JP7336284B2 - Laminate and covering structure - Google Patents

Description

The present invention relates to novel laminates and coating structures.

2. Description of the Related Art When structures such as buildings and civil engineering structures are exposed to high temperatures due to fire or the like, there is a problem that the physical strength of steel frames constituting columns, beams, and the like rapidly decreases. On the other hand, a coating structure is known in which a steel frame is coated with a coating material having heat protection properties to delay the temperature rise of the steel frame in the event of a fire, thereby suppressing the deterioration of the physical strength of the steel frame.

As such a covering structure, there is a method of adhering a thermally foamable sheet to a steel frame via an adhesive. A thermally foamable sheet is made by molding a mixture of synthetic resin, flame-retardant foaming agent, and polyhydric alcohol into a sheet.・It is carbonized to form a carbonized heat insulating layer and has the effect of exhibiting heat resistance protection (for example, Patent Document 1 etc.). Such a thermally foamable sheet has the characteristics that it can be applied relatively simply simply by sticking it with an adhesive or the like, does not require extra space, and can have a uniform thickness. In addition, since the surface side can be colored or painted to improve design, there are many requests for application to sites that impart aesthetics and design.

Japanese Patent Application Laid-Open No. 2002-201733

However, the heat-foamable sheet of Patent Document 1 may cause damage such as cracks and defects in the formed carbonized heat insulating layer due to hot air during a fire or the like, physical impact, or the like. At such damaged portions of the carbonized heat insulating layer, the surface of the steel frame is likely to be exposed, and it may be difficult to maintain the desired heat resistance protection performance.

As a result of intensive studies to achieve the above object, the present inventors have found a laminate having a thermally foamed layer, a decorative layer on the surface thereof, and an inorganic fiber nonwoven fabric in a specific manner on the back side of the thermally foamed layer. The present invention was completed by considering the body and the covering structure.

That is, the present invention has the following features.
1. A covering structure in which a thermal foaming layer and a decorative layer are laminated on the surface side of a steel frame ,
The thermal foaming layer has an inorganic fiber nonwoven fabric on the back side,
The inorganic fiber nonwoven fabric is laminated so as to be partially or fully embedded in the thermal foaming layer ,
A covering structure, wherein the inorganic fiber non-woven fabric of the thermal foaming layer is placed facing the steel frame .
2. 1. The inorganic fiber nonwoven fabric has a basis weight of 10 to 150 g/m ² . The covering structure according to .
3. 1. The inorganic fiber nonwoven fabric is characterized in that the fibers of inorganic fibers arranged at random are bonded with a resin component. or 2. The covering structure according to .
4. A covering structure further laminated with a reinforcing layer,
The reinforcing layer is
Laminated so as to be interposed between the thermally foamed layer and the decorative layer, or
Laminated so as to be partially embedded or fully embedded in the surface side of the thermal foaming layer, or
1. Laminated so as to be partially embedded or fully embedded in the back side of the decorative layer . ~3. The covering structure according to any one of .
5. The decorative layer contains a resin component and colored powder,
1. Characterized in that inorganic particles are included as the colored granules. ~ 4. The covering structure according to any one of .

INDUSTRIAL APPLICABILITY The present invention is excellent in design and can maintain stable heat protection when the steel frame is exposed to high temperatures due to fire or the like.

It is a sectional view showing an example of the layered product of the present invention. 1 is a cross-sectional view showing an example of a thermally foamed layer used in the present invention; FIG. 1 is a cross-sectional view showing an example of a thermally foamed layer used in the present invention; FIG. 1 is a cross-sectional view showing an example of a decorative layer used in the present invention; FIG. It is a sectional view showing an example of the layered product of the present invention. It is a sectional view showing an example of the layered product of the present invention. It is a sectional view showing an example of the layered product of the present invention. 1 is a cross-sectional view showing an example of the covering structure of the present invention; FIG. 1 is a cross-sectional view showing an example of the covering structure of the present invention; FIG. 1 is a cross-sectional view showing an example of the covering structure of the present invention; FIG.

A: Laminates 1, 11, 11a: Thermal foam layer (thermal foam sheet)
1a: Inorganic fiber nonwoven fabric 1b: Adhesive layer 1c: Releasable sheet 2: Decorative layer (decorative sheet)
2b: Adhesive layer 2c: Releasable sheet 2d: Surface protection layer 3: Reinforcement layer 13: Thermal foam layer (thermal foam sheet)
23: Decorative layer (decorative sheet)
B: Steel frame X: Joint

EMBODIMENT OF THE INVENTION Hereinafter, the form for implementing this invention is demonstrated.

FIG. 1 shows a cross-sectional view of the laminate A of the present invention. The laminate A of the present invention has heat-resistant protective properties, design properties, etc., and as shown in FIG. It is laminated on the surface side of the thermal foaming layer 1 so that the layer 2 can be visually recognized.

(Thermal foam layer)
The thermal foaming layer 1 of the present invention foams when the ambient temperature rises due to a fire or the like and the temperature of the layer reaches a predetermined foaming temperature (preferably 180 ° C. or higher, more preferably 200 to 400 ° C.). to form a carbonized heat insulating layer.

The thermal foaming layer 1 is preferably made of a mixed composition containing a resin component, a flame retardant, a foaming agent, a carbonizing agent, and a filler as constituent components. When a fire breaks out, each of these components exerts functions such as expansion of the layer, formation of a carbonized heat insulation layer, and generation of non-flammable gas through the combined action of each other, thereby exhibiting excellent heat insulation and heat protection. be able to.

Examples of resin components that can be used include thermoplastic resins such as vinyl resins, polystyrene resins, polypropylene resins, acrylic resins, acrylic styrene resins, polyamide resins, polyurethane resins, vinyl acetate resins, and ethylene vinyl acetate resins. Also natural rubber, isoprene rubber, butadiene rubber, styrene-butadiene rubber, chloroprene rubber, nitrile rubber, butyl rubber, chlorinated butyl rubber, ethylene-propylene rubber, chlorosulfonated polyethylene, acrylic rubber, epichlorohydrin rubber, polyvulcanized rubber, silicone rubber , fluororubber, urethane rubber and the like can also be used. These can be used singly or in combination of two or more. Among these resins, acrylic resins, acrylic styrene resins, vinyl acetate resins, ethylene vinyl acetate resins, and the like are preferably used.

