present invention. The fireproof heat insulating sheet 1 is obtained by laminating and integrating fireproof layers 3 and 4 made of a fireproof resin composition on both sides of a sheet-like base material layer 2 made of a fiber material. In the present embodiment, one of the refractory layers is a thermally expandable refractory layer 4 that expands by heat, and the other is a carbonized refractory layer 3 that carbonizes by heat. Hereinafter, among the refractory resin compositions, those used for the thermally expandable refractory layer are referred to as “thermally expandable refractory material”, and those used for the carbonized refractory layer 4 are referred to as “carbonized refractory material”.

The base material layer 2 is a layer made of a sheet-like material made of a fiber material, and examples of the form of the fiber material sheet include a nonwoven fabric shape, a paper shape, a woven fabric shape, and a pre-glyph shape.

As a fiber material that can be used for the base material layer 2, not only a non-combustible fiber material but also a combustible fiber material can be used. Examples of non-combustible fibers include mineral fibers such as basalt fibers, rock wool, slag wool, glass wool, alumina fibers, silica fibers, silica alumina fibers, stainless steel fibers, steel wool and other metal fibers, and carbon fibers. Inflammable fibers include flame retardant fibers such as modacrylic fiber, vinylidene fiber, polyvinyl chloride fiber, polyclar fiber, cotton, hemp, rayon fiber, cupra fiber, acetate fiber, promix fiber, acrylic fiber, polyethylene Examples include flammable fibers such as fibers and polypropylene fibers, and fibers such as hair, silk, nylon fibers, vinylon fibers, polyester fibers, and benzoate fibers. These fibers may be used for the base material layer by appropriately blending them.

The carbonized refractory layer 3 is a refractory layer composed of a resin composition (carbonized refractory material) containing a resin material that is carbonized by heating. The carbonized refractory material is a refractory resin composition that does not contain an expansion material described later. As the resin constituting the carbonized refractory material, a resin material that can be used for the thermally expandable refractory layer 4 described later can be used. In particular, since the phenolic resin is cured and carbonized by heating, it is desirable that the carbonized refractory layer 3 is particularly composed of a phenolic resin. Further, the carbonized refractory layer 3 may be added with a phosphorus compound or a water-containing inorganic substance described later.

The thermally expandable refractory layer 4 is a refractory layer composed of a resin composition containing a resin material and an expandable material as main components (hereinafter referred to as a “thermally expandable refractory material”).

Rubber or resin is used as the resin material. Resin materials rich in elasticity include butadiene rubber, styrene butadiene rubber, acrylonitrile butadiene rubber, natural rubber, isoprene rubber, ethylene propylene rubber, butyl rubber, acrylic rubber, urethane rubber, silicone rubber, fluorine rubber, thermoplastic elastomer, α- Examples include olefin copolymers and ethylene copolymers.
You may use the said resin material individually or in mixture as appropriate.
Furthermore, the resin material includes polyolefin resins, polyester resins, polycarbonate resins, polystyrene resins, acrylic resins, acrylonitrile styrene butadiene resins, polyamide resins, epoxy resins, phenol resins, etc. A resin material may be mixed. Since the phenolic resin is cured and carbonized by heating, when the phenolic resin is mixed, it is possible to prevent the refractory resin composition from being easily softened / deformed / dropped / burned when exposed to a flame or the like.

As the expansion material, an expansion material that expands by heating, such as thermally expandable graphite or a foamable nitrogen compound, can be used. Among them, it is desirable to use conventionally known heat-expandable graphite as the expansion material because the expansion ratio of the composition can be increased. It is desirable to use heat-expandable graphite that has been neutralized so as not to react with a phosphorus compound described later. A preferable expansion ratio of the expansion material in the present invention is 2.5 to 200 times, more preferably 5 to 150 times in terms of volume expansion coefficient.

In addition to the refractory resin composition of the present invention, the following can be appropriately added as necessary.

Addition of phosphorus compounds such as red phosphorus, phosphate esters, metal phosphates, and ammonium polyphosphates can increase flame retardancy and improve the fireproof and heat insulating effect. Addition of ammonium polyphosphate is particularly preferable.

When a hydrous inorganic substance such as aluminum hydroxide or magnesium hydroxide is added, a dehydration reaction occurs during heating, and the heat-insulating performance can be improved by the endothermic action of the generated water.