The flame retardant generally exhibits at least one effect such as a dehydration cooling effect, a nonflammable gas generation effect, and a carbonization promoting effect of the thermoplastic resin in the event of a fire, and has an effect of suppressing the combustion of the resin component. The flame retardant used in the present invention is not particularly limited as long as it has such action, and known flame retardants can be used. Examples include chlorine compounds, antimony compounds, phosphorus compounds, and boron compounds. These can be used singly or in combination of two or more. Moreover, these may be either uncoated products or coated products. Among these, phosphorus compounds such as ammonium phosphate and ammonium polyphosphate are preferably used.

The mixing ratio of the flame retardant is preferably 50 to 1000 parts by weight, more preferably 100 to 800 parts by weight, still more preferably 200 to 600 parts by weight, per 100 parts by weight (solid content) of the resin component. In the present invention, by including the flame retardant in such a relatively high proportion, good performance in terms of heat protection can be obtained.

The foaming agent generally has the effect of generating a nonflammable gas in the event of a fire, foaming the carbonizing resin component and the carbonizing agent, and forming a carbonized heat insulating layer having pores. The foaming agent is not particularly limited as long as it has such action, and known foaming agents can be used. Examples thereof include melamine and its derivatives, dicyandiamide and its derivatives, azodicarbonamide, urea and thiourea. These can be used alone or in combination of two or more. Among these, melamine, dicyandiamide, azodicarbonamide and the like are preferably used.

The mixing ratio of the foaming agent is preferably 5 to 500 parts by weight, more preferably 30 to 200 parts by weight, still more preferably 40 to 150 parts by weight with respect to 100 parts by weight (solid content) of the resin component. Within such a range, excellent foaming properties can be exhibited, and good performance in terms of heat insulation and heat protection can be obtained.

Carbonizing agents generally have the effect of forming a thick carbonized heat insulating layer with excellent heat insulating properties by dehydrating and carbonizing the thermoplastic resin itself in the event of a fire as well as carbonizing the thermoplastic resin. The carbonizing agent used in the present invention is not particularly limited as long as it has such effects, and known carbonizing agents can be used. Examples thereof include polyhydric alcohols such as pentaerythritol, dipentaerythritol and trimethylolpropane; starch, casein and the like. Carbonizing agents can be used alone or in combination of two or more. Among these, pentaerythritol, dipentaerythritol and the like are preferably used.

The mixing ratio of the carbonizing agent is preferably 5 to 600 parts by weight, more preferably 20 to 300 parts by weight, still more preferably 40 to 150 parts by weight, per 100 parts by weight (solid content) of the resin component. Within such a range, a dehydration cooling effect and a carbonized heat insulating layer forming effect can be exhibited, and good performance in terms of heat insulation and heat protection can be obtained.

The filler generally has the effect of maintaining the strength of the carbonized heat insulating layer. The filler is not particularly limited as long as it has such action, and known fillers can be used. For example, carbonates such as calcium carbonate, sodium carbonate, magnesium carbonate, and aluminum oxide; metal oxides such as titanium dioxide and zinc oxide; silica, clay, talc, clay, kaolin, diatomaceous earth, shirasu, mica, wollastonite, Inorganic powders such as silica sand, silica stone, quartz, vermiculite, alumina, and fly ash are included. These can also be used by 1 type(s) or 2 or more types. The shape of the filler is not particularly limited, but examples thereof include spherical, granular, plate-like, rod-like, scale-like, needle-like and the like.

The blending ratio of the filler is preferably 10 to 300 parts by weight, more preferably 20 to 250 parts by weight, still more preferably 50 to 160 parts by weight, per 100 parts by weight (solid content) of the resin component. Within such a range, the strength of the carbonized heat insulating layer can be maintained, and good performance in terms of heat protection can be obtained.

The thermally foamed layer 1 of the present invention preferably contains fibrous substances in addition to the above components. By containing the fibrous substance, the carbonized heat insulating layer is prevented from coming off, etc., and the effect of retaining the shape of the carbonized heat insulating layer is enhanced. This action mechanism is not limited to the following, but since the carbonized heat insulating layer is formed while the fibrous material is entwined with the inorganic fiber nonwoven fabric 1a laminated on the back side of the thermally foamed layer 1, the carbonized heat insulating layer falls off. and the like, and a uniform carbonized heat insulating layer is formed on the surface of the inorganic fiber nonwoven fabric 1a. As a result, stable heat resistance protection can be obtained.

Examples of fibrous materials include mineral fibers such as rock wool, glass fiber, silica-alumina fiber, ceramic fiber, potassium titanate fiber, and carbon fiber, and organic fibers such as pulp fiber, polypropylene fiber, vinyl fiber, and aramid fiber. be done. These can also be used by 1 type(s) or 2 or more types. Among these, heat-resistant inorganic fibers and carbon fibers are preferred, and rock wool and glass fibers are particularly preferred. The fiber length is preferably 1-30 mm, more preferably 2-20 mm, and the fiber diameter is preferably 1-20 μm, more preferably 2-15 μm.

The mixing ratio of the fibrous substance is preferably 0.1 to 50 parts by weight, more preferably 0.5 to 30 parts by weight, per 100 parts by weight (solid content) of the resin component.

Moreover, in addition to the above components, the thermal foaming layer 1 may contain various additives as necessary. Any additive may be used as long as it does not significantly impair the effects of the present invention. agents, antifoaming agents, cross-linking agents, ultraviolet absorbers, light stabilizers, antioxidants, diluent solvents and the like.

The thickness of the thermally foamed layer 1 may be appropriately set depending on the application site and the like, but is preferably about 0.2 to 10 mm, more preferably about 0.3 to 6 mm.

As shown in FIG. 2, the present invention is characterized in that an inorganic fiber nonwoven fabric 1a is laminated on the back side of the thermal foaming layer 1, and the surface side on which the inorganic fiber nonwoven fabric 1a is laminated is a laminate. Back side of A. As a mode of lamination of the thermally foamed layer 1 and the inorganic fiber nonwoven fabric 1a, for example,
(I) Semi-embedded [Fig. 2 (I)]: A mode in which the surface of the inorganic fiber nonwoven fabric 1a on the thermally foamed layer 1 side is embedded and the opposite surface is exposed.
(II) Fully embedded [Fig. 2 (II)]: A mode in which the entire inorganic fiber nonwoven fabric 1a is embedded in the thermal foam layer 1,
etc. In the aspect (II) above, the inorganic fiber nonwoven fabric 1a to be completely embedded is located on the back side with respect to the central portion of the thickness of the thermal foaming layer 1, and the inorganic fiber nonwoven fabric 1a is embedded. The face side becomes the back side and is installed facing the steel frame side. (Hereinafter, the portion of the thermal foam layer 1 in which the inorganic fiber nonwoven fabric 1a is semi-embedded or fully embedded (the portion that bites into the inorganic fiber nonwoven fabric 1a) is also referred to as the “thermal foam layer 11a”, and the other portion is also referred to as the “thermal foam layer 11”. say.)

In the present invention, with the aspects (I) and (II) above, the effect of preventing the carbonized heat insulating layer from falling off can be enhanced, and the effects of the present invention can be fully exhibited. In addition, in the case of the above aspect (I), when it is installed on the steel frame via an adhesive material described later, the adhesion to the steel frame surface can be improved, and the fall-off prevention effect of the carbonized heat insulating layer can be further improved. can be enhanced.

The thermally foamed layer 1 having the mode (I) [FIG. 2(I)] or (II) [FIG. 2(II)] forms a structure having at least two layers, the thermally foamed layer 11 and the thermally foamed layer 11a. When exposed to a high temperature due to fire or the like, the thermally foamed layer 11 and the thermally foamed layer 11a each form a carbonized heat insulating layer. In particular, in the carbonized heat insulating layer formed by the thermally foamed layer 11a, the inorganic fibers contained in the inorganic fiber nonwoven fabric 1a act as a carbonized layer reinforcing component, and it is speculated that a strong carbonized heat insulating layer can be formed. Even if the thermal foaming layer 11 is damaged, the carbonized heat insulating layer formed by the thermal foaming layer 11a prevents the steel frame from being exposed. As a result, the steel frame is not exposed and stable heat protection is maintained. can be done.

Such an inorganic fiber nonwoven fabric 1a preferably has a basis weight of 10 to 150 g/m ² (more preferably 15 to 100 g/m ² ). In such a case, the voids between the inorganic fibers of the inorganic fiber nonwoven fabric 1a are easily filled with the thermally foamable layer 1, and the thermally foamable sheet of the aspect (I) or (II) is easily obtained, and the basis weight is satisfied. As a result, a strong carbonized heat insulating layer can be formed in the vicinity of the steel frame, and as a result, there is no fear that the steel frame 1 will be exposed, and stable heat resistance protection can be maintained.

The inorganic fiber nonwoven fabric 1a is a cloth (sheet-like) made of individual inorganic fibers (formed without weaving). For example, inorganic fibers are arranged in one direction. , crossed inorganic fibers, and randomly arranged inorganic fibers. In the present invention, inorganic fibers arranged randomly are suitable. Furthermore, examples of bonding methods between inorganic fibers include chemical bonding using a resin component (chemical bond), fusion bonding by heating (thermal bond), mechanical entanglement (needle punch), sewing (stitch bond), and the like. In the present invention, an inorganic fiber nonwoven fabric in which the fibers of inorganic fibers are bonded with a resin component (chemical bond) is suitable.

In this way, by using the inorganic fiber nonwoven fabric 1a in which the fibers of the randomly arranged inorganic fibers are bonded with the resin component, the carbonized heat insulating layer formed by the thermally foamed layer 11a when exposed to high temperatures due to a fire or the like. In this case, the inorganic fiber contained in the inorganic fiber nonwoven fabric 1a acts as a reinforcing component for the carbonized heat insulating layer, and the resin component has an effect like a carbonizing agent, so that a stronger carbonized heat insulating layer can be formed. It is speculated that As a result, there is no possibility that the steel frame will be exposed, and more stable heat protection can be maintained.

The inorganic fibers constituting the inorganic fiber nonwoven fabric 1a are not particularly limited, but examples thereof include rock wool, glass fiber, silica fiber, silica-alumina fiber, carbon fiber, silicon carbide fiber, and metal fine wires such as iron and copper. mentioned. Glass fibers are preferred in the present invention. Moreover, the inorganic fibers may be those subjected to some surface treatment. Furthermore, the cross-sectional shape of the fiber is not particularly limited, and any shape such as circular, polygonal, or flat can be used. The resin component for bonding the inorganic fibers is not particularly limited, but examples include acrylic resins, polyurethane resins, polyester resins, vinyl acetate, polyvinyl alcohol, SBR resins, NBR resins, epoxy resins, melamine resins, and the like. . The thickness of the inorganic fiber nonwoven fabric 1a may be appropriately set, but is preferably about 0.1 to 2 mm, more preferably about 0.15 to 1 mm.

Further, in the present invention, the inorganic fiber nonwoven fabric 1a may contain organic fibers in addition to inorganic fibers as long as the effects of the present invention are not impaired. Examples of organic fibers include pulp fibers, polyester fibers, polypropylene fibers, aramid fibers, vinylon fibers, polyethylene fibers, polyarylate fibers, PBO fibers, nylon fibers, acrylic fibers, vinyl chloride fibers, and cellulose fibers. The organic fiber may be one that melts in a temperature range of about 150° C. and becomes liquid, but one that does not melt in such a temperature range is preferable. These can also be used in combination of two or more.