The preferable range of the volume expansion coefficient during heating of the heat-expandable refractory material in the present invention is 2 to 40 times, more preferably 5 to 30 times. If the expansion ratio is low, it is uneconomical because a large amount of heat-expandable refractory material is required to ensure fireproof performance. If the expansion ratio is too high, the expanded heat-expandable refractory material tends to dissipate. The fireproof insulation layer formed becomes brittle.

Hereinafter, the manufacturing method of the fireproof heat insulation sheet | seat of this invention is demonstrated.
The fire resistant resin composition prepared and kneaded with necessary material components by a Banbury mixer or kneader is molded into a sheet by a molding method suitable for the resin material used as a base, such as extrusion molding, injection molding or roll molding.

By arranging these fire-resistant resin compositions formed into a sheet shape on both surfaces of a sheet-like base material layer as a heat-expandable fire-resistant layer or a carbonized fire-resistant layer and integrating them with an adhesive or the like, the present invention Can be manufactured. As the adhesive, it is desirable to use a phenol resin-based adhesive that can carbonize and become part of the carbonized refractory layer when heated. In addition, the integration of the base material layer and the fireproof layer is not necessarily performed by an adhesive. If the fireproof resin composition or the base material layer includes a thermoplastic material, the fireproof layer is used without using an adhesive. Alternatively, the surface of the base material layer may be heated and melted, integrated by the adhesiveness of the molten resin, and then cooled to obtain the fireproof heat insulating sheet of the present invention.

The fireproof thermal insulation sheet 1 of the present invention has a carbonized refractory layer facing the surface side of a structure such as a wall or a pillar of a building that requires fire resistance, and the side of the thermally expandable refractory layer 4 is opposite to the structure. Use it by wrapping or pasting it. The fixing to the surface of the structure may be performed using a temporary holder such as a bolt, a nail, an attachment jig, or a tucker, but may be performed using an adhesive or an adhesive.

When a fire occurs, when the flame or hot air reaches the fireproof heat insulating sheet of the present invention, the heat-expandable fireproof layer 4 expands by heat to form a fireproof heat insulating layer, and the structure is protected from the flame and heat. The base material layer 2 maintains the form of the sheet while the thermally expandable refractory layer 4 expands. That is, if the base material layer 2 does not function, the heat-expandable fireproof layer 4 expands in the surface direction when the heat-expandable fireproof layer 4 expands, and not only a sufficient expansion ratio cannot be obtained in the direction perpendicular to the sheet surface. If the refractory heat insulation sheet extends and separates from the surface of the structure, there is a risk that flames or hot air may enter the gap and the structure may not be sufficiently protected. It can be ensured that the base layer 2 does not lose its function while the layer 4 expands.

That is, in the present invention, the base material layer 2 is integrated so as to be sandwiched between fireproof layers, and since the base material layer 2 is not exposed, even when a flame or hot air wraps around the back side of the fireproof heat insulating sheet 1, It is possible to prevent the base material layer from being easily melted and burnt out to lose its function. That is, in the present invention, the base material layer is separated from the flame and hot air by the refractory layer, and the temperature rise of the base material layer is slower than that of the refractory layer. The timing to lose the function can be delayed. Moreover, since the base material layer is sandwiched on both sides by the fireproof layer, it is shielded from the air and is not easily burned out. Therefore, even if a flammable fiber material or a flammable fiber material that could not be conventionally used for the base material layer 2 is used for the base material layer, the base material layer 2 is in a state where the thermally expandable refractory layer 4 is expanded. As a result, the range of selection of the fiber material that can be used for the base material layer can be expanded. In particular, since a woven fabric such as cotton, linen or polyester fiber can be used for the base material layer, the fire-resistant and heat-insulating sheet can be inexpensive, flexible, and easy to handle and work.

Moreover, even if it is a case where a nonflammable fiber material or a flame-retardant fiber material is used for the base material layer 2, in the present invention, since the base material layer 2 is sandwiched on both sides by the fireproof layer, The temperature rise of the layer 2 becomes relatively gradual and the supply of air is cut off, so that the fiber material necessary for the base material layer 2 can be saved. Moreover, since the base material layer 2 can be made thin in that case, it becomes easy to make a fireproof heat insulation sheet flexible, and can make the fireproof heat insulation sheet obtained excellent in the handleability.

Hereinafter, in the embodiment of the present invention, more preferable embodiments will be described.