As a method for producing the thermally foamed layer 1, the inorganic fiber nonwoven fabric 1a may be laminated so as to be partially embedded or fully embedded in the thermally foamed layer 1. Examples of the method include the following methods.
- A method of pouring a mixed composition of the constituent components of the thermal foaming layer 1 into a mold, further laminating the inorganic fiber nonwoven fabric 1a, and demolding after drying.
- A method of preparing a mixed composition of the constituent components of the thermal foaming layer 1 and then coating and laminating it on the inorganic fiber nonwoven fabric 1a.
After preparing a kneaded product (hereinafter also referred to as “kneaded product for thermal foaming layer”) by kneading the constituent components of the thermal foaming layer 1 with a kneader or the like, the kneaded product is laminated on the inorganic fiber nonwoven fabric 1a, and a rolling roller or the like is applied. A method of processing into a sheet by
The thermally foamable layer 1 of the present invention is preferably a sheet-like thermally foamable layer (hereinafter also referred to as "thermally foamable sheet") obtained by the above method.

As shown in FIG. 3, in the thermally foamable layer 1 (thermally foamable sheet) of the present invention, an adhesive layer 1b can be laminated on the outer side (back side) of the inorganic fiber nonwoven fabric 1a [FIG. 3(I)]. . In this case, the inorganic fiber nonwoven fabric 1a is laminated so as to be semi-embedded in the thermal foaming layer 1 (the aspect of (I) above), and the exposed inorganic fiber nonwoven fabric 1a is semi-embedded in the adhesive layer 1b. A preferred embodiment is one. This can further enhance the effects of the present invention. Furthermore, the surface of the adhesive layer 1b can be covered with a release sheet 1c [FIG. 3(II)]. By using such a thermally foamed layer 1, working efficiency can be improved.

The method of laminating the adhesive layer 1b and the release sheet 1c is not particularly limited. Alternatively, a method of forming an adhesive layer 1b by applying an adhesive on the release sheet 1c in advance, and laminating the adhesive layer 1b on the thermally foamable layer 1 on the inorganic fiber nonwoven fabric 1a side, etc. is mentioned.

Examples of adhesives that form the adhesive layer 1b include water-dispersed types, water-soluble types, and the like, which are mainly composed of acrylic resins, silicon resins, epoxy resins, vinyl resins, phenol resins, polyester resins, urethane resins, paraffin, and the like. A known adhesive such as a solvent type adhesive can be used. A flame retardant, a foaming agent, a carbonizing agent, a filler, and the like, which are blended in the above-described thermally foamable resin sheet, may be added to the adhesive, if necessary. Further, in the present invention, adhesives also include pressure-sensitive adhesives. The adhesive layer 1b preferably has a thickness of 25 to 200 μm, or an application amount of 0.05 to 0.5 kg/m ² .

The release sheet 1c protects the adhesive layer 1b during storage or transportation of the thermally foamable layer 1, and can be easily peeled off from the adhesive layer 1b when the thermally foamable sheet is used. As such a release sheet, a known one can be used, for example, paper or film coated or impregnated with a release agent such as silicon, wax, fluororesin, or a sheet not containing the release agent. Synthetic resin films such as polypropylene and polyethylene, which themselves have releasability, and the like can be mentioned.

(Cosmetic layer)
The decorative layer 2 of the present invention is not particularly limited as long as it can impart design properties, but is preferably a composition containing a resin component and colored powder (hereinafter also referred to as "composition for decorative layer" It is formed by

The resin component mainly plays a role of fixing the colored powder particles. Various synthetic resins can be used as such a resin component. Examples of resin types include acrylic resin, silicone resin, acrylic silicone resin, fluorine resin, vinyl acetate resin, acrylic/vinyl acetate resin, vinyl chloride resin, urethane resin, acrylic urethane resin, epoxy resin, alkyd resin, and polyvinyl alcohol. Resins, polyester resins, ethylene resins, polyvinyl alcohol, cellulose and derivatives thereof, and composites thereof. Such a synthetic resin may have the property of causing a cross-linking reaction.

The glass transition temperature of the resin component is preferably -60°C to 60°C, more preferably -40°C to 30°C, still more preferably -30°C to 20°C. In the case of such a range, it becomes possible to impart appropriate flexibility. The glass transition temperature is a value determined by the Fox formula.

The colored powder or granular material plays a role of imparting color, pattern, etc. to the cosmetic layer. As such colored powder particles, for example, known ones such as coloring pigments, extender pigments and aggregates can be used, and these can be used singly or in combination of two or more.

The decorative layer 2 of the present invention preferably contains granular inorganic particles as the colored particles. As a result, the granular inorganic particles are fixed by the resin component, and the decorative layer 2 exhibiting a color tone based on the granular inorganic particles and a design property due to the connection (aggregation) of the granular inorganic particles is obtained. That is, the color tone of the decorative layer 2 is based on the color tone of the granular inorganic particles. Moreover, the decorative layer 2 may have a plurality of colored regions having different color tones. In this case, the decorative layer 2 can be formed by curing a plurality of decorative layer compositions having different color tones. Due to the granular inorganic particles, the decorative layer 2 not only enhances the design but also has excellent surface strength, so that the thermally foamed layer 1 can be prevented from being dented or damaged. Furthermore, the granular inorganic particles can enhance the heat resistance. The action mechanism is not limited, but under high temperature such as fire, the steel frame temperature rises rapidly due to the heat reflectivity and heat resistance of the granular inorganic particles until the thermal foaming layer 1 reaches the foaming start temperature. It is thought that it is possible to suppress the rise in

As the granular inorganic particles, both natural products and artificial products can be used as long as the base material is inorganic. As the granular inorganic particles, an embodiment containing at least granular colored inorganic particles is suitable. As such granular colored inorganic particles, those having a light transmittance of less than 3% are particularly preferable, and those having a light transmittance of 2% or less are more preferable. Specific examples of such granular colored inorganic particles include marble, granite, serpentinite, granite, sandstone, slate, basalt, gabbro, diorite, andesite, limestone, pulverized products thereof, and pulverized ceramics. , pulverized ceramics, metal particles, and the like. In addition, fluorite, cold water stone, feldspar, silica, silica sand, pulverized products thereof, pulverized glass products, glass beads, etc., which are colored so as to satisfy the above conditions, can also be used.