It is desirable that the sheet-like base material layer 2 made of a fiber material is not easily stretchable in the sheet surface direction, and is a paper-like base material layer, a woven cloth-like base material layer, or a pre-glyph-like base material layer. It is particularly desirable to be. If the base material layer is difficult to expand and contract, it is possible to reliably prevent the fireproof heat insulating sheet from extending during a fire and causing a gap between the structure to be protected and the fireproof heat insulating sheet.

Furthermore, the fiber material used for the base material layer 2 is desirably a fiber material that can maintain functions such as strength and rigidity as a fiber up to a temperature higher than the expansion start temperature of the thermally expandable refractory layer 4. That is, in the case of a fiber made of a synthetic resin that melts and softens at a high temperature, it is desirable that the melting point and softening point of the resin be higher than the expansion start temperature of the thermally expandable expansion material. For fibers made of other synthetic resins and natural fibers such as cotton and hemp, it is desirable that the decomposition temperature of the fiber material be higher than the expansion start temperature of the thermally expandable expansion material. By using such a fiber material, the base material layer 2 can reliably perform its function while the thermally expandable refractory layer 4 expands.

Further, when a fiber material containing a thermoplastic resin is used as the fiber material used for the base material layer 2, the thermoplastic fiber material of the base material layer 2 is melted into the expanded heat-expandable fireproof layer 4. Therefore, the effect of preventing the fire-resistant and heat-insulating layer composed of the expanded heat-expandable fire-resistant layer 4 from being scattered and peeled off is enhanced, and the fire-resistant and heat-insulating properties are enhanced.

The fire-resistant layer facing the building structure side of the fire-resistant heat-insulating sheet of the present invention may be the carbonized heat-resistant layer 3 described above, but the heat-expandable fire-resistant layer 4 (in this case, the base material as shown in FIG. 2) It may be configured such that both sides of the layer 2 are sandwiched between the thermally expandable refractory layers 4 and 4). If the fire-resistant layer facing the building structure side is also made of the heat-expandable fire-resistant layer 4, the expansion ratio of the fire-resistant heat-insulating sheet will be high. It is particularly suitable for applications that sometimes close the gap.

On the other hand, when the refractory layer facing the building structure is the carbonized refractory layer 3 as in the first embodiment, the carbonized refractory layer 3 is relatively strong when exposed to a flame or hot air. Therefore, the expanded refractory heat insulating layer can be prevented from being scattered and dropped off and can be reliably held on the surface of the structure. Therefore, when the fireproof heat insulating sheet of the present invention is used on the surface of a structure such as a column or wall, it is desirable that one of them be the carbonized fireproof layer 3. Furthermore, if a thermoplastic resin is mixed with the refractory resin composition constituting the carbonized refractory layer 3, a part of the carbonized refractory layer 3 is melted when heated, thereby building structures such as columns. It comes to adhere to the surface, and it is possible to further prevent a gap from being formed between the refractory heat insulating sheet and the surface of the structure or a gap from being enlarged. The melting point of the thermoplastic resin contained in the carbonized refractory material is preferably lower than the melting point, softening point, and decomposition point of the fiber material constituting the base material layer, in which case the base material layer 2 loses its function. As soon as the thermoplastic resin in the carbonized refractory material melts, the refractory heat insulating sheet 1 can be adhered to the building structure.

Examples of the present invention are given below, but the present invention is not limited thereto.

(Preparation of thermally expandable refractory material)
50 parts by weight of neutralized heat-expandable graphite (50 mesh), 50 parts by weight of ammonium polyphosphate, and 100 parts by weight of thermoplastic urethane elastomer were kneaded to obtain a heat-expandable refractory material. Thermal expansion graphite having an expansion start temperature of 200 ° C. was used.

(Base material layer)
A woven fabric (thickness 0.5 mm) made of polyester fiber (melting point 260 ° C.) was used as the base material layer.

(Manufacture of fireproof insulation sheets)
The thermally expandable refractory material was heated and melted at 140 ° C. and extruded into a sheet having a thickness of 2 mm to form a thermally expandable refractory layer. While the extruded thermally expandable refractory layer was still hot and sticky, the woven fabric made of polyester fiber as the base material layer was superposed and pressed by a roll to integrate them. Then, a carbonized refractory layer is formed by extruding a mixed composition of a thermoplastic polyester elastomer and phenol novolac resin melted at 180 ° C. into a sheet having a thickness of 1 mm so as to overlap the opposite side of the base material layer. And a fireproof heat insulating sheet of the present invention as shown in FIG. 1 was obtained.