The above-mentioned light transmittance is a value of total light transmittance measured by a turbidity meter. In this measurement, a sample of granular inorganic particles is filled in a transparent glass cell having an inner thickness of 5 mm, water is then gradually filled, and air bubbles in the cell are removed by vibration.

In addition to the above-mentioned granular colored inorganic particles, it is also possible to adopt a form containing granular transparent inorganic particles. The use of such granular transparent inorganic particles is suitable for improving the appearance. As the granular transparent inorganic particles, those having a light transmittance of 3% or more (more preferably 3 to 50%, still more preferably 10 to 30%) are suitable. Granular transparent inorganic particles include, for example, silica, cold water stone, feldspar, silica stone, pulverized products thereof, pulverized glass, glass beads, and the like. Either type can be used.

The particle size of the granular inorganic particles is preferably 0.01 mm to 5 mm, more preferably 0.02 mm to 2 mm, still more preferably 0.03 to 0.8 mm. Various combinations of granular inorganic particles having different particle diameters can also broaden the range of designability. The particle size of the granular inorganic particles is measured by sieving using a metal mesh sieve specified in JIS Z8801-1:2000.

The mixing ratio of the resin component and the colored powder is preferably 2 parts by weight or more and 50 parts by weight or less (more preferably 3 parts by weight) with respect to 100 parts by weight of the total amount of the colored powder in terms of solid content. parts to 30 parts by weight, more preferably 4 parts to 20 parts by weight, particularly preferably 5 parts to 19 parts by weight). With such a ratio, it is easy to obtain the decorative layer 2 composed of a connected body (aggregate) of colored powder particles. As a result, under high temperatures such as fires, a rapid temperature rise is suppressed, and gas generated by the foaming of the thermal foam layer 1 can be efficiently permeated, and a uniform carbonized heat insulating layer can be formed without hindering the foaming. can be formed.

The decorative layer composition may optionally contain components (additives) other than those described above as long as the effects of the present invention are not significantly impaired. Examples of such components include plasticizers, anti-algae agents, antibacterial agents, deodorants, adsorbents, flame retardants, thickeners, antifoaming agents, cross-linking agents, coloring pigments, extender pigments, glitter pigments, Luminescent pigments, fluorescent pigments, aggregates, fibers, ultraviolet absorbers, light stabilizers, antioxidants, catalysts, and the like.

The decorative layer 2 of the present invention preferably has an uneven pattern on its surface. The pattern of the decorative layer 2 is not particularly limited, and may have various shapes, such as a stone-like pattern, a wood-grain pattern, a joint pattern, and the like. Moreover, the thickness of the decorative layer 2 is preferably 0.2 to 30 mm (more preferably 0.5 to 20 mm).

The decorative layer 2 may be formed by applying the composition for the decorative layer, but in the present invention, a sheet formed in advance (hereinafter also referred to as "decorative sheet") is used. It is preferred to use The method for producing the decorative sheet is not particularly limited, but an example thereof includes a method of pouring the composition for the decorative layer into the inner surface of the mold and demolding after curing.

As shown in FIG. 4, the decorative layer 2 (decorative sheet) of the present invention can optionally have an adhesive layer 2b laminated on the back surface [FIG. 4(I)]. Furthermore, the surface of the adhesive layer 2b can be covered with a release sheet 2c [FIG. 4(II)]. By using such a decorative layer 2, work efficiency can be improved.

The method of laminating the adhesive layer 2b and the release sheet 2c is not particularly limited. A method of forming an adhesive layer 2b by applying an adhesive on a release sheet 2c in advance, and laminating the back surface of the decorative layer 2 on the adhesive layer 2b may be used. As the adhesive material forming the adhesive layer 2b and the releasable sheet 2c, the same materials as those usable in the above-described thermal foamable sheet 1 can be used.

Furthermore, the decorative layer 2 of the present invention may have a clear layer 2d [Fig. 4 (III)] on the outermost surface for the purpose of surface protection (water resistance, weather resistance, etc.), antifouling properties, etc. . A known clear paint can be used as the clear layer.

It is preferable that the laminate A of the present invention has a reinforcing layer 3 laminated therein. This makes it possible to prevent the formed carbonized heat insulating layer from cracking, falling off, and the like. Furthermore, physical properties such as flexibility and strength of the laminate A can be enhanced.

(reinforcing layer)
Examples of the reinforcing layer 3 include nonwoven fabrics, woven fabrics, and woven fabrics. These can also be used in combination of two or more. Moreover, two or more layers can be laminated as long as the present invention is not hindered.
In the present invention, the term “nonwoven fabric” refers to a fabric (sheet) made by entangling individual fibers one by one as described above, or bonding them with heat or an adhesive (non-woven fabric). ). A "knitted fabric" is a fabric in which a group of yarns arranged in one direction and a group of yarns arranged in a different direction are set up, crosswise or obliquely arranged, and laminated and bonded. As for the structure of the braided fabric, it is sufficient that it has a mesh structure. Shaft cloth and the like can be mentioned. A "fabric" is formed by a group of fiber yarns in the same manner as a knitted fabric, and is woven by vertically interlacing warp and weft threads. Examples of the structure of the woven fabric include plain weave, twill weave, satin weave, warp double weave, weft double weave, warp and weft double weave, pile weave, leno weave, and patterned weave.

In the present invention, it is preferable to use a braided fabric and/or a woven fabric as the reinforcing layer 3 . In addition, as the fabric and / or woven fabric, the density of both the warp and the weft is preferably 3 / 25 mm or more and 20 / 25 mm or less (more preferably 5 / 25 mm or more and 18 / 25 mm or less). It preferably has a basis weight of 5 to 150 g/m ² (more preferably 8 to 130 g/m ² , more preferably 10 to 100 g/m ² ). When such a range is satisfied, a uniform heat insulating layer can be formed without hindering the foaming of the thermally foamed layer 1 .