(Comparative example)
The thermally expandable refractory material was heated and melted at 140 ° C. and extruded into a sheet having a thickness of 2 mm to form a thermally expandable refractory layer. While the extruded heat-expandable fire-resistant layer is still hot and sticky, the woven fabric made of polyester fiber as the base material layer is layered and pressed with a roll to integrate both, and the fire resistance of the comparative example An insulating sheet was obtained.

(Fire resistance evaluation)
The following fireproof performance evaluation was performed with respect to the fireproof insulation sheet of an Example and a comparative example. Each fireproof heat insulating sheet was cut into a square shape of 50 cm square, and attached to an iron plate provided substantially vertically by an adhesive so that the heat-expandable fireproof layer faced the outside. The fireproof performance evaluation was performed by heating with a burner from the front of the fireproof heat insulating sheet toward the center of the sheet, and observing the state of formation of the expanded fireproof heat insulating layer.

In the fireproof thermal insulation sheet of the example, heating was started and the thermally expandable fireproof layer started to expand, and an expanded fireproof thermal insulation layer was formed. Even if heating is continued, it is not observed that the refractory insulation sheet extends in the surface direction, and the gap between the refractory insulation sheet and the iron plate does not expand, or the sheet does not lift from the iron plate. It was. Examination after the end of the test revealed that although the polyester fiber woven fabric, which is the base layer of the fireproof insulation sheet, is partially carbonized, it retains its original shape and is a carbonized fireproof layer polyester elastomer and phenol. A part of the novolac resin mixed composition was adhered to the iron plate while carbonizing, and the fireproof heat insulating sheet was a fireproof heat insulating layer adhered to the surface of the iron plate as a whole.

In the fireproof heat insulating sheet of the comparative example, heating was started and the thermally expandable fireproof layer started to expand, and an expanded fireproof heat insulating layer was formed. The cloth gradually lost its function, and the refractory insulation sheet on the upper side of the portion heated by the burner might hang down from the iron plate, or the refractory insulation sheet might float from the iron plate. Also, at the part where the flame or hot air of the burner hits directly, the shape of the refractory heat insulating sheet collapsed greatly, the expanded thermally expansible refractory material was scattered and dropped, and part of the iron plate could be exposed .

According to the present invention, a fireproof heat insulating sheet for applying a heat insulation coating to a building material, which reliably prevents the expansion of the fireproof heat insulating sheet accompanying the expansion of the thermally expandable material, It is possible to provide a fire-resistant and heat-insulating sheet that can reliably form a fire-resistant and heat-insulating layer on the surface of a building structure without creating a gap therebetween, and can expand the range of materials that can be used for the base material layer.

It is a cross-sectional schematic diagram which shows embodiment of the fireproof heat insulation sheet | seat of this invention. It is a cross-sectional schematic diagram which shows other embodiment of the fireproof heat insulation sheet | seat of this invention.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Fireproof heat insulation sheet 2 Base material layer 3 Carbonized fireproof layer 4 Thermal expansion fireproof layer

Claims (4)

Both sides of the base material layer made of a sheet material made of fiber material
A fireproof heat insulating sheet integrated so as to be sandwiched between fireproof layers made of a fireproof resin composition,
Including a flammable fiber material in the base material layer,
The softening point, melting point and decomposition temperature of the combustible fiber material are set higher than the expansion start temperature of the expansion material,
One refractory layer is a heat-expandable refractory layer containing an expansion material ,
A fireproof heat insulating sheet in which the other fireproof layer is a carbonized fireproof layer containing no expansion material . The fireproof heat insulation sheet according to claim 1, wherein a thermoplastic resin is mixed in the fireproof resin composition constituting the carbonized fireproof layer . Melting point of the thermoplastic resin contained in the refractory resin composition constituting the carbide refractory layer, the softening point of the flammable fibrous material constituting the base material layer, according to claim 2 which is lower than the melting point and the decomposition temperature Fireproof insulation sheet. A fireproofing method for subjecting a building to fireproofing using the fireproof heat insulating sheet according to any one of claims 1 to 3, wherein the carbonized fireproof layer faces the structure surface of the building, and has a thermal expansibility. A fireproofing method for fixing a fireproof heat insulating sheet to a structure so that the side of the fireproof layer is opposite to the structure .

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