Furthermore, it is preferable to use a woven fabric (more preferably a entwined woven fabric) as the reinforcing layer 3 . This can further enhance the effect of preventing the carbonized heat insulating layer formed by foaming the thermally foamed layer 1 from cracking or coming off under high temperatures such as in the event of a fire. Although this action mechanism is not limited to the following, the woven fabric is woven by interlacing the warp and the weft, so that misalignment and deformation are small. As a result, it is considered that the carbonized heat insulating layer can be stably supported and cracks and falling off can be prevented. Furthermore, the entwined fabric is a fabric in which the warp threads are entangled with each other and the weft threads are woven (a fabric with a grain that looks like the weft threads are tied with the warp threads), and has stretchability in the diagonal direction. For this reason, the above effect can be exhibited without inhibiting the foaming of the thermally foamed layer 1, so it is considered that the effect of the present invention can be further enhanced.

The fibers used for the reinforcing layer 3 are not particularly limited, and various fibers such as organic fibers and inorganic fibers that can be used for the inorganic fiber nonwoven fabric 1a can be used. The reinforcing layer 3 preferably contains inorganic fibers (especially glass fibers), which have excellent heat resistance and are difficult to melt even at high temperatures, as a main component.

The thickness of the reinforcing layer 3 is preferably 0.01-3 mm (more preferably 0.05-1 mm). With such a range, the effects of the present invention are more likely to be obtained.

(Laminate)
Laminate A of the present invention, as shown in FIG. It is laminated on the surface side so that the decorative layer 2 can be visually recognized. When laminating the thermally foamed layer 1 and the decorative layer 2, the layers can be laminated by, for example, the following method.
- A method of applying a decorative layer composition to the surface of the thermally foamed layer 1 and laminating a decorative layer 2 thereon.
- A method of laminating a decorative layer 2 (decorative sheet) in which a decorative layer composition is formed in advance on the surface of the thermally foamed layer 1 via an adhesive.

When the reinforcing layer 3 is laminated on the laminate A of the present invention, the reinforcing layer 3 can be laminated at any position inside the laminate except for the back surface of the thermally foamed layer 1 and the surface of the decorative layer 2 . As a mode in which the reinforcing layer 3 is laminated, for example, a mode in which the reinforcing layer 3 is laminated between the thermally foamed layer 1 and the decorative layer 2, or a mode in which the thermally foamed layer 1 is laminated on the surface side and/or the decorative layer 2 is laminated. Examples include a mode in which the layers are laminated so as to be half-embedded or fully-embedded on the side.

5 to 7 show an example of a laminate A in which the reinforcing layer 3 is laminated.
FIG. 5 shows a mode in which the thermally foamed layer 1 and the decorative layer 2 are laminated so that the reinforcing layer 3 is interposed therebetween. In this case, the reinforcing layer 3 is not embedded in either the thermally foamed layer 1 or the decorative layer 2 .
Such a laminate can be laminated by, for example, the following method.
- A method in which the reinforcing layer 3 is adhered to the surface of the thermally foamed layer 1 via an adhesive, and then the decorative layer 2 is laminated by applying a decorative layer composition.
- A method in which the reinforcing layer 3 is adhered to the surface of the thermally foamed layer 1 via an adhesive, and then the decorative layer 2 (decorative sheet) formed by forming the composition for the decorative layer in advance is laminated via an adhesive.

In FIG. 6, a reinforcing layer 3 is laminated on the surface side of a thermally foamed layer 1 so as to be partially embedded [FIG. 6(I)] or fully embedded [FIG. 6(II)], and a decorative layer 2 is provided on the surface side. It is a laminated aspect. In the embodiment of FIG. 6(II), the fully embedded reinforcing layer 3 is located on the surface side with respect to the central portion of the thickness of the thermal foaming layer 1 .
For such a laminate, it is preferable to use a thermally foamed layer 13 (thermally foamable sheet 13) in which the reinforcement layer 3 is partially or fully embedded in advance on the surface side of the thermally foamed layer 1. Yes, and can be laminated by, for example, the following method.
A method of applying a decorative layer composition to the surface of the thermally foamed layer 13 to laminate the decorative layer 2 .
- A method of laminating a decorative layer 2 (decorative sheet) formed by forming a decorative layer composition in advance on the surface of the thermally foamed layer 13 via an adhesive.

In addition, as a manufacturing method of the thermal foaming layer 13 (thermal foaming sheet|seat 13), the following methods etc. are mentioned, for example.
- A method of laying the reinforcing layer 3 in the mold, then pouring the mixed composition of the constituent components of the thermal foaming layer 1, further laminating the inorganic fiber nonwoven fabric 1a, and demolding after drying.
- A method of laminating the reinforcing layer 3 after preparing a mixed composition of the constituent components of the thermal foaming layer 1 and applying it to the inorganic fiber nonwoven fabric 1a.
A method of preparing a kneaded product by kneading the constituent components of the thermally foamed layer 1 with a kneader or the like, filling the kneaded product between the inorganic fiber nonwoven fabric 1a and the reinforcing layer 3, and processing it into a sheet shape with a rolling roller or the like.

In FIG. 7, the decorative layer 2 is laminated on the surface side of the thermally foamed layer 1, and the reinforcing layer 3 is partially embedded [FIG. 7(I)] or fully embedded [FIG. 7(II)] on the back side of the decorative layer 2. It is a mode laminated so as to do. In the embodiment shown in FIG. 7(II), the fully embedded reinforcing layer 3 may not be exposed on the surface of the decorative layer 2, but should be located on the back side of the central portion of the thickness of the decorative layer 2. is preferred.
Such a laminate can be laminated by, for example, the following method.
- A method of laminating a decorative layer 2 by placing a reinforcing layer 3 on the surface of the thermally foamed layer 1 and applying a decorative layer composition.
A decorative layer 23 (decorative sheet 23) is laminated on the surface of the thermally foamed layer 1 on the back side of the decorative layer 2 in advance so that the reinforcing layer 3 is semi-embedded or completely buried in advance via an adhesive. Method.

In addition, as a manufacturing method of the decorative layer 23 (decorative sheet 23), the following method etc. are mentioned, for example.
- A method of applying a decorative layer composition to the reinforcing layer 3 .
- A method of pouring the decorative layer composition into a mold, further laminating the reinforcing layer 3, and demolding after drying.
- A method of pouring the composition for the decorative layer into the mold, laminating the reinforcing layer 3, further pouring the composition for the decorative layer, and removing the mold after drying.

As the laminate A of the present invention, the embodiment shown in FIG. 7 is particularly preferable. In this case, the effect of preventing the formed carbonized heat insulating layer from cracking, falling off, etc. is enhanced, and more excellent heat protection can be exhibited. Furthermore, physical properties such as flexibility and strength of the laminate A can be enhanced. Moreover, the thickness of the laminate A is preferably 1.2 to 65 mm (more preferably 1.5 to 50 mm).

(Coating structure)
The covering structure of the present invention has the above-described laminate A on the surface of a steel frame.
FIG. 8 shows an example of the covering structure of the present invention. As shown in FIG. 8, the covering structure of the present invention is a covering structure in which a thermal foaming layer 1 and a decorative layer 2 are laminated on a steel frame B. In the present invention, the inorganic fibers of the thermal foaming layer 1 The nonwoven fabric 1a is covered facing the steel frame B side, and the decorative layer 2 is arranged so as to face the surface side. Such a coated structure is coated so that the decorative layer 2 can be seen, and is excellent in design and maintains stable heat protection when the steel frame is exposed to high temperatures due to fire or the like. be able to.

Further, FIG. 9 shows another example of the covering structure of the present invention. As shown in FIG. 9, the covering structure of the present invention is a covering structure in which a thermal foaming layer 1, a reinforcing layer 3, and a decorative layer 2 are laminated on a steel frame B, and the inorganic fibers of the thermal foaming layer 1 The nonwoven fabric 1a is covered facing the steel frame B side, and the decorative layer 2 is arranged so as to face the surface side. Such a coated structure is coated so that the decorative layer 2 can be seen, and is excellent in design, and when the steel frame is exposed to high temperatures due to fire, etc., more stable heat protection is provided. can be maintained.

The steel frame B is not particularly limited, and examples thereof include square, round, H-shaped, and I-shaped steel frames, which are used as columns, beams, etc. that constitute structures. .

Examples of the coating method for such a coated structure include the following methods.
(1) A method in which a steel frame B is coated with a thermally foamed layer 1, (reinforcement layer 3), and decorative layer 2 in this order.
(2) A method in which the steel frame B is coated with the thermally foamed layer 13 and the decorative layer 2 in this order.
(3) A method of covering the steel frame B with the thermal foaming layer 1 and the decorative layer 23 in this order.
(4) A method of covering a steel frame B with a laminated body A in which a thermal foaming layer 1, a (reinforcing layer 3) and a decorative layer 2 are laminated in advance.
In the above methods (1) to (4), when the steel frame B is covered with the thermally foamed layer 1 (thermally foamed layer 13 or laminate A), the surface (back surface) on which the inorganic fiber nonwoven fabric 1a is laminated is It is characterized in that it is installed facing the steel frame B side.

Specific methods for covering the steel frame B with the thermally foamed layer 1 (thermally foamed layer 13 or laminate A) include, for example, the following methods.
(a) The thermally foamed layer 1 (thermally foamed layer 13 or laminate A) is wound around the steel frame B with the inorganic fiber nonwoven fabric 1a side facing, and the ends are fixed with fixing members.
(B) After applying an adhesive to the surface of the steel frame B and/or the surface of the inorganic fiber nonwoven fabric 1a, the thermal foaming layer 1 (thermal foaming layer 13 or laminate A ).
(C) When the thermally foamable layer 1 (thermally foamable layer 13 or laminate A) has an adhesive layer 1b and a release sheet 1c, the release sheet 1c is peeled off to expose the adhesive layer 1b. and attach it to the steel frame B (which may be coated with an adhesive in advance).
In addition, the covering structure of the present invention is suitable for a mode in which the steel frame B is directly (adherently) covered (adhered and covered).

In the above (a), the fixing member for fixing the end of the thermal foam layer 1 (thermal foam layer 13 or laminate A) is not particularly limited, but for example, washers (screws), tackers, welding pins, bolts , tapping screws, etc. can be used. As these materials, nonflammable materials such as metal are preferable.

When applying the adhesive to the surface of the steel frame B and/or the inorganic fiber nonwoven fabric 1a, for example, tools such as a brush, roller, trowel, spatula, and spray can be used. The coating amount of the adhesive may be appropriately set, but is preferably 0.1 to 0.5 kg/m ² . Moreover, when attaching the thermally foamed layer 1 (thermally foamed layer 13 or laminate A) to the steel frame B, it is desirable to press-fit. When crimping, a pressing tool such as a roller or trowel can be used as necessary.

In the above methods (1) to (4), the method for laminating each layer is the same as the method for producing the laminate shown in FIGS.

As the coating method for the coated structure of the present invention, the above method (3) is particularly suitable. In this case, workability and finish are excellent. Furthermore, it is preferable to provide a joint portion X as shown in FIG. The location where the joint portion X is provided is not particularly limited, but is preferably a location other than the corner portion of the steel frame B. By providing the joint part X, the thermal foaming layer 1 can be foamed efficiently, and the effects of the present invention can be further enhanced.

Examples are shown below to further clarify the features of the present invention.

<Production of thermally foamed layer (thermally foamable sheet)>
・Kneaded product 1 for thermal foaming layer
A mixture containing 100 parts by weight of thermoplastic resin (acrylic resin), 90 parts by weight of melamine, 90 parts by weight of dipentaerythritol, 320 parts by weight of ammonium polyphosphate, and 100 parts by weight of titanium oxide is pressurized at a temperature of 120°C. The mixture was kneaded with a kneader to prepare a kneaded material 1 for thermal foaming layer.
・Kneaded material 2 for thermal foaming layer
Thermoplastic resin (acrylic resin) 100 parts by weight, melamine 90 parts by weight, dipentaerythritol 90 parts by weight, ammonium polyphosphate 320 parts by weight, titanium oxide 100 parts by weight, glass fiber (fiber diameter 7 μm, fiber length 6 mm) 4 parts by weight was kneaded with a pressure kneader set at a temperature of 120° C. to prepare a kneaded material 2 for thermal foaming layer.

Non-woven fabric 1: inorganic fiber non-woven fabric in which glass fibers are randomly arranged and bonded with polyvinyl alcohol resin, basis weight 25 g / m ² , thickness 0.2 mm
Non-woven fabric 2: inorganic fiber non-woven fabric in which glass fibers are randomly arranged and bonded with polyvinyl alcohol resin, basis weight 50 g/m ² , thickness 0.4 mm
Non-woven fabric 3: inorganic fiber non-woven fabric in which glass fibers are randomly arranged and bonded with polyvinyl alcohol resin, basis weight 140 g / m ² , thickness 1.0 mm
Non-woven fabric 4: Polyester (organic fiber) non-woven fabric in which polyester long fibers are randomly arranged and bonded with polyvinyl alcohol resin, basis weight 60 g/m ² , thickness 0.5 mm

In the combination shown in Table 1, the kneaded material for thermal foaming layer was laminated on the nonwoven fabric, and the nonwoven fabric was (I) semi-embedded or (II) fully embedded into a sheet by rolling rollers. Eight types of sheets (450 mm x 1200 mm) were produced.
In addition, a thermally foamable sheet (450 mm × 1200 mm) in a mode [(III) without embedding] in which the thermal foaming layer kneaded product is formed into a sheet with a rolling roller and then laminated on the thermal foaming layer and the nonwoven fabric via an acrylic adhesive ) was prepared.

(reinforcing layer)
Inorganic fiber fabric: glass fiber, leno weave, warp density 10 × 2/25 mm, weft density 10/25 mm, basis weight 60 g/m ² , thickness 0.2 mm

(Composition 1 for decorative layer)
200 parts by weight of acrylic resin emulsion (solid content 50% by weight), 1000 parts by weight of granular colored inorganic particles (brown) with an average particle size of 150 μm, water, and additives (thickener, antifoaming agent, etc.) are uniformly mixed by a standard method. The mixture was mixed to produce a decorative layer composition 1.
(Composition 2 for decorative layer)
A cosmetic layer composition 2 was produced in the same manner as above except that the granular colored inorganic particles of the decorative layer composition 1 were replaced with granular colored inorganic particles (brown:black=1:4) having an average particle size of 100 μm.

<Production of decorative layer (decorative sheet) 1>
The decorative layer compositions 1 and 2 were poured into a woodgrain mold, cured at 23° C. for 24 hours, and demolded to produce a woodgrain sheet (600 mm×1200 mm, thickness 3 mm). Next, a clear paint was applied to the outermost surface at an application amount of 0.3 kg/m ² .

<Production of decorative layer (decorative sheet) 2>
The decorative layer compositions 1 and 2 are poured into a woodgrain mold, the reinforcing layer (I) is laminated so as to be semi-embedded, cured at 23 ° C. for 24 hours, and then demolded to form a woodgrain sheet ( 600 mm x 1200 mm, thickness 3 mm). Next, a clear paint was applied to the outermost surface at an application amount of 0.3 kg/m ² .

(Manufacture of test specimen)
Using the above 9 types of thermally foamable sheets and the above 2 types of decorative sheets, the following coated structures were produced.
The inorganic fiber non-woven fabric side of the produced thermally expandable sheet 1 is attached to a rectangular steel frame (300 mm × 300 mm, thickness 9 mm, length 1200 mm) via an adhesive so that the rectangular steel frame side is attached, and then a decorative sheet is attached. A covering structure adhered via an adhesive was used as a test piece.

During the heating test for 1 hour according to the standard heating curve of ISO834, the carbonized heat insulating layer in the process of being formed was subjected to impact 20 minutes after the start of the test (around 280°C). After the crack was generated, the test was continued, the temperature of the steel frame (steel material temperature) at this time was measured, and after the test, the shape of the carbonized heat insulating layer other than the cracked portion and the shape of the carbonized heat insulating layer in the cracked portion were evaluated. . Each evaluation criterion is as follows. Moreover, the results are shown in Table 1.
(Evaluation 1: steel material temperature)
(steel material temperature)
AA: less than 475°C A: 475°C or more and less than 500°C B: 500°C or more and less than 525°C C: 525°C or more and less than 550°C D: 550°C or more (evaluation 2: shape of carbonized heat insulating layer)
The shape of the carbonized heat insulating layer other than the cracked portion was visually confirmed. The evaluation criteria are 5-level evaluation (excellent: AA > A > B), with "AA" for a uniform carbonized heat insulating layer formed without falling off of the carbonized heat insulating layer, and "D" for a case where the carbonized heat insulating layer has fallen off. >C>D: inferior).
(Evaluation 3: Carbonized heat insulating layer at cracked portion)
The shape of the carbonized heat insulating layer at the crack was visually confirmed. The evaluation criteria were a 5-level evaluation (excellent: AA>A>B>C>D: inferior) with "AA" for a carbonized heat insulating layer and "D" for an exposed steel frame.

Claims (5)

A covering structure in which a thermal foaming layer and a decorative layer are laminated on the surface side of a steel frame ,
The thermal foaming layer has an inorganic fiber nonwoven fabric on the back side,
The inorganic fiber nonwoven fabric is laminated so as to be partially or fully embedded in the thermal foaming layer ,
A covering structure, wherein the inorganic fiber non-woven fabric of the thermal foaming layer is placed facing the steel frame . The covering structure according to claim 1, wherein the inorganic fiber nonwoven fabric has a basis weight of 10 to 150 g/m ² . 3. The covered structure according to claim 1, wherein the inorganic fiber nonwoven fabric is made by bonding inorganic fibers randomly arranged with a resin component. A covering structure further laminated with a reinforcing layer,
The reinforcing layer is
Laminated so as to be interposed between the thermally foamed layer and the decorative layer, or
Laminated so as to be partially embedded or fully embedded in the surface side of the thermal foaming layer, or
4. The covering structure according to any one of claims 1 to 3 , wherein the covering structure is laminated so as to be partially embedded or fully embedded in the back side of the decorative layer . The decorative layer contains a resin component and colored powder,
5. The coated structure according to any one of claims 1 to 4, wherein inorganic particles are included as the colored powdery particles.

Images